Instruction Manual For Diesel Generator DOOSAN MAN DIESEL 5L23 30H 720RPM

Volume 1
Maintenance
DOOSAN - Diesel
5 23/30 720 RPM
Hull 3071
Engine Type 5 L23/30 720 RPM
Project Name: SETA3071-1,2&3
Project . DMM1-5182/5183/5184
NICE Service
Necessary /nformation for Customers' Expectation
Access NICE Service via website, by e-mail
http://nice.doosanengine.com
e-mail: nice.service@doosan.com
DOOSAN ENGINE CO" LTD, 69-3, Sinchon-dong, Seongsan-gu Technical Serice : +82 55 260 6996
CUSOMER SASFAC ON Changwon-si, Gyeongnam, Korea 642-370 Parts Sales : +82552606260
T e l e f a x : +82552606772
Doosan Engine
"ti'f= Doosan Engine 23/30 Vol. 1
Index for Maintenance Manual
CHAPTERI IL__~
T1~TL~E~______________________________~
500 Main Data for Engine

501 Operation of Engine
502 Engine Performance and Condition
503 Troub. shoot
504 Lubricating Ol Specification
505 Cylinder Head
506 Piston, Connecting Rod and Cylnder Liner
507 Camshaft and Camshaft Drie
508 Operating Gear for Vale and Fuel Injection Pumps
509 Control and Safety Systems
510 Crankshaft and Main Bearings
511
512
513
514
Engine Frame and Base Frame
Turbocharger System
Compressed
Internal Fuel

l
System
System
515 Internal Lubricating l System
516 Cooling Water System
519 Spec. plant
520 Tools
'.
Section 500
Main Data for Engine
cription
(? 5
'n J~ta for Engine 500.00

.~ .
' odJctIon 500.01
,.,tr 500.02
fety
f;~ 55 f;ection 500.05
o
,
(;r fo r Engine Designation 500.10
t'e~jgn~tion of CyIinders 500.11
:J in e Rotation CIockwise 500.12
~"'~ Iclentification for Instruments 500.20
(;0 odJction to PIanned Maintenance Programme 500.24
r
I",t ned Maintenance Programme 500.25
f'1~;ration Data & Set Points 500.30
" ee n Passport" 500.33
.or ta fo r Pressure and Tolerance 500.35
:J~ ta for Tghtening Torque 500.40
:J~ Iar~tion of Weight 500.45
t'1e C
v dering of Spare Parts 500.50
Or r ice Letters 500.55
f;e "5n Table 500.60
(;0 'c 5ymboIs for Piping 500.65
13~5
Dcscrition
Page 1 (1) Warnlng 500
General
Warning!
(Marine engines an/y)
! is impartant that aII Diesel engines are oper-

ated within the given specifications and performance
tolerances specified in the engines' Technical Files
and are maintained according 10 the Diesel
maintenance instructions in order to comply with
given emissions regulations.
In accordance with Chapter 1I,e Code Federal

Regulations, Part 94, Subpart C, 94.211 NOTlCE
is hereby given that Chapter the Code Fed-
eral Regulations, Part 94, Subpart , 94.1004
requires that the emissions related maintenance
the diesel engine shall be performed as specified in
Diesel instructions including, but nol Iimited
to, the instructions to that effect included in the
Technical File.
08.16-ESO
',M$%','MAN DieSeII
Description
Page 1 (1) Main Data for Engine 500.00
Edition 11
23J30
Cycle 4-stroke
Configuration -
CyI. Nos. available 5-6-7-8
Power range 650-1280 kW (885-1740 )
Speed 720501900
Bore 225mm
Slroke 300mm
Stroke/bore ratio 1.33:1
Piston area per cyI. 398 cm'
Swept volume per cyI. 11.91Ir.
Compression ratio 13:1
Max. combustion pressure 130 bar'
urbocharging principle Constant pressure system and intercooling
Fuel qualiIy acceptance HFO up 700 cStJ50 C (BSMA 100-9)
----_._-
Power lay-out MCR version
Speed rpm 720 750 90

-------_.. ~- .. _-----
Mean piston speed m/sec. 7.2 7.5 9.
Mean effective presSlIre bar 18.2 18.1 17. 9
Max. combustion pressure bar 130 130 13
Power per cylinder kW/cyl. 130 135 16

BHP/cyl. 175 185 21
------
Over!oad rating ( 10 1%) allowable 1 houl' for cvery 12 hours
Power per cylinder

____.____ 1 kW/cyl.
~HP_/c~y_I._'__ _ __L__
175
239
*For l23/30H-900 rpm V a pressure of 135 bar reasured at the indicator cock correspond 10
130 bar the combustion chamber.
05.17 - ES1
MiMMAN DieS~
Description
Introduction 500.01
Page 1 (1)
Edition 02
General
Descrip!ion
This instructio book serves the purpose provide Reliable and economical operation the plant iS
general information operation and maintenance, conditional its correct operation and mainte-
and describe the design. can also be used as nance accordance with & Diesel /
a reference when ordering spare parts. instructions. Emissions related maintenance the
diesel engine shall be performed as specified
& W Diesel A/S' instruclions and any additional
instruclions 10 that effect included the Technical
File. Consequently, is essential that the engine
room personnel are l acquainted with the con-
tents this book and, respect instructions
emissions related maintenance the diesel engine,
also the additional instructions that effect set
Secion 505-519
Spare parts plates the Technical File.
The book is a basic instruction manual the particu-

WOI"kiI1g card lar engine supplied, with plant-adapted information
such as basic media-system drawings, electrical
wiring diagrams and test bed reports.
Description
The first v seclios (500-504) the book serve

as a guide engine operation, and the fiftee
seclions (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 a number main com-

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

scriptions the systems/components, followed by
working cards and the spare parts illustration plates
and parts lists.
03.36 - ESO
DescripHon
Safety 500.02
PageI (2)
Edition 02
General
GeneraI Spares
Proper maintenance, which iS the aim this bool<, Large spare parts should, as lar as possible, be placed
iS a crucial aspect achieving optimum salety well slrapped Ihe area use and should be
the engine room. The general measures mentioned accessible by crane. The spare parls sl10uld be well-
here should, therelore, be a natural routine lor the preserved against corrosion and protecled against
entire engine room staft. mechanical damage. Slock Sl10Uld be checl<ed at
intervals and replenished in time.
CIeanliness
Lgh!
The engine room should be kept clean above and
below the Iloor plates. 1I grit or sand blows the Ample working lighl should be permanently installed
engine room while the ship iS in port, the ventilation appropriate places tl,e engine room, and
should be stopped and ventilating ducts, skylights, able working light explosion-prool fittings should
and doors the engine room should be closed. be available everywhere.
In particular, welding work which causes the

spreading grit and chips must be avoided near Freezing
the engine, unless this iS closed or covered, and the
turbocharger air intake filters are covered. 1I there is a risk damage due Ireezing when the
plant is service, engines, pumps, coolers and
The exterior the engine should be kept clean and systems should be emptied cooling water.
the paintwork maintained, so that leakages can
easily be detected.
Warning
Fire Opening cocks may cause discharge hot liquids

gases. Dismantling parts may cause springs
If the crankcase iS opened belore the engine iS cold, be released.
welding and the use naked lightwill involvethe risk
explosions and lire. The same applies inspection The removal luel valves ( other valves the
l tanks and the space below the cooler. Attention cylinder head) may cause l to down the
should lurthermore be paid the dangeroffire when pislon crown, and l the piston is hot an explosion
using paint and solvents with a lowflash !. Porous may then blow out Ihe valve.
insulating material drenched with l Irom leal<ages
iS easily inllammable and should be renewed. See When testing ll valves with the hand pump do
also: "Ignition Crankcase" section 503. touch the spray holes, as the jet may pierce the skin.
Consider belorehand which way the Iiquids, gases
Ilames wll move, and keep clear.
Order
Hand tools should be placed 10 be easily accessible Crankcase Work

1001 boards. Special tools should be lastened 10
1001 panels (l supplied) the engine room close Check belorehand that the starting air supply the
tI,e area use. major objects may be left engine is shut 011.
unlastened, and Ihe Il and passages should be
kept clear.
01.32 ESO
I+llMMAN DieseII
500.02 Description
Safety Page 2 (2)
Edition 02
General
FeeIing Over Turning
Whenever repairs alterations l,aVe been made After prolonged out-of-service periods overhaul
the running gear, apply the "feel-over sequence" worl< which may l a risk accumulation of liquid
il ! iS ensured that there iS undue heating, oil- the combustion spaces, turning should always be
mist formation, blow-by, failure ! cooling water effected through at least w complete revolutions.
lubricating l systems.
Check and
FeeI-over 8eqlence
Lubricating l condition, l elements and meas-
Feel over after 5-15 and 30 minutes' idle running and uring equipment, see "Planned Maintenance Pro-
finally when the engine is running at ll load. 8ee gramme".
also ''Operation'' the section 501.
01.32 - ESO
Description
Page 1 (1) Cross Section 500.05
Edition 06
23/30
99.40 - ES1
4 DieS1
DescripIion
Cross Section 500.05
Poge 1 (1) Edition 06
23/30
99.40 - ES1
'!,'.( DieseI[
Description 500.10
Page 1 (1) Key for Engine Designation Edilion 03
General
Engine Type Identification
The engine types the Diesel programme are identilied by the lollowing ligures:
cylnders
5, 6, 7, 8, 9
t2, 16, 18
EngineType
l-l
V : V-built
CyI. diam/stroke
16/24: 160/240
21/31: 210/310
23/30: 225/300
27/38: 270/380
28/32: 280/320
32/40: 320/400
Design Variant

CR
Raling
MCR Maximum continuous rating

ECR: Economy continuous rating
08.16 - ES1
ill$MIMAN DieseII
Description
Designation Cylinders
500. i 1
Page 1 (1)
Edition 03
General
Front end Flywheel end
Exhaust side Right side

Service side Fuel Pump side Left side
98.19 - ES1
', .lf DieseII
Description
Engine Rotation Clockwise 500.12
Page1 (1)
EcItion 02
Generai
..
[
-~
.. _-
'---"
Direction "Clockwise" of diesel engine seen from flywheel end
/ Engine
(
Alternator
,,,' DieseI!
Description
Code !dentification for Instrument 500.20
Page 1 (2) EdJtion 03
General
Exp/ana!ion of Symbo/s
(40T')~"""'- Measuring device

Local reading
Iemperature )ndicator
. 40 '

"'r= Measuring device
.... . ~...... Sensor mounted engine/unit
22 Readinglidentification mounted a panel the engine/unit
f'ressure indicator
. 22 '
Measuring device
Sensor mounted engine/unit
Reading/identification outside the engine/unit
Iemperature Jj,larm High

.12'
~
.. Measureing device
..- Sensor mounted engine/unit
22 Reading/identification a panel the engine/unit and reading/indication outside
the engine/unit
Pressure Transmitting
.22'
Refer standard location and instruments on the following pages.
Specilication letter code lor measuring devices

1st le1ter Following letters
r rlOW f\ Alarm
Ll Differential
Pressure Element
S Speed, System High
Temperature Indicating
U Voltage Lw
V Viscosity S Switching, Stop

Sound Transmitting
Position Failure
V Valve, Atuator
04.36' ES1
500.20 Code Identification for Instruments
Description
Edition 03 Page 2 (2)
Genera\
Standard Text for Instruments
Diesel EllgineJAlternator
LTWater System
l 10 cooler 04 l 10 alternaor 07 l lub. l cooler
02 outlet from air cooler 05 outlet from alternato. 08 inlel 10 fresh water cooler (SW)
03 out!et from lub. ! cooler 06 outlet from fresh water cooler (SW) 09
Water SysteIn
1 l 10 engine 14 l 10 cQoler 17 ou!let from fresh waler cooler
1 FW l 10 engine 14 FW jnlel 10 cooler 18 ll 10 fresh waler cooler
11 outlet from each cylinder 148 FW from cooler 19 prehealer
12 outlet from engine 15 l from sysem 19 l 10 prechaJnber
13 l \0 pump 16 ll from tl!rbocharger 198 l fronl precllamber
Lubricating i Systenl
20 inlet 10 cooler 24 sealing l - l engine 28 level base frame
21 autlet from coolcl' / l 10 fiJter 25 prelubricating 29 main bearings
22 outlet froln filter l 10 engine 26 ll rocker arms and roller guides
23 ll 10 trbocharger 27 intermecliate bearing J allernator bearing
Charging Alr System

30 l 10 cooler 34 charge conditioning 38
31 l from cooler 35 surplus l 39
32 jet assist system 36 il11el 10 lurbocharger
33 outlet fOm TC ( / l 10 TC COmpl", 37 charge air from mixer
Fuel 011 System

40 l \0 engine 44 ll from sealing 011 pump 48
41 outlet from engine 45 fLlel-rack pos1tion 49
42 leakage 46 l 10 precllamber
43 l \0 filter 47
Nozzle Cooling System

50 inlet 10 fuel valves 54 58 011 splastl
51 outlet from fuel valves 55 valve timing 59 alternalor load
52 56 injecIion tjming
53 57
Exhaust Gas System

60 l from cylinder 64 68
61 lfrom turbocharger 65 69
62 l 10 turbocharger 66
63 compustion chamber 67
Compressed System
70 l 10 engine 74 l 10 reducion valve 78 l 10 sealing l syslem
71 10 slop cylindel' 75 microswilch for 1urning gear 79
72 l 10 balance arm l 76 jnlet tl!rning gear
73 control 77 wasle gate pressure
Load Speed
80 overspeed 84 engine stop 88 index - fuel injection pump
81 overspeed 85 microswitch for overload 89 turbocllarger speed
82 emergency stop 86 shutdown 90 engine speed
83 engine slart 87 ready 10 slarl
Miscellaneous
91 natural gas - l! 10 engine 94 cylinder lubricaling 97 remote
92 mist detector 95 vollage 98 alternator winding
93 knocking sensor 96 switCll for operating location 99 common alarm
04.36 - ES1
', DieseII
Descriton
Introduction to Planned Maintenance Programme 500.24
Pago 1 (2)
Editlon 03
General
General The Iront page indicates the lollowing:
The overhaul intervals are based on operation 1) Salety regulations, which MUST be carried !
a specilied l l quality at normal service output, belore the maintenance worl< can start.
which means 70-100% MCR.
2) briel description the worl<.
the long , ! is ! possible to achieve safe and
optimum economical running without an effective 3) Relerence any work which must be carried
maintenance system. !before the maintenance worl< can start.
The structure and amount inlormatIon the main- 4) Related procedures - indicates other works,
tenance programme mean that it can be Integrated depending the present work - or worl<s
the ship's!power station's maintenance system which ! would be epedient carry !.
or ! can be used separately.
5) Indicates numberof men number hours
The core the maintenance system is the I<ey dia- accomplish the worl<.
gram, see pages 500.25 and 500.26, indicating the
inspection intervals ' the components!systems, The stated consumption hours is only intended
so that the crew can make the necessary overhauls as a guide.
based the engines' condition and!or the time
cri1eria.
The maintenance system is divided 2 main

groups:
Q
n::::n
a. Major overhaul ! inspection (page 500.25):
These works are be carried ! during major N~'II
overhauls and inspections the engine.

u''''''''-';<-'
u"~","",."
g~~~~:::::''''
n,,-"'''''''''"
'"
"',.,
b. Duty during operation (page 500.26): indicated "'''~~''''''''.{
the works be carried ! by the personnel

2
during the daily operation the engine.
The stated recommended intervals are only 3 .

guidance as different service conditions, the quality I"""~'~~''N"~'
o""""",,,,,,",,,,,'-'~
"">"",<,",-.,..-",,,.,.
8
the fuel l and the lubricating l, treatment
4
the cooling water, etc., ll decisively influence the
actual service results and thus the intervals between
necessary overhauls.
5 -
..,,.,,,-.,
~''''
~. '''''
""~-,...,,,,,...,,,,,,
<>11'0'
9
Eperience with the specilic planVpersonnel should '"
6
be used adjust the time between overhauls. It
should also be used adjust the timetable stated
lor guidance the working cards.
Working Cards Fig. 1 Instrction guide for working cards.
Each the working cards can be divided : a

Iront page and several pages describing and
illustratIng the maintenance work.
98.19' ESO
+ DieseII
500.24 Introduction to Planned Mzintenznce Programme
Description
Page 2 (2)
Edilion 03
General
Experiece with the specific station/personnel may 8) Various requisite hand tools.
lead to updating.
9) Indicates the components/parts which l is
6) Refers to data required to carry ! the work. advisible 10 replace during the maintenance
work. Please note that \11is is a condition for
7) Special tools which must be used. Please l the inlervals stated.
that ! all tools are standard equipment.
98.19- ESO
f+1,}f'!.'IMAN DieseII
Descrfn 500.25
Page 1 (4) Pl:l Maintenance Programme Editon19H
23/30
900 RPM
Time Between Overhaul

Working
::;: OVGrhauJ to be carried !
Description l:'i! :;:: CI1Gck the cdin

'f}

~ ~

g

Card
'" ~
Operaling Engine:
Readings data engine and alternor, wl -

rence "Engine Performance Data", section 502.01 ..... 502-01.00
--,,-~~~ .. _~.,,_._~~~~_._~_._ ~- .. - ..-__ -~-+-+-+-I-+ ..__
Cylinder Head:
/n/et and ehaust va/ve - overhaul and regrinding

spindel and valve seat ................................................. .. ~ 505-01.1
Inspection inlet, ehaust valves and valve guide ........ . iI!I 505-01.05
Checl< valve rotators' rotation during engine rotation . 505-01.05
Sleeve lor luel injector .................................................. .. 11 505-01.30
Salety valve - overhaul and adjustment opening
pressure .................................................................. .. 505-01.25
Indicator valve ............................................................... . lIIi 505-01.26
Cylinder head cooling water space - inspection ............ . 11 505-01.45

Cylinder head nut - retightening .................................. . 200 505-01.40
~ .........- . - -.....- _.........- . ._ ..- .. - - - - - - -......- ..- .... ... ~ ..... __ ....- .-...... - . -........ - . -
Piston, Connec!ing Aod and Cylinder Liner:
Inspection pistO/1 ..................................................... . 506-01.1

Piston ring and scraper ring ........................................ .. 11> 506-01.1
Piston pin and bush cO/1necting rod - checl<

clearance .................................................................... . 506-01.15
Connecting rod - measuring big-end bore .................. . liIII 506-0115
Inspection big-end bearing shells .............................. . 506-01.16
Connecting rod - retightening ........................................ .. 200 liII 506-01.25

Cylinder liner - cleaning, honing and measuring ............ . 506-01.35
Cylinder lner removed - check the water space and
wear ring in frame ............ " .................................. " ...... . liiI 506-01.40
_. _ _..._ ... _ ...._ __._._ _..._ -.~--- ....-- ..- .." - --1- ... - .. " r " - -..- , , - . -
Camshafl and Camshaft Drie:
Camshaft - inspection gear wheels, bolts, connections

etc................................................................................... 200 11 507-01.00
Camshaft bearing - inspection clearance .................. . 11 507-01.05
Camshaft adjustment - check the condition .................... . 57-01.20
Lubrication camshaft bearing - check ........................ .. 507-01.00
06.02' ESO
500.25 Planned Maintenance Programme
Description
Edition " 9 Page 2 (4)
23/30
900 RPM

Working
= Overhaul to be carried out
Description mJ :;:: Check the condition

,r:~ggONO

Card

Operating Gear for Inlel Valves, Exhaus! Valves and

Fuel Injeclion Pumps:
Roller guide lor valve gear . __ .. _.. ____ . _________________ ._ lIiI 508-01,00
Valve gear - valve bridge, spring, push rod, etc _______ _ 508-01-10
Roller guide luel injection pump _____ _ ________ _ liII 508-01_05
Roller guide housing. __ . ___ ._____ . ________ ._- ___ . ___ _ 508-01-10
Inlet and exhaust valve - check and adjustment valve
clearance ____________________________ - , ______ ,___ , ___ _ 11 508-01-10
Lubricating operating gear - checl< __________ . _____ -- liI 508-01,00

508-01,05
------- ---.---.--.------------.--.---.. .--.------..--------c--. - --- -1-- ---- -- --1-- -----,,---
Control and Safety Syslem, Automatics and

Instruments:
Salety, alarm and monitoring equipment __________ . ___ _ 509-01 _00
Lambda controller - adjustmen. _____ . __ ,, ____ .- __ .--. 509-10,00
Governor - Clleck olllevel, see governor instruction

book, section 509 ____________ ",_, _______ ,, __ ,____ , ___ .
' - - - - - - - -.. .- - - . . -----.---------~--+- . . t- +-I-+-+-t-- -1-+-------

Crankshafl and Main 8earing:
Checking main bearings alignment, (autolog) _______ , 510-01 _00

Inspection af main bearing _________________ - ____ '' 510-01,05
Inspection guide bearing _____________________ , ____ , 510-01,10
Vibration damper - check the condition ___________ , __ _ 510-04,00
Lubricating gear wheel lub. l pump and cooling

water pump etc, _' __ " __ ' ____ ' __ ' __ "_"'_"_"'_'_' _____ ' __ '_' __ '
Counterweight - retightening, see page 500.40_,,, __ . __ , 900'
Main- and guide bearing cap - retightening _____ ,, ____ _ 200 510-01,05
510-01,10
, 1I screw can be tightened then the screw have to be
loosened and retIghtened alter page 500.40.
06,02 - ESO
f,!ifM'lMAN DieSeI!
Description 500.25
Page 3 (4) P/anned Maintenance Programme Edition "19
23/30
900 RPM

Working
._ OVerl1aullo be carried oU
Description 8 g Card
! "" Check the condition 8

Engine Frame and Baseframe:
Holding down bolts - retightening, see page 500.40 ....... 200 11

Bolts between engine Irame and base Irame -
retightening, see page 500.40".""""""""""",. ............. 200
For Ilexible mounted engines - check anti-vibration

mountings ................. , """ " '" ""."." "",""""""'''' . 200 liI 519-03,00
Safety cover - lunction test"", ... ,,"""""" """''',,'' """" iIII 511-01,00
r-,,--- -- .. ----..-..- .-...--.---........... -.--... ... --.-... ----..... -- -- -.... -+.. -1 .. I-- .. _ ..
Turbocharger SysIem:
Wet cleaning trbine side, ."""""""""", """",""""" 512-15,00

Water washing compressor side '" """ ""'"'''''' ".,,'" 512-05.00
Cleaning air Iilter - compressor side (see trbo

charger Jnstruction bool<)"" .. ".""""""""""" " ",,'" """
Turbocharger complete - dismantling, cleaning, inspec-
etc, (see turbocharger instruction book) """",'" ... ,,'
Charging air cooler - cleaning and inspection '" "", ",,'" liII 512-01,00
Charging air cooler housing - draining""" """"""". ~

Exhaust - compensator". """"'" ,,""""" .. ,,'''' "" 11
.......... -
Compressed System:
, starter motor - dismantling and inspection """" ".,,'" liI 513-01,30

Function test - main starting valve, starting valve, main
valves and emergency start valve """""'" " """,,""""" 513-01.40
Dirt separator - dismantling and cleaning." ""."""""""

Muffler - dismantling and cleaning"""""" "" """ """"" CO
Compressed air system - draining"""""" """"'" ,"""'" ~ 513-01,90

Compressed , system - check the system""""" ..... 513-01,90
06.02 - ESO
Description
Ed!tion 19 Page 4 (4)
23/30
900 RPM

Working
., "" Overhaul to be carr"ied
Description f!I == ChHck Ihe condition

~

Card

~ 55
Fuel System and Injeclion Equipment:
Fuel IHter dismantling and cleaning ...................... . 51401.15

Fuel l leed pump ..................................................... . @ 51410.00
Fuel l injection pump dismantling and cleaning .. (\ 51401.05
FueI injection valve . adjustment opening pressure ... 200 11 51401.10

Fuel l highpressure dismantling and check . ..... 11 51401.05
Adjustment the maimum combustion pressure ......... . 51405.01
Fuel l system check the system................... .. ...... . 11 51401.90

Nozzle cooling system checl< the system l instalied .... . 51401.90
Fuel l samples after every bunkering, see sec.504

-----.. .....-.....................---....... - - - ..................... j..+++-e-++------j
Lubricating l System:
Lubricating l pump . engine driven ........................... . 51501.00

Lubricating l llter cleaning and ehange ................. . 51501.10
Lubricating cooler .................................................. . (\ 51506.00
Prelubricating pump . el.driven .................................. .. 51501.05

Thermostatic valve .. .... ..... .. ..................................... . 51501.20
Centrilugal lilter . cleaning and ehange paper ...... ..
51515.00
Hand pump ................................................................. . CI& 51510.00

Lubricating l . l samples, see section 504 .... .. 11
Lubricating system check the system .................... .. 11 51501.90
.....-.-..---...- - - -................... - - - . -....-...- - - - -........ r-- ..- ........ -.-f-- -. - - . -....
Cooling Water System:

~

Cooling water pump . enginedriven (sea water and
.f
Iresh water) ................................................................... .. 51604.00
51604.00
:3cn
Thermostatic valve ...................................................... .. 11
cn
Cooling water system . check the system ...................... . 51601.90

Coolng water system water samples, see sec. 504 .....
~

00

06.02 ESO
Description 500.25
Page 1 (4)
Planned Maintenance Programme dtn 21
23/30
7201750 RPM

Working
._ Over))aul 10 be carried out
Description m _ Cf)GCk Ihe condition
Card

Operating Engine:
Readings datafor engine and allernalor with rele-

rence ''Engine Performance Dala", section 502.01 ..... 502-01.00
--_._-~_ . _._...._.-'-'- - I--I--~-+-+-I-+-+- I---"-'-'~--
Cylinder Head:
Inlel and exhausl valve - overhaul and regrinding

spindle and valve seat .................... ............. ......... ..... .. * 505-01.1
505-01.05
Inspection inlet, exhaust valves and valve guide .........
Check valve rotators' rotation during engine rotation .. 505-01.05
Sleeve for luel injector ........... .... .... .................. ............ 11 505-01.30
Salety valve - overhaul and adjustment opening
pressure ........ ... ...................................... ...................... 11 505-01.25
Indicator valve ............................ ............................... .... 11 11 505-01.26
Cylinder head cooling water space - inspection .............. 505-01.45

Cylinder head - relightening. "....................... .......... 200 505-01.40
_._--
Piston, Connecting Rod and Cylinder Liner:
Inspection piston ................................................... . 11 506-01.1

Piston ring and scraper ring ...... """ ........................... .. 506-01.1
Piston and bush for connecting rod - check

clearance .............................................................. """'" 11 506-01.15
Connecting rod - measuring big-end bore ................ . 506-01.15
Inspection big-end bearing shells .............................. . 506-01.16
Connecting rod - retightening .......................... ........ ...... 200 506-01.25

Cylinder liner - cleaning, honing and measuring .... ' .... .. 506-01.35
Cylinder liner removed - check the water space and
wear ring in frame .............. ,......................................... . 11 506-01.40
I------~----_ .. __ ... _---------+---+-++.+-
Camshaft and Camshaft Drive:
Camshaft - Inspection gear wheels, bolts, connections

etc ................... ,............. '"'''''''''' ............................. ,........ 200 lIIi 507-01.00
Camshaft bearing - inspection clearance.. .. ............ . liII 507-01.05
Camshaft adjustment - check the condition .................... . 507-01.20
Lubrication camshaft bearing - check ........................ .. 507-01.00
06.02 - ESO
Description
23/30
720/750 RPM

Working
,_ Overhau! 10 be carried out
Description m :;: Check the condition

lfJOOO~p
Card
~ ,
Ope,ating Gear , Inlet Valves, Exhaust Valves and

Fuel Injeclion Pumps:
Roller guide 10r valve gear .......................................... . lIIi 508-01.00

Valve gear - valve bridge, spring, push rod, etc ............ .. lIIi 508-01.1
Roller guide l injection pump ....... .. .................. .. 11 508-01.05
Roller guide housing ............................................... . ! 508-01.1

Inlet and exhaust valve - check and adjustment valve
clearance ....................................................................... . 508-01.1
Lubricating operating gear - check ......................... .. 508-01.00

.. -~~--- .. _--~~~_ .. _--_........... . ~~..j... .-1-1- -'" ............ 508-01.05
'-- -+''-''''--''-'-'''''--
Control and Safety System, Automatics and

Inslruments:
Salety, alarm and monitoring equipment ..................... .. 509-01.00
Lambda controller - adjustment .................................... .. 509-10.00
Governor - check oillevel, see governor instruction

book, section 509 ........................................................ .
..- - - -..........---~........- _.....- ..- - -..........J---~ ...... - ....... 1- ~"--I- "1-- .......- ..-...._-
Crankshafl and Main Bea,ing:
Checking main bearings alignmenl, (aulolog) ............ .

Inspection al main bearing ...................................... ..
Inspection guide bearing ........................................... .
Vibra!ion damper - check the condition ........
Lubricating gear wheel ' lub. l pump and cooling

waler pump elc ............................................................ ..
Counterweight - retightening, see page 500.40 .............. .
Main- and guide bearing cap - retightening ............... .
/f screw can be lighlelJed tlJen the screw have 10 be

/oosened and relighlened afler page 50.0..40.
06.02 ESO
Descriplion 500.25
Page 3 (4) Planned Maintenance Programme Edilion 21
-
23/30
7201750 RPM

~ w Worl<ing

c
= Over!1aul 10 be carried out
'"
.

Description ~~ ~

c
Q
Card
"' s:~

"e
~
! = Check the condilion
~
,i
ro c
-6. ~ ~

i w
Jl~~

()
Engine Fra.ne and Baseframe:
Holdingdown bolts - retightening, see page 500.40 ........ 200 !

Bolts between engine frame and baseframe -
retightening, see page 500.40 ......................... .............. 200
For flexible mounted engines - checl< anti-vibration

mountings ..................... ,.... " ... " .. .............. ....... .... ....... 200 519-03,00
SaIety cover - function test . ............... ....... , .... , ........ 511-01,00
f--------.--.--------------- ..... _-_ .. _--- _. -- - ---._- _.... _~
Turbocharger Syslem:
Wet cleaning turbine side ............. ....... ...................... ~ 512-15,00

Water washing compressor side ......... ....................... ~ 512-05,00
Cleaning air filter - compressor side (see turbo-

charger instruction book) ................................ ......... .....
Turbocharger complete - dismantling, cleaning, inspec-
! etc. (see turbocharger instructIon bool<) .................. ,
Charging air cooler - cleaning and inspection ............. , .. 512-01,00
Charging air cooler housing - draining ..................... .......
Exhaust - compensator ....... ......................... , .........
- .. _--_.. ----_.. _-~----------

----_._--- -- -- -- -- - ..-
Compressed System:
starter motor - dismantling and inspection. ............... ltI! 513-01,30

Function test - main starting valve, starting valve, main
valves and emergency start valve .... , ....... ...................... 11 513-01.40
! separator - dismantling and cleaning .. .....................

Muffler - dismantling and cleaning ............. .....................

Compressed air system - draining ...................................
Compressed air system - check the system ................
513-01.90
513-01,90
06,02 - ESO
} DieseII
Description
Page 4 (4)
Edition 21
23/30
7201750 RPM
Description
.. = Overhaul 10 be carried out
~

Q
.~ ~ ~

-" ~E
.~
Worl<ing
Card

= Check Ihe condition
" C:S ;:5
13~.!:

00

':'!

~o
C

~ ~

1~ffi.
U < "

Fuel l Syslem and Injection Equipmenl:
Fuel l ll - dismantling and cleaning ............. ............ @ 514-01.15

Fuel l leed pump ......................... ................ .... .... ~ 514-10.00
Fuel l injection pump - dismantling and cleaning .. ....... ~ 514-01.05
Fuel injection valve - adjustment opening pressure .... 200 lIiI 514-01.10
Fuel il high-pressure - dismantling and check ....... lIiI 514-01.05
Adjustment the maximum combustion pressure .......... ~ 514-05.01
Fuel l system - check the system .. ............................... ! 514-01.90
Fuel il - il samples after every bunkering, see 8ec.504

.. --_.__._. . ..
Lubricating l Syslem:
Lubricatlng 011 pump - englne-driven . ........... , ...... ......... ! 515-01.00

Lubricatlng 011 llter - cleaning and exhange .. ......, . ........ 4t 515-01.10
Lubricating il cooler ........ ...................... ....... ......... ~ 515-06.00
Prelubrlcating pump - el. driven ......................... ... ........ 515-01.05

Thermostatic valve ...... ...... ....... ... ............................... 515-01.20
Centrllugal Iilter - cleaning and exhange paper ........... 515-15.00
Hand pump .............. .............. ....... ........................... ... , ~ 515-10.00

Lubricating il - l samples, see section 504 ......... .......
Lubricatlng 011 system - check the system ...... ...... ! 515-01.90
- .."._.. ,.~ .... .. _-, .(. .. -
Cooling Water SysIem:
Cooling water pump - engine-driven (sea water and

Iresh water) .............................................. ....................... 11 516-04.00
Thermostatic valve ................. ................... .................... 516-04.00
Cooling wa!er system - check the system ................ ..... 11 516-01.90
Cooling water system - water samples, see sec. 504 " .., ! liII
06.02 ESO
Description 500.30
Page 1 (2) Operation Data & Set Points Edijion 46
23/30
---- ----------------- - - - - _ . _ - - - - ,-- .. _._._-

AcceptabIe
value at sho
Normal Value at Fult load Alarln Set point Autostop of engine
test or after
_._.._-
,-----_.
Lubricating l Sy stem
Temp. before coole r SAE 30 20 60-75' C <750 C 20 " C

(l engine) SAE 40 20 65-82" C <82" C 20 100" C
Temp. afler cooler SAE 30 22 45-65' C 22 75"C TSH 22 Q
<65" C 85 C
( engine) SAE 40 22 50-72 Q C <72" C 22 85"C TSH 22 95' C
Pressure after filter (inlet eng) 22 3.1-4.5 bar >4.0 bar L 22 3 bar PSL 22 2.5 bar
Etevatod pressure .g. when

centrifugal fittel' ins tal!ed 22 4.1-5 bar >4.5 bar L 22 4 bar PSL 22 2.5 bar
drop acro55 filter PDAH 21-22 0.5-1 bar <0.5 bar PDAH 21-22 1.5 ba!"
PI'elubricatil1g press 25 0.1-0.5 bar >0.2 bar LL 25 leel switch

Pressure inlet turbo charger 23 1.5 0.2 bar >1.5 bar
lub. l, loe! bas e frame LL 28/ !ow/high leel

L 28
Temp. main bearing s 29 75-85" C <85" C 29 95" C
Fuel System
Pressure after filter MDO 40 2.5-5 bar L40 1.5 bar

HFO 40 5-16 bar () L 40 4 bar
Leaking L 42 !eakage
Press. nozz. coo!. l, l 011g. 50 2-3 bar L50 1.5 bar (8)
Temp. nozz. cool. , l eng. 51 80-90" C ()
Coollng Water System
Press. LT-system, let engil1e 01 1-2.5 bar () >1.3bar L bar + (C)

Press. HT-system, j nlel engine 10 1.5-4.6 bar >1.8-<6 bar L 10 0.4 bar + (C)
Temp. HT-system, ll engine 60-75' C

Temp. HT-system, utl. cyl.units 11 70-850 C <850 C
Temp. HT-system, Ul engine 12 90" C TSH 12 950 C

12-2 93"C
Temp. raise across c yl. max. 100 C
Exhaust Gas and C harge Air
l. gas temp. befo reTC 62 425-475' C 62 5500 C

62-2 600" C
Exh. gas lemp. l cyl. 60 280-390" C 60 420"C
. between individ ual cyl. average TAD60 average
25"C 50"C
l. gas Iemp. after TC 61 275-350" C k

61 5000 C
61 320-390" C"
Ch. air press. after coo!er 31 2-2.5 bar

31 35-55" C 31 Q
Ch. air temp. after co oler <55" C 65 C
Compressed Air Sy stem
PreS5. engine 7-9 bar >7.5-<9 bar L 7 bar

--'---'
Specific ptanIs !1 not comprise alarm equipment and autostop for aH parameters listed above. For specific plants additional parameters
can be included. For remarks 10 some parameIers, overleaf.
~ for 720/750 rpm ** for 900 rpm.
06.06 - ES1
I Dieseil
500.30 Operation Data 8< Set Points Description
EdiIiOI1 46 Page 2 (2)
23/30
AcceptabIe
l sho
NormalValue at Full load test Alarm Set point Autostop of engine
after

f------ _.. ---
Speed Control System
Engine speed
Mechanical
Elec. SI90 720 rpm 820 rpm SAH 81 815 rpm SSH 81 825 rpm
Mechanical SSH81 815 rpm
Mechanical SSH 81 850 rpm
SSH 81 1015rpm
Turbocharger speed SI89 SAH 89 ()
--
Remarks individual Parame!ers C. Cooling Water Pressure, Alarm Set

Points
. l l Pressure, HFO-operation As the system pressure case pump lailure wll

depend the height the expansion tank above
When operating HFO, the system pressure must the engine, the alarm set po;nt has to be adjusted
be sufficient to depress any tendency to gasilication to 0.4 bar plus the static pressure.
the hot luel.
The system pressure has to be adjusted according D. Press. -system, ll engine ( 01)
to the fuel il preheating temperature.
With two-string cooling water system the normal
value can be higher, max. 4.0 bar.
. Nozzle Cooling il System
The cool;ng 0;1 system is only applied for . LimiIs forTurbocharger Overspeed Alarm
stationary eng;nes. (SAH 89)
Engine type 720 rpm 750 rpm 900 rpm
5L23/30H 55.290 55,290
6L23/30H 55,290 55,290 42.680
7L23/30H 42,680 42,680 42,680
8L23/30H 42,680 42.680 42.680
06.06 - 1
Description
"Greer Passport" 500.33
Page 1 (1) Edition
Gereral
List potentially hazardous materials 10

stroke diesel engines thatare relevant be delivered
recycling lacilities according resolution
.962(23) Adopted on 5 december 2003.
PIastic Materials
Type
f--''''-'--------------- ...............Location
- ......-..--.- Approximate quanIiIy/votlJme
Copolymer, based acrylnitriie and O-rings (Inside engine) ')
butadiene: 8
Copolymer, based vinyIidene-fluOl"ide O-rings (!nsidc engine) ")
and Ilexafluoro-propene: FPM
FP1155, Flame retar"dant according 10 Cable jacket < 100 m
IEC 332-3 cat. 3
Ma1eriaIs containing PCBs, PCTs, PBBs al levels of 50 Ing/kg or rnore

C=:=~:~=~ ____________L_______.___________ l No ne_________ ::]
Gases sealed the machinery
[~_~~_==~~:==:~:=.~.-_~~_~~~.~::~~=.=~=~_ Eh~~~errno~~ter_~___________~__~~~[==_-~~~~==~~~:. _________.~. ]

Chemicals engine
~~~~~~=-lI~::~-j
Other Substances engine
Type ..:_L-O.:C-"--t-~~-n.-.__.________________..___.__________ . __ ~?E~?~~_~_~~~~_ty/_volume
-----:-.-------'.-
Fuel l Engine F.o. syst:::e:::m'-_____--J_<:::0=',-"02=-0:...::.m:::3_____._
Lubricating l Engine frame See instruction manual
~-----~--------------I--~----------------+---- ---
Filter cartridge Lub. l filter on engine 2 pCS. 1)
1-,, -.,... ,...,..",." ..,.....,..,..,." ... - .. - ---1-----
Filter cartridge
.. _.. _._---_._-------_. __ .. __
Lub. filter engir)c/fi!ter candles 2 pcs.l48 pCS. 2)
.. _--------- --_._._-----_...__ ... _.. --_..-
Mercury
....."..,..."....", ...,., ...,. ', ......,... ', ......,.. ,............,", ..',.,.,',.........,.................,...,., .... ,.._-- ,._="'-----
Uthium baItery (if installed) Electronic cabinet 1 pcs.
r-.---.---.-.... --.-..---......-...-- .....-----.-....-........-.-.--...- ..-.----.-.-.-.-................- ...-- .-.---..--.-.-.-....-----------1
---_._.._-_.. __..._.._-_._-_..._--_.__.__._---_.----_._-----..------ -,---_._----.-'.------._-._-_.-----
Lead Pb - fo' so!dering circuit board Electronic cabinet < 10 g/engine 2)
__
...._. __ .... _-_ ... __._. ._--------._-------_._--
*) The component iS most !ikely bound in an alloy or present at a very LW concentration

1) onJy valid for GenSets
?) only va!id for Propulsion engines
07.36 - ESO
Mi# :( DieseII
Descriptiol1 500.35
Page 1 (1) Data for Pressure I::!
Edition 29
23/30
Section Descriplion mm./bar
505 Maximum inner diameter, valve guide 14.25 mm.

For grinding valve spindle and valve seat ring
(see also working card 505-01.1 )
Minimum height valve head, l valve and ehaust valve, '" 1 5.0mm.
Maimum height spindle above cylinder head, '" 2 83.3 mm
506 Piston and piston ring grooves (see working card 506-01.1 )
Clearance big-end bearing 0.15-0.20 mm
Clearance between connecting rod bush and piston pin 0.15-0.25 mm
Maximum clearance between connecting rod bush and piston 0.35 mm
Maimum ovalness big-end bore (without bearing) 0.08 mm
New cylinder liner, inside diameter 225,000-225,046 mm.
Maximum inside diameter cylinder l, ma. ovalness 0.1 mm 225.50 mm
507 Clearance between camshaft and camshaft bearing 0.11-0.20 mm

Maximum clearance between camshaft and camshalt bearing 0.35 mm
Clearance between teeth intermediate wheel 0.2-0.3 mm.
508 Valve clearance, Inlet valve (cold engine 15 - 55"C) 0.50 mm.
Valve clearance, Ehaust valve (cold engine 15 - 55"C) 0.90 mm.
Maimum clearance between rocker arm bush and rocker arm shaft 0.30 mm.
509 Clearance between pick-up and impulse wheel 1 0.3 mm
510 Dellection crankchaft (autolog) (see working card 510-01.00)

Clearance between cranl<shaft and sealing ring, (upper and lower part) 0.30 - 0.40 mm.
Clearance main bearing 0,2-0,3 mm
Clearance connecting rod bearing 0.13 - 0.29 mm
Clearance guide bearing (aial) 0.15 - 0.44 mm
Maimum clearance in guide bearing (axial) 0.8mm
Clearance between bearing and gearwheel shaft:
Clearance when new bearings are mounted 0.085-0.135
Maximum clearance 0.185
514 Maimum combustion pressure at lullload 130 3 bar

Individual cylinders; admissible deviation Irom average 3 bar
change the height the thrust piece spacer ring 0.1 mm

ll
change the maimum pressure by 1 bar
1" turning camshaft gear wheel changes max. pressure by appro 3 bar
Measurement "" belween thrust piece and roller guide housing 5 .5 + 2.5 mm
--1.5 mm
For L23/30 900 rpm version a pressure 135 bar measured at the
indicator cock correspond 10130 bar the combustion chamber
Opening pressure luel valve 320 bar
08.03 - ESO
',lJ,@':MAN Die~
Destn 500.35
Page 1 (1) Data for Pressure and Tolerance Edlion 22
23/30
Section Descriplion mm./bar

f-- .....-..........-.......- ..........-..- ..-. - - -. - .. -. .... - . - - - - - - - - - - . - -....-.- ... -. 1--...._--_. _ _ ..._-_.._.-
505 Maximum diameter, valve guide 14.25 mm.

For grinding valve spindle and valve seat ring
(see also worl<ing card 505-01.1 )
Minimum height valve head, inlet valve and exhaust valve, '" 1 5.0mm.
Maximum height spindle above cylinder head, '" 2 83.3 mm
506 Piston and piston ring grooves (see working card 506-01.1 )
Clearance big-end bearing 0.15-0.20 mm
Clearance between connecting rod bush and piston 0.15-0.25 mm.
Maximum ovalness big-end bore (without bearing) 0.08 mm.
cylinder liner, inside diameter 225,000-225,046 mm.
Maximum inside diameter cylinder Iiner, max. ovalness 0.1 mm 225.50 mm
507 Clearance between camshaft and camshaft bearing 0.11-0.20 mm

Maximum clearance between camshaft and camshaft bearing 0.35 mm
Clearance between teeth intermediate wheel 0.2-0.3 mm.
508 Valve clearance, Inlet valve (cold engine 15 - 55"C) 0.50mm.

Valve clearance, Exhaust valve (cold engine 15 - 55C) 0.90mm.
Maximum clearance between rocker arm bush and rocker arm shaft 0.30 mm.
509 Clearance between pick-up and impulse wheel 1 0.3 mm
510 Dellection crankchaft (autolog) (see working card 510-01.00)

Clearance between crankshaft and sealing ring, (upper and loer part) 0.30 - 0.40 mm.
Clearance main bearing 0,2-0,3 mm
Clearance guide bearing (axial) 0.15 - 0.44 mm
Maximum clearance guide bearing (axial) 0.8mm
Clearance between bearing and gearwheel shaft:
Clearance when bearings are mounted 0.085-0.135
Maximum clearance 0.185
514 Maximum combuston pressure at lull load 130 3 bar

Individual cylinders; admissible deviation Irom average 3 bar
change the height the tl1rust piece spacer ring 0.1 mm

ll
change the maximum pressure by 1 bar
1 turning camshalt gear wheel changes max. pressure by approx 3 bar
Measurement "" between thrust C and roller guide housing 5.5 2.5 mm
1.5mm
For L23/30 900 rpm version a pressure 135 bar measured at the
indicator cock correspond 130 bar the combustion chamber
Opening pressure luel valve 350 bar
06.18ESO
/ Die~~
Description
Data for Tightening Torque 500.40
Page1(1)
Edi\ion 21
23130
72050 rpm
Tightening
Section Descriplion Thread Torque Pressure Lubricant
Nm bar
__ __..._-
-~ --_._._._----_.. - . .
505 Cylnder cover stud ( frame) Stud 48 200 Loctite 243
. cylinder cover stud 45 750 Oil/Molykote
(Unimol gl 82)
Cooling jacl<et cylinder cover Screw 22 -~.
506 Connecting rod (see section 506) Molykote

Connecting rod screw Stud 33 2 (Unimol gl 82)
(hydraulic tightening) 33 2 750 -
507 Camshaft assembly 12 85 -

ltermedate wheel shaft 20 1.5 250 -
Intermediate wheel gear 12 40 -
Gear wheel camsllaft Screw 12 70 -
508 Housing for valve gear Screw 12 60 -

Valve gear bracket rocker arm 16 150 -
510 Main bearing stud ( frame) Stud 48 200 Lc 243

for main bearing stud 45 3 750 Molykote
(Unimol gl 82)
Main bearing side screw Screw 24 300 -
Counterweight crankshaft Screw 30 2 200 -
+ 600 turn
Vibrationdamper crankshaft 27 400 -

Frame / baseframe 24 500 -
Flywheel mounting (focted bolt) 20 200 -
Flywheel mounting (standard heagon boIt) 20 300 -
Gear rim flywheel Screw 34 -
Gear wheel crankshaft 10 40 -
514 Fuel pump distribution C Screw 8 25 - 30 -

Fuel pump flange (barrel) Screw 10 55 - 65 -
Fuel pump caviation plugs Plug 20 1.5 100-120 -
Fuel pump mounting
(bottom flange) Screw 16 150 -
Fuel valve (nozzle ) 26 1.5 100 - 120 -
Fuel valve mounting 16 40 -
Fuel valve (cap ) 70 -
Fuel valve adjusting (lock ) 100 -
High pressure 181.5 40 -
515 Gear wheel lub~ l pump 300 -

519 Conical elements mounting
Upper mounting Screw 24 150 -
Lower mounting 24 200 -
07.10
Description 500.40
Page 1 () Data for Tightening Torque Edition 22
23/30
900 rpm
Tightening
SecIion Descriplion Thread Torque Pressure Lubricanl
Nm bar
_.. __ .. _._----_.- " "-""-._-_..- ....._.....-_. __ .. _.....
._""---~~_.~
--- --_._.__._-- . -.-... _-_. .. _._.- ---- ._..."._----_.. ._-_._"---......._"--
505 Cylinder cV' stud (n Irame) Stud 48 200 Lc 243
, cylinder cV' stud 45 750 Oil/Molykote
(Unimol gl 82)
Cooling jacket cylinder cover Screw 22 -
506 Connecting rod (see section 506) Molykote

Connecting rod screw Stud 33 2 (Unimol g182)
(hydraulic tightening) 33 2 750 -
Nut 12 85 ..-
507 Camshaft assembly
Intermediate wheel shaft 20 1.5 250 -
Intermediate wheel gear 12 40 --
Gear wheel camshaft Screw 12 70 -
508 Housing lor valve gear Screw 12 60 -

Valve gear bracket rocker arm 16 150 -
510 Main bearing stud ( frame) Stud 48 200 Lc243

Nut lor main bearing stud Nut 45 3 750 Molykote
(Unimol g182)
Main bearing side screw Screw 24 300 -
Counterweight cranl<shaft Screw 30 2 200 -
+ 60" turn
Vibrationdamper crankshaft Nut 27 400 -

Frame / baselrame 24 500 -
Flywheel mounting (fitted bolt) Nut 20 200 -
Flywheel mounting (slandard hexagon boIt) 20 300 -
Gear rim flywheel Screw 34 -
Gear wheel crankshaft 10 40 -
514 Fuel pump distribution C Screw 8 25 - 30 -

Fuel pump flange (barrel) Screw
10 55 - 65 -
Fuel pump caviation plugs Plug 20 1.5 100-120 -
Fuel pump mounting
(bottom flange) Screw 16 150 -
Fuel valve (nozzle ) Nut 26 1.5 100 - 120 -

Fuel valve mounting 16 40 -
Fuel valve (cap ) 70 -
Fuel valve adjusting (Iock nut) Nut 100 -
High pressure Nut 18 1.5 40 -
515 Gear wheel lub. l pump 300 -
519 Conical elements mounting

Upper mounting Screw 24 150 -
L' rnounting 24 200 -
-
07.10
'll'M'iMAN DieseI[
DescripIion 500.45
Page 1 (1) Declaration of Weight Edition 01
23/30
Section Component Plate . lIem . Weight Kg.

,--_._--- ..,,,-_._---- -- ..__..__..__.__......_......_------- ... __ ..........__ ....._- ......._- -----------------",. - ................- ....... _----- ---,----------- ------------
505 Cylinder Head. complete 50501-50502 250

50508-5051
506 Piston, complete 50601 081 45

Piston 50601 019 19
Connecting Rod, complete without bearing 50601 068 95
Cylinder Liner, complete 50610 018 100
Cooling Water Jacket 50610 055 33
507 Camshaft, section 50705 014,026,038 29
508 Housing for Roller Guide 50801 016 17
509 Governor, complete 50901 021,104,116 28
511 Main Bearing Cap 511 108 75

Guide Bearing Cap 511 300 85
Front cover 51102 019 164
End cover, complete 51106 237 179
512 Turbocharger, complete See special

instruction
Intermediate C 51202 181 9
, Cooler 51203 054 450
Inlet Bend 51203 138 93
513 , Starter 51309 756 40
514 Fuellnjection Pump 51401 381 15

Fuel Injection Valve 51402 177 5
Fuel l Feed Pump 51410 290 22
515 Lubricating l Pump 51501 330 45

Thermostatic Vale 51503 115 29
Prelubricating l Pump, cl. el-motor 51504 242 20
Centrifugal Filter 51515 337 24
516 Thermostatic Vale 51604 114 29

Cooling Water Pump 51610 201 30
97.06 - ESOU
DcscripIion
Ordering Spare Parts 500.50
Page 1 (2)
Edition 02
General
When spare parls are ordered (or referred 10 These dala are necessary 10 ensure supply the
correspondence, etc.) Ihe following data must be correct spare parts lor a particular engine, even
indicaled for the engine concerned: though the spare part illustrations contained Ihis
bool< may 110 always be complete accordance wilh
Name customer/ship Ihe individual components of a specilic engine.
number
Engine Type Nole: For ordering spare parls for governor, turbo-
Engine chargerand alternator, please see Ihe special chapter
il by the instruction book lor these components.
Plate number
lIem
Description
Oty.
Informalion found page 500.15 or Ihe nameplate !he engine(s)
Example: Name customer/ship I Eng. type Eng.no il by

DANYARD 705 L9007489 5L28/32 20433 Holeby
Information lound on each plate:
Plate Edition Item Description Oty.

506-21 13 10 Piston ring 10 pcs
07.04
DescripIion 500.50
Page 2 (2) Ordering of Spare Parts
Edition 02
General
Name of customer/ship no
Engine type Engine number l by
Plate no Ed. no Item no Description
---~~~~-I----__- --.-.-.------.-.- ........---.-----.---.-...-.-....- ..-..-..-.
----J-~~~-I---- . ---...-..----~----- ......--------.-- .---..----
L ____ ~~_._._._._._
----J-----..- - --.-.. - - - - - - ---~-

._-+_ .._---_._--_._...- .~~---~~~-+-----~
---- --.---.---.-.-.--+-~--....--....--------------.--.--.------I--~~
1----_ ...__._._------+-------------_._-- ...-------~--- ----------- -----.-------
---I-~----_ .. _..._._. __ ._-~~~~_._-
----~~~-.-----.- ... --_f~~-
f----.-~--- ....-.-~-.. -.-----.-.-..-.. ---+-~-........----~~-. -.----.-.--.-.-....---t--~~-
- - - - - - - - 1 - - - - - - - -.--.----~-----.- ..-- .. -~~~~-------~
----_._. __. __. _.-._-~--+------- 1-----------_.-......._----------
._-_._._--_._~---- _._._--_.--- ---_.-
1------._-_._-- -------~I--------------- ----------~------_.~-
--------- .__._._. _. _----_.1---- ~~~._----------_._._ . _--_. _. _---~.I--~--
I-~~~_._-_.~-----I----~----- -----.-.-.--.-...---~~---
07.04
Description
Service Letters 500.55
Page 1 (1)
Edition
Gereral
Description
orderto ensure the most efficient, economical and Since new service letters might be great impor-
up-to-date operation our engines, regularly send tance the operation the plant, we recommend
! "Service Letters" con!aininglirs!-hand inlorma!ion that engine staft l them as supplements to the
regarding accumulated service experience. relevant chapters this instruction book.
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 relerer1Ce when prepare up-dated editions
instruction books.
97.40 ESO
Description
Corversior Table 500.60
Page 1 (3) Edition
Gereral
Basic SI Unils Velocity, Speed (m/s) (3.6 km/h = 1 m/s)
Quantty Nanle SYfnbo! 1 kn (knot);;;: 1 naticaJ mile/h 1.852 km/h = 0.5144 m/s
Cincerning ottler conversions, see IabJe for Iength
lengtt1 metre ,
mass kilogram kg
tirne second s Densi!y
electric current
absoJute temperaIuI'e*
amount of substance
ampere
kelvin
mole

L[t_1_lb_k_U_b._ft____________1_6__ .02k~_m_'___________ J
Uminous inlensity candela cd
Force (1 kg m/s' =1 )
AIso named "thermodynamic tempcI'atre"
1 kp (kHopouncJ)' 9.80
Supplementary SI Units 1 poundal" 138.3 10-~
1 Ibf (poLInd force) 4.448
QU8fJtity Narne SynIbof
Can occasionaIIy be found staled as kgf (kiJogram force).
plane angle raclian rad Standard acceleI'at1on of free fall gn ;;;: 9.80665 m/s2
sold angle steradian sr .. Unit force in the ft-Ib-s system
Addilional SI Units Stress ( 1 N/m' = 1 ., N/mm')
Quantity Name SynIbof DefifJitiofJ 1 kp/mm:! = 100 kp/cm~ 9.807 N/mm2

1 Ibf/sq. (psi) = 0.07031 at 6.895 103 N/mm~
time minute rnin 1 min ;;;: 60 s
time hour h 1h "" 60min
plane angle degree 10 = (/180) rad Dynamic viscosity ( s/m')
volume lilre 11 1 dm3
;;;:
preSSlJre bar bar 1 bar = 10s Pa 1 kp s/m? 9.807 s/m 2 ;;;: 98.07 (poise)
1 poundaJ s/sq.ft 1.488 s/m 2
1 Ibf/sq.ft 47.88 s/m~
Lengtll (m)
poise is a speciaJ r)ame taken from the CGS system. 1 "" 0.1 s
1 (!nch) 25.40 mm ;;;: 0.0254 m 1 cP == 1 mPa s = 103 Pa s
1 (foot) :=: 12 inches 0.3048 m
1 yd (yard) ;;;: 3 ft '" 36 inches 0.9144 m Kinematic v;scosity (m'ls)
1 statute mile :=: 1760 yds 1609 m
1 n mile (international nautical il) 1852 11 sq.fVs 92.90 10-:J m:;s =: 92.90 103 cSI *
1 cSt (centi stokes) =: 1-; m2fs. Stokes is a specia! name

SI Prefixes taken from the CGS system. 1 St ::: 104 m?Js
Factor Prefix Symbof Factor Prefix Symbof Energy, Work (1 Nm =1 J, Wh)

1018 ea 10'1 deci d 1 cal . 4.187 J'
101~ peta 10-2 centi c 1 kpm 9.807 J
10'?' tera 10;1 milli m 1 hph (metric) 2.648 100 J =: 0.7355 kWh
10' glga G 10-6 micro 1 Ibf 1.356 J
10" mega 1 9 n 1 hph (UK, US) 2.685 100J;;;: 0.7457 kWh
10' kilo k 1 l pico 1 BTU (UK, US) 1.055 103J = 1.055 KJ
102 heclo h 10'1~ fcrnlo f
10 deca da 10-18 atto a Exact vaJue: 4.1868 J
.. = Jnternational Steam Table
Area (m')
1 sq. (square inch) 0.6452 103 m 2

1 sq. (! (square foot) 92.90 1O~ m?
04.37 . ESO
500.60 Conversion Table Description
EditIon Page 2 (3)
General
(1 kg m'ls' = 1 m/s = 1 J/s = 1 W) Specific heai capacty (J/(kg })
1 kpm/s 9.807 W 1 kcal j /(kg "C) 4.187 10"JI(kg )

1 (metric) :::: 75 kpmIs 735.5 W = 0.7355 kW 1 U(lb "F) = 1 kcal" I(kg "C) 4.187 1o~ J/(I<g )
1 kcal,:/11 1.163 W ---------'
1 ft Ibfls 1.356 W British Thermal ! (see table for energy conversions)
1 hp (UK, US) :::: 550 ft.lbf/s 745.7 W
1 BTUlh 0.2931 W
Heal conduclance (W/(m
Momeni Force, Torqtle (kg m2fs' = Nm) 1 caII.r/(cm s "C) 418.7 WI(mK)
1 kcal./(m h "C) 1.163 WI(m )
Can oly be cIerived from the above labJes. 1 (11 11 "F) 1.731 ( )
Bri!ish Thormal ! (see !able energy conversions)

Momen! Inerlia (kg m')
1 GD2 (old noIaIion) '" 4 ' kg m2 Hea! !ransmission (W/(m 2

1 A~ (old )* ;;;: 1 1* kg m?
1 cl r/(cm s C) 41.87 103 W/(m? )
1"" j dm r~ m, -= mass ! the radius r 1 kcallT/(m" h "C) 1.163 WI(m' )
G:::: W ='mass in kg D", Dian1eter of gyralion 1 ( 2 h F 5.678 WI(m' )
R == Radius gyration
Specific l l consumption (SFOC)

Specific fuel consumpIion' (g/kWh)
Reference conditions
11 g/hph (meIric) 1.360 glkWl1 8pecific l il consumption values refer 10 brake power,
and the following reference conditions:
See also Iable for specific fuel 01] consumplion values
Reference conditions (180)
Temperalure difference () 810wer inlet temperature 25C 298

Blower inlet pressure 1000 mbaI"
1 "C (Celsius) 1 Charge coolant temperature 25 C Q
298
1 "F (Fahrenheil) 5/9 Fue! ! lwer Clc ! (10200 I<cal/I<g) 42-107 kJ/kgl<
Temperature levels ()
(see "Derived 51 Unils wilh special Names)
C (Celsius) 'c + 273.15;;;:

j~F (Fahrenheit) 5/9(1, - 32) + 273.15 :;;:
Celsius from Fahrenheit: , = 519(1, - 32)
Fahrenheit from Celcius: t r = 9/5 'c + 32
Derived 5 Uni!s wilh Special Names
QU8IJtty Name Syrnbo! Expressed in basic,

sup/eInentary or
derived 81 units
Irequency horIz 1 1 SI
lorce newton 1 1 kg m/s~
pressure, pascal 1 Pa 1 N/m 2*
energy, working quantity heat joute J 1J 1 Nm
power watt W 1 1 J/s
lCc potentIal (DC) ! 1 1
temperaure Celsiu$ "C 1"C 1 k"
For mechanical $Iro$$o$ N/mm 2 widely u$ed. 1 N/mm2 :::: 1 N/m2

,.
t ("C) =() - ,(), where , =273.15
04.37 - ESO
+#,' DieseIj
Description
Conversion Table 500.60
Page 3 (3) Edilion
Generai
Volume (1 m' = 1000 )

1 cub. (cubic inct1) 16.391 m'
1 cub. ft (cubic fool) 28.32 10"3 m:i::: 28.321
1 ga!lon' (imperial, UK) 4.546 103 m3 ;;;: 4.546

1 gallon' (US) 3.785 10-3 m3 == 3.785
1 balTcl (US petroleum barrel) ;:;: 42 gaIIon (US) 0.1590 l~'
1 bbl (dry barrel, US) 0.1156 m'

1 I'cgister '::: 100 cub. fl 2.832 m:J
1 galJon ;:;: 4 quarts =: 8 pints
Mass (kg)
1 Ib (poLInd mass)::: 16 02S (ounces) 0.4536 kg

1 cwt (UK) (hundredweight) ;;;: 112 Ibs 50.80 kg
1 Jong ! (UK) =: 20 cwt =: 2240 Ibs 1.016 metric tons =: 1016 kg
1 short ! (UK) ;:;: 2000 Ibs 0,907 metric tons =: 907 kg
1 slug' 14.59 kg
n and mass in the ft-Ib-s sysIem
Pressure
(1 N/m' = 1 Pa, 1 bar = 1 ' Pa, 1 mbar = 10-' bar)
1 kp/cm2 ;:.: 1 al :::: 0.9678 98.07 1 ::: 0.9807 bar
1 aI :::: 735.5 mm Hg* ::: 10 m *" (" 277 )
750 mm Hg' 105 Pa := 1 bat'
1 mm Hg* ("273 ) 133.3 Pa '" 1.333 mbar
1 mn1 H~O" ("277 ) 10'4 at ::: 9.807 Pa := 98.07 10-3 mbaI'
1 Hg" (" 273 ) 3386 ::: 33.86 mbar
1 ;>" (:= 277 ) 249.1 Pa ::: 2.491 mbar
1 alm (standarc! atmosphere) 760 mm Hg, 1.013 105 Pa:::: 1013 mbar
1 alm == 1.033 a!
1 Ibf/sq.in (psi) 6895 Pa =: 68.95 mbar
Mercury. 1 mm Hg := 1 Torr
Values table provided gn ::: 9.80665 m/sz
.. Water coJumn (WC)
Some physical daia SI unils
Nomenclature
t ::: temp. in "C :::: temperature difference
r =: density kg/m 3 Cp ::: heat capacity J/(kg )
c, C"
range
Water 18 999 4.1810 3
Lubricating l ( 15 900 1.9610 3

Atmospheric air (dy) (=1 bar) 1.276 998 0-150 1005
Exhaustgas 200-400 1080
Viscosily: 100-140 cSt at 40"C
750 mm Hg:= 1 bar= 105 Pa
1 alm (standard pressure ! sea level) ::: 760 mm Hg::;:: 1013 mbar
Gas constant for and exhaust gas " 287 J/(kg )
Water, heat of evaporation 100"C 1.013 bar 2.256 10$ J/kg
Fuel l. Lower caiorifJc l 41-43 10 G J/kg
ISO 3046/1-1986 standard reference fuel 43 1QG J/kg
Diesel engine reference fuel (see beiow)
04.37 - ESO
DescripIion
Page 1 (3) Basic Symbols for Piping 500.65
Edition
General
Symbol Symbol desigIlaIion SymboI Symbol desigllatiOJl
;,::. ~ vpecac e !Iange

1. CONVENTlGNAL SVS -j 11--
--1.1-- .__...._-_._.- ''-"----- "... --------~--- .."- .,.--.- ~- ---..----...-.- .
-rfice---- ----~------- ...,."-.-
-----2'-----'--- ! w1TrlcficatioilOfCfi?ectlon
_._--"........ - ......
of flOW------' [-2 -------"
-T3~ ------ITaves, gate valves, cc<sa:nafa~-[2-:-/-----+L.cv'''CAeansn~--------

_
-1:f--
~~
.. /
.....
-nflce .--.----.----.,------.
l><I -3-
---- [J+ApjJfailCeS -----I:8 9>-+< ""iio coupIIng------------
r"T.S- -c':)' ----!-rncflcaTng ana measurmg'1ilstrumenis--' --'2 -' '--pneumatrcrrow o""Tiaio atmosrJ"f1ere-
V
-r- ....,---.-- ~ign-pressTeprp-e-',---------- . ---- -.---- _ _.M.__. _L..... .._ _ _ _ _ .. - - - - - - . - - ... ~"-"."-.
",] 3. VVS, VALVES, CGCKS AND FLAPS
05.02 - ESO
J
500.65 Basic Symbols for Piping

Descriplion
Page 2 (3)
Edition
General
Symbol Symbol designation Symbol Symbo! designalion
." uouOIe-sea l,;Iiangeover va v

~I 4. CONTROL I PARTS
"+--m.8
-"3,c.1'" .,~:,'-_-S-(iCfr'vavCfi-eSt----------- --4','-" -~---an:-eratec-_----
Suclion varve chest wlth non-retlirrlvalves "~~' ~ "Rementrl
~ (
~-'" LJouble-seateJ changeover lV, straTgfi-+-4.3--f------,,----,s-rg--
f:*1 j
,-+--'---..
c,,''-,. '''.< LJOUQle-soaIoa cnangeover vaIve, angle --r--~-", --~---fVass-"-----
~1 D
~22--' .__._._-"'-"---- TCk, stralglfthrougfi- ....- - - -..- ..--- -'4-.5- ------ --'Fla-------- .. - - - - - . -
:: -
-"-~~ -- Q1 C-c<" angle - - - - -...-,.--.....- - - - - - -2f{"-- --!--Plsfon-------- ..__.......__. -
-:3:2<' "'c~ ''COc1lnree-way~ L-porTTnplig'----- "4.--' '--f- "l'iemorae"'--------
-'3.~. -- cC"mee-:wa~:6rt p!ug-----~---...~,---""--"-"-Iecrc m-------------

~'J @
----:J:2'6..--~ ....'ck,lur,\a, s'raigliTffiii5ugh ,n pl;:;g-"-' ....4:9- -- f"Y'> .... "Efec,romagnctlc-"
-:2'" ..------""----- _. -COC-w1tf56m cnn-eC6--------~ "2[-fU-' --.--..- - - "lI.afUa(aneumatCVav6S--------
J ~
-'-g:-~ "---"--"'--'-. __._- 5c;sfragfifrcgF[W1ff60f-m corYi".-- -----r.Ti-+---------------rusFbun~ .--....-.--------.--
;J.t:::f --w[X!rJ
"', ang!e, wrtfil5'Qm"connectIon 2. ~
<J=C
wIffi"'50ttom .. _. ._.-
~
. ----COCoffiree-Way, connea~ --:;r.:- ;:,oenoldr---------
. L __ rz:C
1--3:3"'1---(:..~ - Tlieiios'a"c valve-------------~-- zu:[- ----SOen<iinaI10Cffi'ecnaiaiie----------
~----t~-T~'--"-' l wfl11:est Ilang---------- "4.1s------.=----8y plunger rtrace-""-

...-x'll c:(_.
--:J:J'J'''~'''::- '3:way valve tiremotcili(act'ua'r)" "~""-:';:::~C~" --- ....- - -..---"-------.-.- ",.." - - - -
-3:"34-- .".- -.0-- 'l\"::fcUf:iValve (aIr) -------.,..- ---"5:-~] lCl5o------------
"3:35"'- "'-~-"-'--:J72sPlng retrn l., normally closed .-.. ''''''''' 1----ij". . 'HeTor s'raineT--_ --.-
-""3:"3"0 ----.-- 212rng return\ave~(ma~cr~ ----s:.:r-..,. .! --- "IilIagnefc-fe"""-------------
-[[[,r k:::'..J
afJIS)"
-:;'
-o:3~'-I-----''----+-,:--:-:-:-:-
.._.~"1-
-_ ...1
"R""educng iav"{adi3{al------ .. --."5~~L......--- ...
- ...........,.,--..- _ c _
a/ l contro!led by solenoid and l
direclional valve and with spring return
'"
____--+-""'-1-
0.0
.
~3T- -..-.".".--- 372"""Srlng re..'vale conr". by solenOiCf-!---5J.1.- -----+~"'o'"araIo----,- - - - - -..- . - . - -
QJ
D
"""Sfeam trap---- ....-...---.,-----
L>enIrt ugarpImm'"p,-----------1
05.02 - ESQ
Description
Page 3 (3) Basic Symbols for Piping 500.65
Edition
General
Symbol des"lgnat"lOll . Symbol Symbol designaIiorl
I,.)ear 01" scr0W pump

6. HTTINGS
--:---- -i,lncurlii"b"ucke'--"-- """-""".""-"-_."".._----}---,,"'. -,------
-""c~-----------------
EjecIor Q~r- ~:~_"-I~".~--- -01"8Ifl
-----hV-,;a:OrjC;;o;-;:usc;-a;occcc'~e:;;sso;::r;::ie"'s-,("'e::;x" ,"'o'b"'e"'a"'d"'cl"'ed"')C--- "-"l": vvasre nay --------
Piston" pump --~;..4~+----f-waS1lraw,fpu~g------------
5.17
--_.-
Observation glass
5.20
5"23
05.02 - ESO
5ection 501
Operation of Engine
Description
Operating 501.01
Out-of Serice 501.05
Stag-u after Out of Serice Periods 501.10
Guidelines for Longterm Low-Load Operation HFO 501.15
Guidelines Regarding Dlesel GenSets 501.16
Operatingon Low Sulphur Fuel l
Description
Operating
501.01
Page 1 (2)
Edition 01
23/30
Preparalions lr Slarling 4. Check the pressure in thestarting air receiver(s)

and open the starting air supply (blow-offwater, if any,
The following describes what 10 do before slarting, and drain the starting air system before opening.
when the engine has been out service a l
ger period time, if major overhauls have been 5. Regulating gear - please check:
made.
that all ' pumps are set at i nde "" when
1. Check the oil level in Ihe base frame (or in the regulating shaft are in STOP position.
th e lub. oil tank, if the engine is with dry sump), air
lubricator and in the govenor. - that each ' pump can be pressed by hand
ll ind e when the regu lating shaft are in STOP
Start-up the prelubricating pump. position, and that the pumps return automatically
the '''' inde when the hand is removed.
The engine shall be prelubricated at least 2 minutes
prior start. - that the spring-Ioaded ll rod is working cor-
rectly.
Check oil pressures before and after the filter.
- th at the stop cylinder regulating the shaft
2. Open the cooling water supply, start separate works properly, both when stopping normally and at
cooling water pumps where installed, and check the overspeed and shut down.
cooling water pressure.
- that testing is made by simulating these situa-
Nole: avoid shock effects owing large tempe- tions.
rature fluctuations just after the start, it is recom-
mended: 6. Open the indicator valves and turn the engine
some revolutions, check that liquid is flowing
a) preheat the engine. Cooling water at least from any the indicator valves during the tur-
60 "C should be circulated through the frame and ning.
cylinder head at least 2 hours before start:
Slow-turning must always be carried , before the
- either by means cooling water from engines engine is started after prolonged of-service pe-
which are running by means a built-in preheater riods and after overhauls, which may involve a risk
(if installed). liquid having collected in the cylinders.
7. Close the indicator valves.
b) When starting without preheated cooling water, 8. Disengage the turning gear, iftitted. Check that
the engine must only be started (Ma-rine it is locked in the ' position.
DieseI Oil).
The engine should l be run more than 50% Slarling

load begin with, and the increase 100% should
take place gradually over 5 10 minutes. 1. Start the engine by activating the start but-
tom.
Nole: When starting HFO (Heavy Fuel Oil), only
item "a" applies. 2. Check the lubricating oil pressure, cooling
water pressure, ' oil feed pressure. Check that
3. Open the ' oil supply the feed pump. the prelubricating oil pump is stopped.
Starting HFO: circulate preheated luel through the 3. Check that all alarms are connected.
pumps until correct working temperatures have been
obtained. This normally takes 30-60 minutes. See also "checks after starting-up".
96.02 - ESOU-G
501.01 Operating Descriplion
Edilion 01
Pag. 2 (2)
23/30
Tesling during Running 9. Toensure full operationalliability, the condition

of the engine should be conli nuously observed in
When the engine is running, the planned maintenance order for preventive maintenance work be carried
programme and the following should be checked: ! before serious breakdowns occur.
1. The lubricating l pressure must be within

the stated lmts and must not fall below the stated Slopping
minimum pressure. The paper filter cartridges must
be replaced before the pressure drop across the filter 1. Before stopping, ! " recommended run the
reaches the stated maximum value, the pressure engine at reduced load, idle for about 5 minutes
after the filter has fallen below the stated minimum for cooling-down purposes.
value. fi lter cartri dges cannot be cleaned fo r
re-use. 2. The engine is stopped by keeping the fuel pump
delivery rate at '''', by turning the "Ioad-limit" knob
2. The lubricating l temperature must be kept on th e governor '''', by activating the remote
within the stated lmts indicated on the data sheet. stopping device.
3. The fu el l pressure must be kept at th e stated

value, and the filter must be cleaned before the Start and Stop HFO
pressure drop across the filter reaches the stated
maimum value. Start and stop of the engine should take place on
HFO order prevent any incompatibility problems
4. The cylindercooling watertemperature must be by change-over .
kept within the limits indicated and the temperature
rise across the engine should not exceed 10C. should only be used connection with main-
tenance work on the engine longer periods of
5. Th e cooling water temperature at the charging engine standstill.
air cooler inlet should be kept as l w as possible;
however, not as l as produce condensation Before slarting on HFO the engine must be properly
water in the charging air space. preheated as described in "Preparations for Starting"
and as described below.
Adjustment takes place in theexternal system outside
the engine, and the amount of cooling water must Stopping the engine on HFO " no problem , but
be adjusted so th at the temperature rise across the should be ensured that the temperature of fuel pipes
charging air cooler is 3 - 5 C. are not reduced a level below the point of
the fuel, otherwise, reestabilishing of the circulation
6. The exhaust gases should be free from smoke might cause problems.
at all loads. For normal exhaust temperatures, see
the test ! from shop and sea trials.
Slarling
7. th e charging ai r pressure and tempera-
ture under control. For normal values, see the test For starting on there are restrictions except
report from shop and sea trials. lubricating l viscosity may not be higher than 1500
cSt (5 C SAE 30, 10 C SAE 40).
8. Recharge the starting air receivers when the
pressure has dropped about 20 bar. Stop rechar- Initial ignition may be difficult if Ihe engine and am-
ging at 30 bar. bient temperatures are lower than 5 C and 15 C
cooling water temperature.
96.02 - ESOU-G
'li/(MAN Dieserl
Description
Out-of Service
501.05
Page 1 (2)
[difion 01
23/30
1. Standby Engines 4.3. Open all lilters check that l l ' elements
are intact. Filter cartrid ges the lub. l filter is be
During engine standstill stand-by position the replaced belore start, after repai r, or after excessive
media cooling water and luel l should be con- dillerential pressure. After removal, dirty elements
tinuously circulated at temperatures similar the can be examined for parti cles bearing metal at
operation conditions. the botom of the paper lamella. (the elements can
be used again).
The engine shall be prelubricated 2 minutes prior
start. l there is intermittent or continuous pre- 4.4. Check the cylinder walls.
lubricating installed. intermittent prelub. is 2 min
every 1 minutes. 4.5. Take dellection measurements the crank-
shalt.
2. Maintenance during StandstiII 4.6. lubricating l sample should be sent a

laboratory lor immediate analysis.
periods during stand-still the engine (
stand-by position) is recommended start the 4.7. Drain plugs are unscrewed Irom the botom
prelubricating l pump minimum 10 minutes once turbochargers, or the drain cock is opened. 1I drain
every week and totum the engine during the prelu- lacilities are installed the exhaust gas system this
bricating period by 2-3 revolutions. should be opened.
3. Laidup Vessels 5. Work during Repairs
During the lay-up period (and alsowhen laying-up the The lollowing should be made during major re-
vessel) recommend that our special instructions pairs.
for preservation the engines are followed.
5.1. Retighten all bolts and nuts the crankcase
and check their locking devices. Also, retighten
4. Work before Major Repairs loundat on bolts.
4.1 After stopping the engine. while the l is sIill 5.2. Check the various gear wheel drives lor the
warm. start the el-driven prelub. pump, open the camshalt(s).
crankcase and camshaft housings and check th at
the l is Ilowing free ly Irom al l bearings. Also, take 5.3 . Remedy leakages water and l the en-
off the covers the cylinder heads and make gine, and blow through blocked-up drain pipes.
sure that l is supplied for lubrcaton rocker
arms, as non-return valves are fitted which do 5.4. Drain starting air pipes water.
open l th e il pressure at the l the rocker
arms exceeds 1 bar. 5.5. Empty the oil sump lubricating l and remove
the sludge, l done within a period one year.
Alter overhaul of pistons, bearings, etc. this check Clean the sump very thoroughly and subsequently
should be repeated before starting the engine. coat with clean lubricating l.
4.2. After stopping th e prelub. pump, check the

bottom th e l sump lor Iragments babbi t Irom 6. Work after Repairs
bearings
6.1 . 1I an opening-up engine or lubricating l
system may have caused ingress impurities,
cleaning should be carri ed very carelully belore
starting the engine.
96.02 - ESOU-G
501.05 Out-of Service
DeSCfIplion
Page 2 (2)
EdiIIon 01
23/30
The differential pressure across the lub. l filter 6.7 b) Adjustmentspeed: Switch-in thealternator
must be watched very carefully after cleaning and on the switchboard and set the load about 40%.
starting-up the engine. Be sure replace ( cart- an reaching normal l temperatures in governor
ridges in due time. and engine, increase th e load instantlyto about 80%
(by starting the major pump compressor). This
6.2. After restoring normallubricating l circulation, must not cause the frequency fall by more than
turn the engi ne at least revolutions by means of some 8%, and the engine must return a constant
the turning rod check the movability ofthe relevant no rpm after about 3 seconds (although this rpm
parts of the engine. ll be a lttle lower than before owing the speed
droop of
6.3. Close the drain cocks in the turbocharger (or the governor). If the engine is operated in paraIIel
in the ehaust gas system, if mounted). with other engines, an even sharing ! load shall
be established within about 3 seconds. If the gov-
6.4. Lubricate th ebearings and rod connections in ernor reacts slowly, compensating adjustment
the manoeuvring gear. Disconnect the governor and is effected as indicated in Woodward's instruction
move the rod connections by hand check that the manual (Compensating Adjustment).
friction in bearings and fuel pumps is sufficiently low.
If repair of bearings alignment of engine has been Note: It is a condition for this test that the eng ine
made, check no 1, 2, and 5 should be repated. and turbocharger are in perfect operating condition.
so that possible sources of error immediately can
6.5. Checks be made just before starting of the be eliminated
engine are mentioned under 501.0 1.
6.7 c ) Hunting: Run the engine at synchronous
6.6. Add cooling water and check the leakage rpm , and withou t load. Provided the governor l is
pressure system on at the upper and l wer cy-linder warm, the regulating lever must not perform any
lner sealings and at cooling water connection s. major periodical movments, and neither must there
be any variation th e engine speed. If that is the
6.7. Check the governor as follows: case, repeat the compensating adjustment accord-
Start the engine and run at the synchronous ing to Woodward's instruction manual.
number ! revolutions.
6.7 d ) Speed droop: in case ! unsatisfactory
6.7 a) Speed-setting: Before switching-in the load sharing between two ore more engines this
alternator the switchboard please check that the can be rectified by increasing the speed droop !
servomotor adjusts the rpm with a su itable quick- the engine that is subject the greatest load (or
ness after actuation ! the synch ronizer knob on the by reducing the setting of the other engines).
switchboard. The range from - 5% + 5% from the
syn-chronous rpm should be tested. The setting should not normally be increased beyond
70 on the scale, and satisfactory paraIIel operation
can generally be obtained at settings between 40
and 60.
96.02 ESOUG
Oescription 501 ,10
Page 1 (1) Starting-up after Out of Serice Periods
Edition 01
23/30
The lollowing enumerate checks are be made After the last leel-over, repeat check 4 page 501.05,
immediately alter starting, during load increase, see also Ignition Crankcase page 503.04
and duri ng normal running. section 503.
tI,e lo//owing is assUIned Ihat tl1e engine has Alter repair renewal cylinder liners, piston
been service lor some , lor il1stal1ce due rings bearings. allowance must be made lor a
repairs and that c/1ecks duril1g service runn ing-in period, .. the engine load should be
periods have beel1 carried as described 1 tI,e increased gradually as indicated in the tables below.
previous chapter. The engine is determined the basis the
luel index and the load the elec tric switchboard.
When starting alter such an out-ol-service period, the The turbocharger speed gives some indication
lollowing checks must be made in the stated order the engine output, but is directly proportional
in addition normal surveillance and recording. the throughout the service period.
Begin the startingup sequence at a reduced eng ine

1. be Checked immediateIy after Starting : speed, e.g. 400 rpm, l can be known lor cer-
tain that there are hot spots the engine. Then,
1.1. Check that the turbocharger is run ning. increase the speed the normal rpm and connect
the switchboard and ioad.
1.2. Check that the lubricating l pressure is
order. The load increase during the starting-up sequence
may, lr instance, be:
1.3. Check that aII cylinders are li ring (see exhaust
temperatures). 25 % load lor 2 hours
50 % load lor 2 hours
1.4. Check that everyting is normal lor the engine 75 % load lor 2 hours
speed . luel l . cooling water and system l. 100 % load may be on.
1.5. Check by simulation the overspeed shut- The pump index indicated the tables has been
down device that the engine stops. The overspeed given as a percentage the index at lull load .
setting should be according ' Set Points and enable the index to be read directl yoff the luel pumps,
Operation Data ' section 500. the 10lIowing lormula can be employed:
; J..% Ir
2.
be Checked during Starting-up, buI 100
f Required after Repairs Alterations :
, ; Index at lull load (Irom testbed table)
2.1 .
the condition the machinery is not well-
known, especially after repairs aiterations, the % Index expressed as % lull ioad index
'feel-over sequence' shouId always be lollowed, (stated the preceding starting-up
..: sequence).
After 5-15 and 30 minutes' idle ru nning, open the Following the alteration the pump index the
crankcase and the camshalt housing and perlorm
cylinders concerned must be checked
l - the surlaces all moving parts where that when in STOP position the governor is able
Iriction may arise and cause undue heating. move all the luel pumps an average pump index
not exceeding 2 3.
Feel: Main, crankpin, (aI ternator), and camshaft
bearings, piston pins, cylinder liners, roller guides After completing the star ting-up sequence, make
and gear wheels. su re that all luel pumps are set at the same index
and th at the governor can cause aII lue pumps to
move '' index.
96.30 ESOU-G
Oescription
Guidelines for Longterm Low-Load Operation HFO 501.15
Page1(1) Edition 03
General
Part load/low load operation and turbocharger. HFO-operation at loads lowerthan

20% MCR should therelore only take place within
certain ship and powerstation operation modes the certain time limitations according the curves.
diesel generating sets are eposed part load /low
load operation . After a certain period HFO-operation at loads lower
than 20% MCR, a change should take place
During manoeuvring the ship all diesel generating ord er prevent lurther retardation the engine
sets are of1en started lor salety reasons, result- performance condition. Alternatively, the engine load
ing l w should be raised 70% MCR over a period 15
load operation all the engines. During harbour stay minutes and maintained here lor some time order
diesel generator cou ld be low-Ioaded when only burn the carbon deposits, thu s re-establishing
hotel purposes are consuming electricity. adequate performance condition. Af1er such a "clean
burning period" lw load operation HFO can be
Island mode operation diesel generating sets continued.
power stations is Irequently eposed lw load
operation lke a ship. However, the operator must be aware the lact
that louling the combustion air l channels,
part load/low load is Important maintain l any, ill be cleaned at high load operation.
constant media temperatures, .. lr cooling water, Etensive lw load running can therelore result
lubricating l and luel l order ensure adequate the need lor manual cleaning the combustion air
combustion chambertemperature and thuscomplete l chan nels.
combustion.
1I special application conditions requi re continuous
loads lower than 20% MCR there is a risk tim e HFO-operation at loads lower than 20% MCR and
dependant retardation the engine performance occasionally performed "clean-burning" periods are
condition due fouling th e eha u st gas channels inconvenient impossible, special equipment and
and combustion air channels, combustion chambers arrangements must be established.
Load %
20
Admissible lo\v-Ioad operation Necessary operating period
(Ioad percenIIperiod) HFo. with min. 70% load after low-
load operation HFo.
15
10 - - -- - \ a
--- - - - - - - - - -- - -- b
---
Running-up period 10 70%
load: approx. 15 min .
70% load
HFOorMDO
.
5
1 5 10 20 30 40 50 607080 90 1 2 3
Operating period (h) Operating period (h)
Example: a) with 10% load 19 hours maximum operalion HFO admissible, then change-over 10 D
b) operate engine for approx. 1.2 hours with 70% raling minimum, order 10 burn residues.
Aftewards l load operalion HFO can be continued.
Fg 1 Lowload oper8tion.
08.20 - ES1
f':'HMi(MAN DieseI!
Description GuideIines Regarding DIeseI GenSets Operating 501.16
Page 1 (1) SuIphur FueI Edilion
GeneraI
Exhaust emissions from marine diesel engines have L sulphur distillates

been the fOCUs recent legislation. Apart from nitrous
oxides (), sulphur oxides (50) are considered general our Gen5et is developed fo r continuous
to be the most important pollution factor. range operation HFO as well as MDO/MGG. Occa-
new regulations have been implemented and others sionally changes operation mode between HFO
ll ll ( , Directive, and CARB). These and MDOIMGO are considered to be within normal
regulations demand reduction 50 emissions operation procedures for our engine types and do
by restricting the sulphur content the l . That is thus not require special precautions.
to say sulphur l m ts for HFO as well as mandatory
use lw sulphur distillate fuels for particular ap- Running low sulphur l 0.1% 5) l l not
plications. This guideline covers th e engine related cause problems, but please notice the following
aspects the use such fuels. restrictions:
L sulphur HFO order to avoid seizure the l il injecti on

pump components the viscosity at engine l l
From an engine manufacturer's point there inlet must be > 1.5 c5t (except for L32/40 - req uired
is lower limit for the sulphur content HFG. We viscosity at engine l l inlet > 2.0 c5t). order
have not experienced any trouble with th e currently achieve thi s it may be necessary to install a l l
available low sulphur HFO, that are related to the cooler, when the engine is running MGG. Thi s is
sulphur content or specific to l w sulphur HFG. This both to ensure correct viscosity and avoid heating
may change the future new methods are applied the service tank, which is important as the l
for the production lw sulphur HFO (desulphuriza- l injection pumps are cooled by the l.
tion, uncommon blending components). Diesel
l l monitor developments and inform our customers When operating MDO/MGO a larger leak l
necessary. amount from l l injection pumps and l l
injection valves can be expected compared to
the engine is not operated permanently lw eration HFG.
sulphur HFO, then the lubricating l should be se-
lected according to the highest sulphur content order to carry out a quick change between HFO
the fuels operati on. and MDO/MGO the change over should be carried
out by means the valve V1- 2 installed front
the engine.
For the selection the lubricating l the same ap-

plies as for HFG. Fortemporary operation distillate
fuels including l w sulphur distillates nothing has to
be considered. lubricating l suitable fo r operation
diesel l should only be selected a distillate
l is used continuously.
07.12 - ES1
Section 502
Engine Perfonance and Condition
Description
Engine ermance and Condition 502.01

Ealuation of Readings Regarding 502.02
Combustion Condition
Condensate Amount 502.05
Working card
Engine ermance Data 502-01.00

l DieseII
Descriplion
Engine Performance and Condition 502.01
Page 1 (3) Edition 01
L23/30
V28/32S
Perlormance DaIa and Engine CondiIion increase of~e ajrtemperature involves a cOf-
responding increase the exhaust gas temperature
D operation small alterations the engine l!M1! a ratio about 1: 1.5, .. 1' C higher charge
condition continuously take place as a result com- air temperature causes about 1.5' C higher exhaust
bustion, including l ouling airways and gasways, gas temperature.
lormation deposits, wear, corrosion, etc. 1I conti-
nuously recorded, these alterations the condition Reduction the charge air pressure resu lts a
can valuable inlormation about the operational corresponding reduction the compression pres-
and maintenance condition the engine. Continual sure and max. combustion pressure. When checking
observations can contribute lorming a precise the max. pressure adjustment the engine, ! is
and valuable basis lor evaluation the optimal therelore be ensured that the existing charge air
operation and maintenance programmes lor the pressure is correct.
individual plan t.
The injected amount l e l is equivalent supplied
We recommend taking weekly reco rds the most energy and is thus an expression the load and
important perlormance data the engine plant. D mean pressure the engine. The l l pump ;ndex
rin g recording (working card 502-01.00 can be used), can therelore be assumed be proportional to the
the observations are be continually compared mean pressure Consequently, can be assumed
order ascertain alterations at an early stage and that the connected values th e pump index are
belore these exert any appreciable inlluence the proportional the load.
operation the plant.
The specilic lel consumption, SFOC (measured by
As a relerence condition lor the perlormance data, weight) ll , the whole, remai n unaltered whether
the testbed measurements the or possibly the engine is operating HFO or D , when
the measurements taken dur;ng the sea trial at the considering the diffe rence calori metric combustion
delivery the ship can be used. 1I considerable value. However, when operation HFO, the combi-
deviations Irom the normal condi tion are observed, nation densi ty and calorilic value may result an
ll , a majority cases, be possible to diagnose alteration 6% the volumetric consumption
the cause such deviations by means a total at a given load. This ll result a corresponding
evaluation and a set measurements, after which alteration th e l l pump index, and regard should
possible adjustmenVoverhauls can be decided and be paid this when adjusting the overload preven-
planned . tative device th e engine.
Abrasive particles the l e l l result wear lel

EvaIuaIion Perlormance DaIa pumps and l e l valve nozzles. Ellective treatment
the lel l the purilier can limit the content
For example, louling the air side the air cooler abrasive particles a minimum. Worn l e l pumps
ll
manilest itsell an increasing pressure drop, l l result an jncrease the ;ndex account
lower charge air pressure and an jncreased exhaust an increased loss the pumps due leakage.
temperature l ee l (with consequential inlluence
the overhaul intervals lor the exhaust valves). Wh en evaluating operational results, a distinction
is to be made between al terations which affect the
Fouling th e turbine side the turbocharger ll , whole engine (all cylinder units) and alterations
its li rst phase, manilest itsell increasing which occur only or a lew cylinders. Deviations
charger revolutions accoun t increased gas occuring lor a lew cylinders are, as a rule, caused
velocity through the narrowed nozzle ri ng area. by mallunctioning individual components, lor
the long run, the charging air quantity ll decrease example, a lel valve with a lowopening pressure,
account olthe greater llow resistance through the blocked nozzle holes, wear, other delects, an l!
nozzle ring, resulting higher wall temperatures exhaust valve wi th wrongly adjusted clearance,
the combustion chambers. burn ed valve seat etc.
02.47 - ESO
502.01 Engine Performance and Condition Description
23/30
V28/32S
Th e operati onal observations supplemented by Normally, the luel nozzle temperature l l be higher
the daily routine monitoring contribute ensuring than the approx. 180' C, at which cold corrosion
that laulty adjustments and other deviations in the starts occur.
performance individual components are observed
in time avoid operational disturbances and so Abrasive particles in the luel l involve a heavier wear
th at normal routine overhauls can be carried as the luel valve needle, seat, and luel nozzle holes.
scheduled. Therelore, abrasive particles are, tothe greatest pos-
sible extent, be removed at the purilication.
1I abnormal or incomprehensible deviations in the
operation are recorded , expert assistance lor the
evaluation these should be obtained . Exhaust Valves
The overhaul intervals exhaust valves is one the

Turbochargers key parameters when reliability the entire engine is
be judged. Operation on HFO has a negative effect
Service experience has shown that the turbine side on these intervals. The performance the exhaust
is exposed increased louling when operating on valves is therelore extremely inlormati ve.
HFo.
Especially under lavourable conditions, luel quali-
The rate louling and thereby the inlluence on the ties with a high vanadium and sodium content ll
operation the engine is greatest lor small turbo- promote burning the valve seats. Combinations
chargers where the Il openings between the guide vanadium and sodium oxides with a corrosive effect
vanes olthe nozzle ring are relatively small. Deposits ll be lormed duri ng the combustion. Thi s adhesive
especially occuron the guide vanes th e nozzle rin g ash may, especially in the case increased valve
and on th e rotor blades. In the long run , louling l l temperatures, lorm deposits the seats. increa-
reduce the efficiency the turbocharger and thereby sing sodium content ll reduce the melting point and
also the quantity air supplied lor th e combustion thereby the adhesive temperature lor the ash, which
th e engine. reduced quantity air l l result in ll involve a greater risk lor deposits. This condition
higher wall temperatures the combustion spaces ll be especially unlavourable when th e weight ratio
th e engine. lliI increases beyond 1:3.
Va
Detailed inlormation and instructions regarding
water washing the turbocharger are given in th e The exhaust valve temperature depends on the actual
section 512. maintenance condition and the load the engine.
With correct maintenance, th e valve temperature is
kept at a satislactory lw level at all loads. The air
FuelValves supply tothe engine (turbocharger/aircooler) and the
maximum pressure adjustment are key parameters
Assuming that the luel l is effectively purilied and in this connection.
that th e engine is well maintained, the operational
conditions l or the luel valves and the overhaul in- is important lor the lunctioning the valves that the
tervals ll not normally be essen ti ally altered when valve seats are overhauled correctly in accordance
operating on HFo. with our instructions.
11, lor any reason , the surface temperature th e l uel The use rotocaps ensures a unilorm distribution
valve nozzle is lower than the condensation tempe- temperature on the valves.
rature sulphuric acid, sul phuric acid condensate
can lorm and corrosion take place (cold corrosion).
Th e lorma ton sulphuric acid lurther depends on
the sulphur content in the luel l .
02.47 - ESO
',Ji$MMAN DieseII
Description
Engine Performance and Condition 502.01
23/30
V28/32S
InIet VaIves Engine Room VentiIation, Exhaust System
The operational conditions the air l valves are Good ventilation the engine room and a suita-
substantially altered when using residual luel. ble location the Iresh air intake the deck are
important. Seawater the intake air might l
corrosive attack and inlluence th e overhaul intervals
FueI Pumps lr the exhaust valves.
Assuming effective purilication the luel l, the The Iresh air s uili' (ventilation) to the engine room
operation the luel pumps ll not be very much is correspond approximately 1.5 times the air
affected. consumption the engines and possible boilers
operation. Sub-pressure the engine room ll
The occurrence increasing abrasive wear l l an increased exhaust temperature level.
ger and barrel can be a consequence insullicient
purilication the luel l, especially l using a luel The exhaust back-press!Jre measured after the
which contains residues Irom catalyticcracking. Water turbochargers at lull load should exceed 250-
th e luel l involves an increased risk cavitation 300 mm water gauge. increase the exhaust
connection with pressure impulses occurring at th e back-pressure ll also involvean increased exhaust
cutting-oll the luel pump. luel with a high asphalt valve temperature level.
content has deteriorating lubricatin g properties and
can, extreme cases, result sticking th e luel
pump plungers.
02.47 - ESO
" Dieserl
Descriplion EvaIuation of Readings Regarding 502.02
Page1(1) Edilion 01
Combustion Condition
23/30
PRESSURE
INCREASING
(Jimit50% )
Air fillers
fouled .
PRESSURE
INCREA81NG
(limit50%)
side
cooler fouled.
L CYLINPEBS
Exhaust temp. increasing:
' DIFFERENCE
system fouled
LARGE
( fitter-blower-cooler).
flow 100 5ma!1
Exhaust system fouled
(nozzle ring, lurbine wheel).
~I----+- +--

LARGE
cooler fouled.
CYLI NQEB DECREASING CHARGE

Exhaust t emp. PRESSURE:
creasing: Fue! valve Decreasing air amount.
needs overhaul. Fouled urbocharger,
Compression 100 low air flller charge
owing 10 leakage air cooler (air side) .
exhausI valve piSt011
ring blow-by.
...,...., and rnA.< are measured by means
max. pressure gauge.
cor 100 l : Leaky combustion chamber,
charging air pressure 100 low.
See also:
,,,,," 100 low:
r.:otr 100 row, ignilion 100 lale. Engine Performance
and condition 501.01
92.03 - ESOS-G
Description
Condensate Amount 502.05
General
Ambienl air temperature (1 bar)
10 20 30 40 50 60 70 (' C)
0.08
0.06
Max.

c
c
8
0.04
0.02
==:>
Aelative
air humidily 30 40 50 60 70 ('C)
Charge air temperature atter cooler.

lemperature tank.
Fig. 1 Nomogram for ca/cu/alion of condensate amount.
General Then normally, the air cannot absorb the same

amount water as belore.
There iS always a certain amount water air.
When the air iS saturated with aqueous vapour, the Condensation water the engine's charge air
humidity iS said be 100% and there is as much receiver is consequently dependent the humidity
water the air as ! can absorb without condensing. and the temperature the ambient air. lind !
The amount water kg/kg air can be lound Irom l condensation the charge air receiver ll occur
the diagram. The ability absorb water depends the diagram can be used.
the pressure and temperature the air.
Example:
Amount of CondensationWater Ihe Charge Diesel engine 1000 kW

Receiver Ambient air conditi on:
air temperature 35 C
Both higher pressure and lower temperature reduce relative air humidity 90 %
the ability absorb water. turbocharg ed diesel Charge air temperature 50 C
engine takes air Irom outside, compresses and Charge air pressure 2.6 bar
cools the air.
04.31 ' ES2

502.05 Condensate Amount
Description
General
As a guidance, an air consumption 8.2 kg/kWh (Le) Amount Condensate Water Tanks
at lullload can be used lor & engines.
The volume condensate in the air tank iS determi-
Solution according diagram: ned by means the curve at the bottom Ihe right
the diagram, representing an operating pressure
Water content air () 0.033 kg/kg 30 bar.
Max. water cont. air (11) 0.021 kg/kg
Example:
Amou nt condensate in charge air receiver.
Amoun t condensate in air tank.
= (1-11 ) le
= (0.033 - 0.021) 8.2 1000 = 123 kg/h Volumetric capacity tank (V) 4000 dm'
Temperature in tank () 40 C=313K
Internal press. tank () 30 bar
Draining of Condensation Waler = 31 1' N/m2 (abs.)
Gas constan t lor air () 287 Nm/kg.K
This phenomenon l l occur on all turbocharged Ambient air temperature 35 C
engines. For & Four-stroke engine, th ere Relati ve air humidity 90 %
is no risk with a small amount water in the charge Weight air in tank
air receiver. l the charge air receiver is l lled with
water, there is a risk getting water into the cylinder. pxV 3tx10' x4
This water have be drained away. As standard a m= Rx T = 287 313 = 138 kg
valve is mounted on the charge air receiver/cooler
on the engine. This valve is be used lor draining
Ihe water. there is a great amount, the valve can Solution acc. above diagram:
be lelt hall-open. 1I the amount is small, the charge
air rece iver can be drained periodically. Water conten t air ( ) 0.033 kg/kg
Max. water cont. air (111) 0.0015 kg/kg
Amount condensate in air tank
= (1- III)xm
(0.033 - 0.00 15) 138
04.31 - ES2
"l,!iNMAN DieseII
Working Card 502-01.00
Page 1 (4) Engine Performance Data Edilion 01
L23/30
Safely precaulions: Speciallools:
Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water 52005-01 109 Max. pressure
Shut-off fuel l indicator
Shut-off cooling l
Stopped Iub. l circul.
Descriplion: Hand lools:
Measuring engine performance data.
Slarling position:
Engine is running.
Relaled procedure:
Man power: Replacemenl and wearing parls:
Working time , hour Plate no. Item no. Qty./

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

Data ' torque moment (Page 500.40)
Declaration weight (Page 500.45)
96.37 - ESOU-G
502-01.00 Working Card
Edition 01 Engine Performance Data Page 2 (4)
23/30
Engine Performance Data

Engine Type 131 Engine DaleIYear
151 Hour
Tolal Engine
1 2 4 6 Running Hours
Engine Fuel Type Turbocharger Turbocharger

7 Visc. Density 9 Type Serial 10
Switchboard
Effect (kW) Vottage (V) Current () cos lkVr
Cylinder Data
Ave-
15 Cylinder . 1 2 3 4 5 6 7 8 9 161 rage
17 FueJPump Index
18 Maximum Pressure (bar)
19 Compress. Pressure (bar)
20 Exhau$1Temp. ( C)
21 Cooling Water (OC)
Turbocharger
Tem. l blower ( C) Pressure before blower (mmWC) Temp. after blower ( C)
22 23 24
Press. cooler (mmWC) Temp. charge air ( C) Press. charge air (bar)
25 26 27
e m p. ex hausl gas before C ( C) Temp. exhaust gas after TC ( C) PreS$. exhaust 985 alter TC (mmWC)
28 29 30
Lubricating l System
Temp. after engine ( C) Press. before l (bar) Press. after filler (bar)
31 32 33
Temp. inlel engine (" C) Press. before TC (bar)
34 35 36
Cooling Water System

L lemp. inlet air cooler (" C) L lemp. outlet cooler (" C) L press. inlet air cooler (bar)
37 38 39
L lemp. inlet lub. l cooler (" C) L lemp. outlet lub. l cooler (" C) L temp. inlet aJternator (" C)
40 41 42
L temp. outlet alternator (" C) FW temp. inlet engine (" C) FW press. inlet engine (bar)
43 44 45
Fuel l System
Fuel l temp. inlet engine (" C) Fuel l press. before engine (bar)
46 47

Sign.
48 49 1501
96.37 - ESOU-G
,, DieseII
Pag. 3 (4) Engine Performance Data Edition 0 1
23/30
InsIrucIion for Filling n Ihe Diagram ''Engine 13. Current () - can be read the switch-
Performance DaIa" board.
The numbers the instruction are commensurate 14. Cos /kV r - can be read the switch-
with the numbers the diagram. board.
The automatic symbols mentioned the instru cti on

( 01 , 03, etc) reler the diagrams prin- Cylinder DaIa
te d the instruction books lor specilied plants and
page 500.20. 15. Cylinder . - can be read engine plate.
is used lor V-engines.
Engine Performance DaIa 16. Average lor all engine cylinders lor : 17-
18-19-20-21.
1. Name ship, l stationary name plant.
17. Fuel pump index - can be read each
2. Engine type. the high pressure luel l injection pumps.
3. Engine . 18. Max pressure (bar) can be read lor each

cylinder by means indicator or m" gauge.
4. Date/year observations.
19. Compression pressure (bar) - can be read lor
5. Hour, time observations. each cylinder by means the indicator measure-
ment, which is carried out during idling by nominal
6. Total engine running hours - engineer's log- RPM .
book.
20. Exhaust temperature ("C)
7. Engine revolutions per minute () - can be - th ermometer 60.
read tachometer 81 90.
21 . Water outlet cylinder ("C) (jacket cooling)
8. Fuel l type: the viscosity must be stated ( - thermometer 11.
c8t) and the temperature by which the viscosity has
been measured, f.in st. 180 c8V50"C. Density must
be stated: g/cm'. Turbocharger
9. Turbocharger: type and serial number are 22. Thermometer l blower ("C) can be read
stated the rating plate turbocharger and page by means a therm ometer placed the engine
500.00. room near the air l l ' the TC.
10. Turbocharger revolutions per minute () 23. Pressure belore blower (mmWC) - can be
- can be read the tachometer 81 89. read by means a mmWC instrument placed
the engine room near the TC.
SwiIchboard. 24. Temperature alter blower ("C) - can be read

by means a thermom eter 30.
11 . Alternator output (kW) - can be read th e
main switchboard . 25. Pressure ai r cooler (mmIWC) .
12. Voltage (V) - can be read th e switch- 26. Charge air temperature ("C). Temperature
board. the charge air the charge air receiver.
- thermometer 31.
96.37 ESOUG
Edition 01 Engine ermance Data Page 4 (4)
23/30
27. Pressure charge air (bar). Pressure ! the 39. L temperature (L) cooling water pressure
charge air the charge air receiver. (sea, raw or fresh) at inlet charge air cooler (bar)
- pressure gauge 31. - pressure gauge 01.
28. Gas before temperature exhaust TC (' C) 40. L temperature (L) cooling water tempera-
- thermometer 62. ture (sea, raw or Iresh) at inlet lub. l cooler (' C)
- thermometer 07.
29. Exhaust gas temperature after TC (' C)
- thermometer 61. 41. L temperature (L) cooling water tempera-
ture (sea, raw or fresh) al outlel lub. l cooler ' C)
30. Exhaust gas pressure after the TC (bar) - thermometer 03.
- pressure gauge 61.
42. L temperature ( L) cooling water l empera-
ture (sea, raw or fresh) at inlet alternator (' C)
Lubricating l System - thermometer 04.
31. Lub. l inlel cooler lemperalure (' C) 43. L temperature (L) cooling water tempera-
- Ihermomeler 20. ture (sea, raw Iresh) at outlet alternal or (' C)
- thermometer 05.
32. Lub. l pressure belore Ihe filter (bar)
- pressure gauge 21. 44. High temperature ( ) Iresh water tempera-
ture (FW) at inlet engine (' C)
33. Pressure Ihe lu b. il afler Ihe filler (bar) - thermometer 10.
- Pressure gauge 22.
45. High temperature () fresh waler tempera-
The Iilter e/ement should be replaced with a pres- ture (FW) oullet engine (' C)
sure drop across the lilter 1.5 bar (see sec/ion - thermometer 10.
615).
34. Lub. l inlet engine temperature ('C) Fuel l System

- thermometer 22.
46. Fuel l temperature at inlet engine (' C)
35. Lub. l pressure before the turbocharger - thermometer 40.
(bar).
- pressure gauge 23. 47. Fuel l pressure belore engine (bar)
- pressure gauge 40.
Cooling Water System 48.
37. Low temperature (L) cooling water tempera-

ture (sea, raw or fresh) at inlet charge air cooler 49.
(' C)
- thermometer 01.
50. Signature.
38. L temperature () cooling water tempera-
ture (sea, raw or Iresh) at outlet charge air cooler
(' C)
- th ermometer 02.
96.37 - ESOU-G
Section 503
Troub.shoot
Description
Starting FaiIures 503.01

FauIts FueI System 503.02
Disturbances during Running 503.03
Ignition Crankcase 503.04
TroubIe Shooting Guide for CentrifugaI By-pass FiIter 503.05
TroubIe Shooting Guide for Turbine Starter 503.06
TroubIe Shooting for CooIing Water System 503.09
TroubIe Shooting for Lubricating Ol CooIer 503.10
DescripIion 503.01
Page1 ( 1) Starting Failures
EdiIion 02
General
Troub/e Possib/e cause Troub/eshooling
Engine turns as soon as shut- Faults electrical system. Check electrical parts.
off valve is opened, without
start button being acti vated.
Engine does turn when pressure startIng ai r 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 lne between
receiver and engine.
does ! engage with Check the air starter.
th e flywheel.
motor runs, engages Check the air motor for broken

but does rotate. shafti ng, bearin g clutch
jaws,
see Working Card 513-01.30.
Faults electrical system. Check electrical parts.
Engine turns slowly - Worn air motor parts. Remove and disassemble the
regularly when start button is air motor. Examine all parts
activated. and replace any that are
ordamaged. Use the guidelines
for determining unserviceable
parts, see Working Card 513-
01.30.
Start valve is sti cking closed Check start valve.

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

sure.
starter works, but the drive Clutch drive shaft broken. Dismantle the air starter and
shaft does rotate. repair
04.31 . ESO
. '' DieseI[
Descriplion
FauIts FueI System 503.02
Page 1 (3)
Edition 01
23/30
Trouble Possible Caus Trouble ShootIng
EngIne turns starting al(, buI Sluggish movemenl manoeuve- LubncaIe and I10bilIze rod cOI-
ignition lals. Fuel pumps ring gear. nections manoelvering gear.
acluated.
Governor settIng Incorrect. AdjusI governor, see specIalIn-
slruction manual.
Overspeed stop tripped. Cancel overspeed stop .
PIslon stop cYIInder 1$ actuated. Check that plston is l sticking.

Check thal pressure cylinder 1$
reJieed. Check that the Qver-
speed 1$ l aclUaled.
Piston stop cyIinder is actuated Check pressures and tempera-tu-

/ng 10 uncancelled shutdown $. Check for faUts shuI-down
function ( 1). devices.
Farlures governor. Check Ihal governor rs workirlg

properly. For further l locatron,
see specral illslr. manual.
Incorrecl adjuslmenl manoeuve- Check rod connec. Check Ihat

ring gear. fuel pump index is corresponding
10 "Adjustmenls atler Irials
leslbed chart.
Incorrecl adjustment limlter Adjusl seIIing limlter cylinder.

cyllnder.
I:ngine turns a starting air, but Fuel l service lank empty. Pump l the lank.
fuelrs rnjecled o\ving 10 l-
res l systern. fuel pumps and l inJeclion Vent Ihe pumps wlth l
valves (2). wrth-ouI air bubbIes appears.
1I ignition fails just cyl.,
I the re-spectlve luel lnjecIton
valve. 1I igni-lion sIill lails, insIall a
spare valve before altempting 10
slart the engi-ne again.
Worn-oul fuel pump. Cllange fuel pumps.
Defective ll injection valves Change defective fuel valves.

valve nozzles (4).
low pressure belore fuel lnjec- Increase the fuel l feed

l pumps (3). pressure.
Engine turflS starting , fueI Ihe fuel. Orarn 011 water and repeaI venling
is injecIed, but ignition fails. fuer pump s.
Fuel valves nozzles defective (4). Change defective fuel vales,

see Working Card 514-01.10.
Cont.
96.37 - ESOU-G
503.02 Faults FueI System DescriplIon
EdilIon 01
Page 2 (3)
23/30
Trouble PossIble Cause TrOlIble Shooting
Compression dring slart 100 l Check intake and exhaust l

(5). tIght closing. Check cyl.
arId pisIon rIngs.
lncorrect liming camshaff (6). Check fuel pump ltming advance,

and tuel l opening pressure
as l as camshaft adjstmenr.
FIrsI IgnItions 100 vlolerlt (sa- has coIlected pIs!on crown Slow turning with open indicator
fety valves are opening). Engine (7). alves. locate defective fuel
runs erratically. I - , remove !.
Sluggish movemet l10u- LbrIcale and mobilIze rod

ong gear. conneclions and bearings
manoeuverIng gear.
Fuel purnp index 100 high. Check rod connectIon is manoeu-

verIng gear. Check that governor
is working properly. limiler cylin-
der 10 be seI lower.
Remarks
1) 1I Ihe shutdown lunction is due 10 overspeed, 4) 1I the luel is lorced the cylinder through
the shutdown impu lse is cancelled by setting the a delective luel valve through worn-out atomizer
overspeed governor and thus ven ting the stop cy- holes, sluggish atomization may prevent
l n d e r. igniti on, possibly lollowed by l ignition.
2) Whenever air is present the luel l system 5) Toobtain ignition temperature in the cylinders,
repeat ven ting luel pumps. The cause may be the compression pressure during starting should
that a luel valve is kept open position (spind le be normal, see the testbed repor t. This can be
sticking spring broken). Heating luel a checked by measuring the compression pressure
high temperature may have a similar ellect owing du ring starting. Cylinders having l compres-
lor mat on gas in the luel. 1I a sticking valve sion should be inspected.
is lound, should be changed and overhauled.
should be cheked that no l has collected on the
piston crown. in the luel l system may also be 6) Major alterations the combustion charac-
the result the luel l leed pump suckin gin air teristics the luel may demand adlustment the
through a delective stulling bo a leaky seal. timing the luel pumps. One more camshalt
sections may be incorrectlyl itted (after dismantling).
high opening pressure the luel valves l l also
3) If the luel l pressure drops, the l may be delay the injection.
c logged up, the by-pass at the leed pump may
have opened.
96.37 - ESOU-G
f,f,I#,r/iMAN DieseI[
Descrption
FauIts n FueI System 503.02
Page 3 (3)
EditIon 01
23/30
7) l the piston crown ll most cases have 1I a repai r cannot be made th e spot, is decided
leaked down Irom a delective luel valve. As these l l running may continue, wilh orwithout the delective
accumulations are dangerous, the leakage should charger blanked 011.
be lound and remedied belore the engine is started
again. When con tinuing the running with the lurbocharger
operation, the engine must be redu-
ced. The exhaust temperature must exceed
Turbocharger Failure the normal valve, lr lull load running with an intact
turbocharger. For lurther details see the separate
1I heavy vibrations, bearing lalure other trouble turbocharger instr. manual .
ari se a turbocharger, the engine load must be
reduced l the vibrations cease. When possible,
the engine is stopped order locate and remedy
the lault (see turbocharger instr. manual).
96.27- ESOU-G
Descripllon
Disturbances during Running 503.03
Page 1 (3)
Edition 01
23/30
Trouble Posstble Cause Trouble Shooling
Exhaust lemperature(s) ( cyJs.) Increased chargll1g alr See WorkIng Card 512-01 .00.
Increase(s) lemperature due 10 ineHeclive air
coolers.
( cyls.) f ouling air and gas Reduce load and waler-wash tur-
passages. bIne. CJean ,illers and coolers.
(
cyls.) Insufftcieol cleanlng See Descriplion 504.25.
l 011
changed combuslion
characlerisltcs.
( cyls.) Wrong pOStIIOI) cam- Check _. Check camshaft ad-

shaft (maladjustment). justment.
(slngJe cyls.) FueI valve See Worklng Card 514-01.10.

defecltve.
(SingJe cyls.) Leaky exhaust Check the valve clearance.

vaIves (1). Rep Ia-ce cyl. head witt1 defective
vaIve.
(Single cyls. ) 8fow-byleaky c- See Working Card 506-01.00.

buslton chamber (2).
(SingIe cyls.) Dataged I Replace the singJe camshafI

ca. section.
Exhaust temperature(s) ( cyls.) Decreased chargtng Check Ihat thermostatrc l

decrease(s) temperaUre. (by-pass vaIve) coId waler
system is working and
correctfy set.
(StngIe cyIs.) A,r ' pump(s) Venting fl pump(s) !. f

and ' rnjectlon vaIve(s). wtthot air bubbles appears.
Check feed pressure.
(SingIe cyls.) SpindIe l Change and overhaul delective

sttcktng (3). l.
(Single cyls.) FueI pump pIunger Change l pump p lunger/barrel

sliCking leaking. assembly.
Engrne decreases Pressure beIore f pumps 100 Ratse l feed pump pressure
low. to normal. Check .
FueI valve fuel pump defective. Change defective vaIve pump.
Water the l. Drain ! water alld the f

pumps.
Governor defectve (4). Replace defective governor.
Increased friction See Ignition Crankcase'.

engine (5).
COnl.
96.37 - ESOUG
503.03 Disturbances during Running
Oescriptron
Page 2 (3)
EditIon 01
L23/30
Trouble Possible Cause TrOLIble Shooting
Engrne stops. Shuldown. Check pressure 811d ternperatlIres.

, check faults shut-
down devices. See also Starting
Farlures.
Smoky exhaust. Turbine lagging behind en- Aeasonably smoke is norma! when
gine RPM. increases; measures cal-
led for. 1I smoky exhaust durrng
normal ru nning, clean turbine(s)
and check valves.
supply 100 l. Fouling air and gas passages,

see section 512.
Fuel valves nozles defective. See Working Card 514-01.10.
'Trun1pets at nozzle holes. Failure Overhaul fuel valves.

coolrng (especially during hea-
-I operation) (6).
Exhaust valve knocking. Adjusting screw valve setting !nspect and replace defeclrve
loose. Push rod Ihrust disc da- parts as necessary.
maged.
Rising coolrng water lempera- Pump slopped. Increased friction Slop the engine. Check the
ture. (7). coollng water. Find cause Incre-
ased friction and rernedy lau11.
LubrrcaIing l pressure larls. Lubricaling 011 pump defective. SIop the engine. For further
Fillers/cooler fouled. details, see "Ignitron crankcase".
See also Working Card 515-01.00
lub. l pump and Working
Card 515-01.10 lor the lub. 'rlter
Remarks
1) This manifests itself by the exhaust tempe- 2) Blow-by means a serious danger of piston
rature rising and falli ng of the compression and seizure, and the engine must, if possible, be stop-
maximu m combustion pressure of the respective ped and the piston question pulled. If this is
cylinder dropping. possible, the fue l pump index must, as described
above, be moved stop. Leaky piston rings l l
limit the damage to the valves these should be normally result a heavy excess pressure the
changed immediately, if possible, the fuel pump crankcase.
of the cylinder concern ed should be of
operati on by moving the index to stop and locking
this position.
96.37 - ESOU-G
Description
Disturbances during Running 503"03
Page 3 (3)
Edition 01
23/30
3) 1I this happens the lel pump barrel and 6) If the cooling water temperature lor the
plunger must be changed, and l, is necessary engine has risen 90-1 00' C, should be checked
increase the luel pump inde by more than 1 whether steam has developed by opening the test
inde degrees, obtain lll load the respective cocks, l fitted the discharge Irom cylinders. If
cylinder, the ll pump is ot most cases. this is the case, there is water the cooling
Usually this is conlirmed by inspection the lel surlaces, which may therelore be heated unduly
pump plunger which the helical ct-oll edge ll avoid heat stresses arising cylinder lners and
show a pitted and corroded area where material is cylinder heads, l the water returns early, the
plucked ot. that case the pump can be provided engine should be stopped and left cool, while
with a barrel and plunger. the discharge valve is closed. After 15 mintes
is opened a Iittle allow the water rise slowly
the cooling jackets. Check lilling at test cocks . Make
4) The governor ll reduce the luel pump crankcase inspection ascertain that internal water
delivery zero case 01, lor instance, lalre leakage has arisen. Remember slow turning with
the governor l pump, but the engine speed ll open indicator valves at subsequent starting-up.
start Iluctuating.
When the governor is delective the engine is pro- 7) If the lubricating l pressure drops below the
tected against racing by the overspeed , .. the minimum mentioned "Data" lnd the cause the
engine is stopped automatically case ecessive pressure drop and remedy the delect before re-st-
speed. It is therelore, essential, that the overspeed arting the engine. Feel over 5-15-30 mintes after
is kept ll perfect order. Regarding governor starting, and again when lullload is obtained. See
lailure, see special instruction book. section 502.
5) Usually a bearing lailure ll slow down the

engine appreciably, bt the seizure a piston
the cylinder l ner might do so. Repair is necessary
belore starting the engine again. Feelover and look
ot for l mist.
96.37 - ESOU-G
Descriplion 503.04
Page 1 (1) Ignition Crankcase Edilion 03
General
Cause 1) Slop Ihe Engine
During running the atmosphere the crankcase 2) Leave Ihe engine room. Shut doors and keep
contains the same gases (N,-O,-CO,) Ihe same away from them. Make readyfire-fighting equip-
proportions as Ihe ambienl air, but an inlense menl.
spray l drops iS slung around everywhere.
undue friction , and thus heating, arises belween Warning: Do open crankcase l 1 minutes
sliding surfaces, heal iS olherwise Iransmitted 10 afler slopping the engine. When opening up, keep
Ihe crankcase, Ihe healed surface w ll cause eva- clear possible flames. Do use naked light and
poralion Ihe lubricaling l splashed . When do l smoke.
the l vapours condense they form milky white l
mist which can ignile. Such ignition may be caused 3) Cut starting air.
by the same "hot spot" thal produced Ihe l mist. Sel Ihe conlrol panel "610cking Mode" see
a large quantity l misl has developed before descriplion 501 .01.
ignilion, Ihe burning may cause considerable pres- Take all doors one side the crank-
sure rise Ihe crankcase, forcing the relief valves case.
10 open. ln a few cases, presumably when Ihe whole
crankcase has been filled with l misl, a subsequenl 4) Locate the hot spot. Powerfullamps shou ld be
explosion has thrown the crankcase doors and employed al once ( explosion-proof fitti ngs).
caused fire the engine room. Feel over all sliding surfaces (bearings, liners,
pistons, roller guides, etc.).
Every precaution should therefore be laken 10 ()
avoid "hot spots" and (6) discover l mist l ime. Look squeezed-out bearing metal and discol-
oration by heat (blislered painl, burnl l, healed
steel).
''Hot spots" n Crankcase
5) Prevent furlher heating, preferably by making
Overheating bearings is a result inadequate a permanent repair.Special attenlion should be
failing lubrcalon, possibly caused by l l l paid 10 ensuring lubricaling l supply and Ihe
the lubricating l. salisfactory condilion the frictional surfaces
involved.11 is equally imporlanl 10 replace fi ller
is Iherefore imporlanl Ihal the lubricaling l fillralion elemenls time.
equipmenl is perfecl condition. Filter carl ridges may
l be used again Ihey have been removed from 6) Starl eleclrically driven lubricaling l pump
the filler. Checking th e l condition by analysis is and check l l w from all bearings and spray
recommended. pipes crankcase while turning Ihe engine
through at least w revolutions.
l Mist n Crankcase 7) Slop and feel over. Look l mist.
The presence l misl may be nol ed al Ihe venl Especially the frictional surfaces thal caused the
pipe which is usually fitted the l the engine heating should be felt over (5-15-30 minules after
frame. starling , and again when ful lload is obtained). Sec-
501.10.
Measures ( case while l misl).
8) has been possible locate the hot spot,
Warning: Keep away from doors and relief valves step 7 should be intensified and repealed l
crankcase. Do l slay unnecessaril y doorways Ihe cause the l mist has been found and
near Ihe doors Ihe engine room casing. remed ied. very rare cases l mist could be
due 10 "atomi zalion" lubricaling l by the
action an air jet ( instance blow-by,
blow-by through cracked pislon).
00.12 . ESO
Oesc riptIon
Trouble Shooting GUde for Centrifugal By-pass Filter 503.05
Page 1 (1)
Edition 01
23/30
Tabulated below are the corresponding remed ial

actions be taken, the following faults are obser-
ved:
Trouble PossibIe Cause Trouble Shooting
l Ieakage through cover MissIng damaged O-rIng (see Replace O-ring.

Item 291, Plate 51515).
SeaI face damaged. Replace O-rng.
ExcessIve vIbratIons. Rotor ut of balance owlng 10

even bUIldup deposIt rotor
waIls reslIlling 1rom:
MIssing damaged Qrang (see Replace O-ring.

Item 230, Plate 51515), aIIowing
leakage.
O-ring seat rotor joinl faces Replace rotor assembly.

damaged.
Aotor assembIy inadequateJy Tigtlten and bring 10 nolice of main

tIghtened. tenance slaft.
Standtbe Incorrectly sealed -f replace if darnaged.

damaged.
Olrl deposil ! cornpletely remo- Cleatl and brIng 10 notace rnain-

ved. tenance slaff.
Ao!or castings dislorted through Aeplace rolor assembly.

maltreatment.
Aotor assembly componenls liIIed FolJow sequeoce irl Working Card

wrong sequence. 515-15.00 seclion 515.
Bushes loose worn tbe as Fil new bearIng tbe assembly.

sembly.
96.30 - ESOU
' DieseI!
Description 503.06
Page 1 (2) TroubIe Shooting Guide forTurbine Starter Edition 01
23/30
Trouble Possi ble Cause, see workIng card Trouble ShoolIng
Molor ll l (. air suppJy. Check blockage damage 10

suppJy lines lank.

Damaged molor assembly (12). InspecI moIor 8ssembly and power

train and repair power train -
place motor assembly, necessary.
Foreign material motor and/or Aemove motor assembly and pping

piping. and remove Ihe bJockage.
Blocked exhaust syslem. Remove housing exhaust cover (1)

and check bJockage.
Defeclive controf relay l. Aeplace control l relay valve.
Loss power. Low ressure 10 sta rter. Check air supply.
Restricted air suppJy l . Check for blockage damage 10

Iines.

ReIay vaIve maJfunctioning. CIean replace lines reIay

valve. Lubricate relay vaIve.
Exhausl fIow reslricled. Check for blocked damaged

piping. Clean repIace piping.
Check for dirl foreign malerial
and cIean remove. Check for
ice build-up. Melt ice and reduce
moisture buiId-up 10 slar!er.
Damaged molor assembly. Replace molor assembly.
Orive (57) will engage. pressure 10 drive housing por" Check air supply.
Inlernal drive housing ports Remove blockage.

blocked.
Fluid drive ! componen!s. Remove fIuid.
Damaged piS!on assembly Replace damaged parts.

(54), O-rings seals.
O-rings and seals dry. Relubricate O-rings and seaIs.
Mo!or runs, engages, but Damaged broken drive !rain. Disassemble drive ! and replace
does l ro!ate ftywheel. damaged par!s.

Excessive bull engagement. Damaged drive (63) Inspect drive and ftywheel
flywheel. and replace, if necessary.
Damaged s!arter drive (57) com Inspect drive components and

ponenls. reptace worn damaged parts.
Cont..
96.38 - ESOU-G
''" DieseII
503.06 Desc rpt ion
Ed ition 01
TroubIe Shooting Guide for Turbine Starter Page 2 (2)
23/30
Trouble Possible Cause, see working card Trouble Shooting
L pres$ure. Check suply.
Wrong drive . RepIace with dr;ve .
l blowing l exhausl. l i air supply Jine. Inspect air l and remove $ource
l.
Splash deflector retaining $Cf ew (5) In51atl splash defleclor reta ining
ptug missing. screw pe plug.
Worn damaged seals Aeplace slatic seals outside

staIic 0-95. motor send molor 10 Inger5011
Aand 10 be rebuill.
Oilleaking from gear case (28). Worn damaged 0-r;n95. Replace 0-95.
Loose joints. Make sure Ihat joints properly

and sIarter assembly cap screW$
are tightened 60 ft-Ib (81 Nm )
torque. Make sure all seals and
O-rings l t and seal I at their
perimeters. 1I they do l replace
wilh seals and Orings.
Excessive high-speed operalion. according 10 recommen-

dalions.
High number slart cycles. Replace worn components.
Loose leaking l ugs (1 ) Tighten replace plugs using

(1 1). Ingersoll-Rand 5MB-441
sealanl.
Splash delleclor retaining screw TighIen splash dellector retaining

loose plug missing. screw replace pipe plug.
gas leakage. Loose joinls. Make sure that joints ll I

and starter assembly cap screws
lightened 10 60 fl-lb (8 1 Nm)
torque. Make sure all seals and
O-rings l and seaI properly at their
perimelers. 1I they do nol, replace
with new seals and O-rings.
Excessive highspeed operation. Operate according 10 recommen

dalions.
High number start cycles. Replace worn components.
Loose leaking pipe plugs. Tighten replace plugs.
Splash deflector relaining screw Tighten splash deflector retaining

loose plug missing. screw replace plug.
96.38 - ESOU-G
IIl1 MAN DieseII
Descriplion 503.09
Page 1 (1) TroubIe Shooting for CooIing Water System
Edition 03
GeneraI
Description The pump bearings are lubrcated automatica lly with

l from the lubricating l system the engine.
The built-on fresh water pumps the high and lw
temperature circuits are the centrifugal type. They the pump leaks and the shaft sealing ring s are
are mounted th e ! end box and are driven worn, ! is recommended to replace the shaf1 seal,
through th e gearing. see Working card 516-02.00.
Trouble Possible cause Troubleshooting
l water flows ! the inspec- Worn rotating sealing. See working card 502-05.00.
l holes.
The pump does l work afler slarl. Pump draws ai r l suction side. Check packings and pipes 'or tightness.
The system is l filled-up. Check Ihe level the expansion tank.
cannot escape delivery side. Vent the system.
Leaking shaft seat. Check the shaft seal.
Pmp capaciIy drops alter normal leakages from shaft seal. Overhaul the shaft seal.
operalion.
Fouled impeller. Clean Ihe imeller,
Pump does l give maximum SucIion valve l fully open. Qpen the suclion alve.
delivery.
Defec1ive seals. Replace Ihe seals.
Worn imel l er and worn wear rings. Overhaul Ihe pump.
Note: Running trouble with the pump, apart from

mechanical faults, is most of1en due to leaks the
suction l . It is therefore essential th at all packings
and gaskets are order and that they are renewed
when necessary. Even a tiny hole the suction lne
ll reduce the pump capacity.
98.20 - ESO
Description 503.10
Page 1 (2) Trouble Shooting for Lubricating Cooler Edition
General
Trouble Shooting Faligue Iracture ll normally necessilale replace-
menl all plales and gaskel s as Ihere may be a
1I is necessary 10 replace damaged plales ga- risk laligue Iracture all Ihe malerial.
skels. case corrosion , all plales musl be examined
carelully!
Firsl examine Ihe exlernal condilions around Ihe Concerning Ihe work 10 be carried l see Working
plale heal exchanger order 10 localize Ihe cause card 515-06.00.
Ihe damage. 00 Ihis very carelully.
Visible Leakage
Trouble Possible cause Troubleshooting
Leakage. high pressure. Reduce the pressure 10 the correct work-

ing pressure, see page 500.30 uOperaling
Data & Se! Points",
Leakage. Insufficienl tightening. Tighlen the plate heat exchanger, buI

(Phase 1) below Ihe minimum dimension and
when Ihe heal exchanger is
under pressure or 40C.
Ihe plate hea! exchanger is still leaky,

proceed 10 phase 2.
Leakage. Fouled deformed plates. Searate Ihe plate heat exchanger and
(Phase 2) Inelastic deformed gaskets. check if the plales are deformed
fouled.
Check that the gaskels are eIastic and
non-deformed, and Ihal Ihe faces of the
joinls are clean.
Replace deformed plates and gaskets,
if any.
Before assembling clean all plales and
gaskets very carefully.
Assemble Ihe pJate heal exchanger and
start again.
Note: l impurities such as sand
grains may cause leakage.
leakage. Gaskets. Separate the plate heat exchanger.

(Even after Iightening of the plale heat Clean Ihe plaIes very carelully.
exchanger minimum dimension.) Replace the gaskeIs.
Assemble the plate heat exchanger and
slart again.
l eakage. Defeclive gasket badly corroded Separate the plaIe heat exchanger.
(Through the drain hoJes the gas- plaIe. Replace defecIive plaIes and gaskets,
kets.) if any.
Assemble the plaIe heat exchanger and
slart again.
98.20 . ESO
'+41' DieseII
503.10 Description
Edilion TroubIeshooting for Lubricating CooIer Page 2 (2)
GeneraI
Non-Visible Leakage
Trouble Possible cause TroubleshooIing
Reduced heat transmission and/or Fouled plates choked l chan- Separate the ptale heat exchanger and
increasing pressure drop. nels. check f Ihe ptaIes are fouled.
Clean the plates carefully.
Assemble Ihe plate heat exchanger and
51art again.
Leakage. Holes plates. suspecIed leakage call be localized

(he fluids ge! mixed.) Corrosion faligue fracture. Ihe following way:
(Phase 1) Remove Ihe lower connec-
l$.
Then Ihe opposite side under pres-
sure.
1I the medium continues 10 l the
lower ipe connections Ihe pressure
has slabitized one several plates are
leaking.
Close down the plate heat exchanger.
Separate the plale heat exchanger and
check the plales very carefully.
Check suspecled plates with a dye pen-
etrant.
Check defective plates and gaskets.
8efore assembling, clean ll plales ancl
gaskets.
Assemble the plale heal exchanger and
check 10 find more defective plates, if any,
by putting side under press.
Start again.
Leakage. Holes plales. Close down Ihe plale heal exchanger.

(The fluids get mixed,) Corrosion faligue fractu re. Separate the plate heat exchanger,
(Phase 2) ll plates 10 dry. Susperld Ihe plates
Ihe plate heat exchanger again and
tighlen .
Circulale medium full capacity one
ll side ( second plale channel).
Keep the olher plale channels unpres-
surised and free from liquid!
Slop the circulalion after a few mintes
of operation and open the plate heat ex-
cllanger again. Take care 10 avoid water
spraying l Ihe dry side!
8 a careful study of the plales l ll be
possible 10 find moist areas, if any, the
otherwise dry l l sides.
Check these areas wilh a dye penetrant!
Replace defeclive plates and gaskets.
8efore assembling, clean ll lales and
gaskets.
Assemble Ihe plate heal exchanger and
check 10 find more defeclive plales, if any,
by puti ng side nde r press.
Slart again.
If the is still leaking, check l l plates
with a dye penetrant!
98.20 - ESO
Section 504
Lubcatng l Specification
Description
Lubricating l Specification 504.01

Maintenance of Lubricating l Condition 504.03
Criteria for Cleaning/Exchange of Lubricating l 504.04
Lubricating Points 504.05
Lubricating l n Base Frame 504.06
Specific Lubricating l Consumption - SLOC 504.07
Fuel l Specification 504.20
Fuel l Quality 504.25
Nomogram for Determination of CCAI 504.26
Analysis Data 504.27
Fuel l Cleaning 504.30
Freshwater System Treatment 504.40
Mi1,,MAN DieseI[
Description 504.01
Page 1 (1) Lubricating Specification Edition 09
Generai
Requirement Th e selection is based typical load proliles
lor marine GenSet (50-60% rated power) and lor
Thi s document is valid lor the lollowing engine slationary GenSet (50-100% raled power)
types: L16/24, 21/31 , 21 /31 CR, 23/30 , 27/38 ,
2 8/3 2 , V28/32H, V28/32S and L32/40. For all engines excepl 32/40
Heavy Outy lubricating l (HOLubricating l) has l type
( be used coresponding ( at least type CF alter (mg KOHlg)

service system (http://api-ep.api.org/lilelibrary/
Gasoil 8-12
ACF1 E1 .pdl) . Further the lubricating l should be
ru st and oxidation inhibited. Marine diesel 10-15
Heay l l (8 <1.5% ) 15-20

Viscosity
H eay fuel l (8) 1.5%) 2040
Marine
Engine SAE class
23/30, L+V28/32H
30 105 cSt @ 40' C For engines 32140
L16/24, 21 /31 , 21/31 CR, 27/38 , 32/40 type
40 145 cSt @ 40' C (mg KOH/g)
Gas l 12-15
Stationary
L16/24, 21 /31 , L27/38, 23/30 , Marine diesel 15-25
L+V28/32H , V28/32S
40 145 cSt @ 40' C Heay fu el (8<1.5%) 2535
Heavy fu el l (S> 1.5%) 3040

! cooling water temperatures above 32' C SAE
40 l can be used.ln this case, please contact
Oiesel , Holeby.
For lw loaded marine GenSet engines the 10wes1

Guiding VaIues for values are recommended and lor high loaded slalion-
ary engines Ihe highesl values are recommended.
When selecting lubricating l, attention must be paid 1I Ihe load prolile is differenl, Ihis should be l aken
( the luel l sulphur content. consideralion. However, the operalion resulls are Ihe
criteria Ihat prove which is the mosl economical
Marine GenSet engines are normally running at lw one lor eflicient engine operation.
load compared ( propulsion engines, therelore Ihe
absolute luel consumption is lower and consequently order ( meet the emission regulalions, more often
the lubricating l is exposed ( a smaller amount luel oils wilh different sulphur contenl are opera-
sulphur. Therelore the BN-value (Base Number) the l. habour/coaslal operalion a lw sulphur luel
lubricating l has ( be lower order ( neutralise l ll be used and al sea operalion a high sulphur
the sulphur ! Irom the luel. luel l ll be used. The lubricaling l value ll
have 10 be evalualed Irom engine running hours
The lubricating l consumption has an inlluence operaling Ihe l differenl luel oils. Normally Ihe
the recommended initial value. When the value should be evalualed Irom Ihe luel l wilh
lubricaling l consumption is high, lw values Ihe highest sulphur conlenl, please see seclion 11
is recommended, and opposile. ( evaluale the 00 "Guidelines Regarding Oiesel GenSels
lubricaling l consumption, please see seclion 12 Operaling Sulphur Fuel l".
15 "Specilic Lubricating l Consumption".
08.20 - ES 1
Description
Maintenance of Lubricating l Condition 504.03
General
GeneraI Continuous lubricating l cleaning during engine

operation is essential.
During operation trunk engines the lubricating
l ll
be contaminated slowly by small particles The centrilugal , decanter and the automatic
originating Irom the combustion. by-pass ll capacity be adjusted according
maker's recommendations.
The burning heavy luels l l normally increase
this contamination due the increased content 1I operating a centrilugal the lollowing recom-
carbon residues and other impurities. mendations can be given:
Contamination lubricating l with water, Iresh The optimum cleaning effect is achieved by keeping
salt, can also take place. the lubricating l a state lw viscosity lor a long
period the centriluge bowl.
certain amount contaminants can be kept sus-
pended the lubricating l without affecting the Sufficiently l viscosity is obtained by preheating
lubricating properties. the lubricating il a temperature 95C - 98C.
the condition the lubricating l should be Slow passage the lubricating l throug h the cen-
kept under observation by analyzing il samples. trilugal separator is obtained by using a reduced
See also 504.04 "Criteria lr Cleaning/Exchange Il rate and by operating the separator 24 hours
Lubricating l". a day, stopping only when manually cleaning the
bowl is necessary.
The engine bearings are protected by the lull-Ilow
lubricating l l l built the engine, the l l ter order keep the amount lubricating l the
cartridges having a l neness 15 micron and the engine good condition , is necessary treat
salety l lter a lneness 60 micron. minimum 0.3 l/kWh.
The condition the lubricating l can be main- For cleaning the lubricating l system after over-
tained/reestablished by exchanging the l at led hauls and inspection the lubricating l piping
intervals based analysis results. system, see section 515.
OperaIion Marine DieseI () DeIerioraIion
The built-on lu ll - l w dept l lter cleans the l thor- l seldom loses its ability lubricate, .. lorm
oughly. For operation recommend a Iriction-decreasing l lilm, but may become cor-
install a built-on centrilugal by-pass llter too. rosive the steel journals the bearings such a
way that the surface these journals becomes
rough and wipes the bearing surface.
OperaIion Heavy FueI l (HFO)
that case only must the bearings be renewed,
HFO operating engines requires effective lubricating but the journals must also be polished. The cor-
l cleaning. order secure a sale operation is rosiveness the lubricating l is ei ther due lar
necessary use a supplemen t cleaning equipment advanced oxidation the l itsell () the
together with the built lull Il depth l l. For presence inorganic acids (SAN).ln both cases the
this purpose a centrilugal , a decanter an presence water ll multiply the effect, especially
automatic by-pass l l can be used. an l sea water as the chloride ions act as an
inorganic acid.
07.11 - ESO - G
504.03 Maintenance of Lubricating Condition Description
GeneraI
Oxidation OiIS Smell l becomes acrid pungent.
normal serice temperature the rate oxidation Machined surfaces crankcase become coffee
iS insignilicant, but the lollowing lactors wl l accele- brown with a thin layer lacquer.
rate the process:
Paint crankcase peels blisters.
High Temperature Excessie carbon is lormed the piston cool-

ing chamber.
1I the coolers are ineffectie the temperature leel
w llgenerally rise. a grave case l deterioration, the system should
be cleaned thoroughly and relilled with new l.
high temperature w l l also arise electrical pre-
heat-ers l circulation is continued lor 5 minutes
after the heating has been stopped, l the heater Water Washing
is only partly l l led with l.
Water washing oils must be carried .
CataIytic Action
Water the
Oxidation the l wll be accelerated consider-
ably l catalytic particles are present the l . Wear 1I the is lw, a minor increase the Iresh water
particles copper are especially harmlul, but also content olthe l is immediately detrimental while
lerrous particles and rust are actie. Furthermore, the engine is running. Naturally, should be brought
the lacquer and arn i s h - l ike oxidation products down again as quickly as possible (below 0.2% water
the l itsell hae an accelerating ellect. Continuous content, which ispermissible). lltheengine is stopped
cleaning the l is therelore important keep the while corrosion conditions are unsatislactory itshould
sludge content low. be turned just over 1/2 reolution once eery hour
(i.e. stop different positions) while the l circula-
and purilying at a high preheating temperature
Signs Deterioration continue remove water. Water the il may be
noted by steam lormaton the sight glasses, by
1I circulating l inlerior quality is used and the appearance, ascertained by immersing a piece
oxidatie inlluence becomes grae, prompt action glass a soldering heated 200-300 C
is necessary as the last stages the deterioration an il sample. 1I there is a hissing sound, water is
may develop surprisingly quickly, i.e. within one present. 1I a large quantity water has entered the
w weeks. Een l this seldom happens, is wise l system, may be prolitable suck sedimented
be acquainted with the signs deterioration. water Irom the bottom the tank. Taste the water
These may be some all the lollowing: lor salt. 1I salty, an l sample should be analysed
immediately lor chloride ions.
- Sludge precipitation purilier multiplies.
07.11-ESO-G
+' DieseI!
Descriti o n 504.04
P_g.' (2) Criteria for CIeaning/Exchange of Lubricating il Edition 07
GeneraI
Replacement of Lubricating l Unil cSI (mm2fs)
The expected lubricaling l lfelme in operalion is Possible lesl

difficult 10 delermine. The lubricaling il lfelme is melhods ASTM 0-445, I 51562/53018,
depending on the l uel l quality, Ihe lubricaling l ISO 3104
qualily, Ihe lubricaling l consumplion, the lubricaling
l cleaning equipmenl efficiency and the engine Increasing viscosity indicates problems wilh inso-
operalional conditions. lubles, HFO conlaminalion, waler conlamination,
oxidalion , nilralion and lw load operalion. Oecrea-
In ord er to evaluate the lubricaling l condilion a sing viscosily is generally due 10 dilul ion wilh Iighler
sample should be drawn on regular basis al least viscosily l.
once every three monlh depending on the latest
analysis result. The lubricating l sample musl be
drawn before Ihe l al engine in operalion. The 2, Flash Point
sample bottle musl be clean and dry, supplied wilh
sufficienl inden tificalion and should be closed im- Min. value 1850 C
medialely after lilling. The lubricating l sample
musl be examined in an approved laboralory in Possible lesl
the lubricaling l suppliers own laboralory. method ASTM 0-92, ISO 2719
lubricaling l replacement an exlensive lubr Normally used to indicale luel dilution.

caling l cleaning is required when Ihe Oiesel
exchange criteria's have been reached.
3, Water Content
Ealuation of the Lubricating l Condition Max. value 0.2 %
Based on the analysis resulls, Ihe lollowing guidance Unil Weighl %

are normally sufficienl lor evalualing Ihe lubricaling
l condil ion. The paramelers Ihemselves can not be Possible tesl
jugded aloneslanding , but musl be evalualed logether melhod ASTM 04928, ISO 3733
in order 10 conclude the lubricaling l condition.
Waler can originale Irom contaminaled luel il , an
engine cooling waler leak lormed as part Ihe
1, Viscosity combustion process. ll waler is delected also Sodium,
Glycol Boron conlenl should be checked in order
Limil value 10 conlirm engine coolanl leaks.
Normal min. max.

value value value 4. Base Number ()
SAE 30 [cSI @40' C) 95 - 125 75 160
Min. value The value should nol be lower
SAE 30 [cSI@ 100' C) 11 - 13 9 15 Ihan 50% Iresh lubricating l
value, bul minimum level never
SAE 40 [cSI @40' C] 135 - 165 100 220 10 be lower than 10-1 2 al operat-
ing HFO!
SAE 40 [cSI @100' C) 13.5 - 15.0 11 19
Unit mg KOH/g
Possible tesl
method ASTM 0 -2896, ISO 3771
07.11 ES1
504.04 Description
Edirion 07 Criteria for CIeaning/Exchange of Lubricating Page 2 (2)
GeneraI
The neutralization capacity must secure that the acidic Weight%

combustion products, mainly sulphur originate from
the fuel l, are neutralized at the lube l consumption Possible test
ll for the specific engine type. Gradually the method ASTM 0-893 procedure n-
w ll be reduced, but should reach an equ ilibrium. Heplane, I 5 1592
Additiona lly
5. Total Acid Number () test Ifthe leel n-Heptane insolubles
is considered high for the type of
Ma. value 3.0 acc. 10 fresh l value l and application, the test could
be fol lowed by a supplementary
mg KOH/g determination Toluene.
Possible test Total insolubles is maily derived from products of

method ASTM 0-664 combusti on blown by the piston rings the crank-
case. also includes burnt lubricating l, additive
is used monitor l degradation and is a ash. rust, salt, wear debris and abrasive matter.
measure of the total acids presenl the lubricaling
l derived from l oidation (weak acids) and acidic
products of fuel combustion (strong acids). 7. Metal Content
MelaI contenl Remarks AIIention limts

6. Insolubles Content
Depend max. 50 ppm
Ma. value 1.5 % generally, depending Chrornium engine Iype and max. 10 ppm
Copper operaling condi- max. 15 ppm
actual dispersant value and the Lead tions max. 20 pm
increase viscosity. max. 10 pm
Aluminium max. 20 pprn
Silicon max. 20 ppm
07.11-ESI
I'l DieseII
Description 504.05
Page 1 (1) Lubricating Points Edition 01
23/30
Lubricating Oiy pes Used the Engine.
Description Lub. l Type
Engine system lubricating l SAE 30 l according lubricating l specilication page 504.01.
Turbocharger Engine system lubricating l .
Governor See governor instruction section 509.
lu br cator SAE 1 0 nondetergent l.
Alternator See special instructions section 518 separal e inslruction.
Hydraulic l ools Hydraul ic il turbine l (wilh a viscocity about SAE 20).
96.02 ESOUG
',I':' DieseI!
Description
Page 1 (1) Lubricating n Base Frame 504.06
Edition 16
23/30
Max.
Min.
3
2
Type L23/30 5 cyl. 6 cyl. 7 cyl. 8 cyl.
Min. level alarm 2 (mm) 200 200 200 200
Max. level alarm 3 (mm) 250 250 250 250
Min. litre 2 291 344 397 450
Max. litre 3 373 44 1 509 577
06.39 - ES1
DescripIion
Lubricating Base Frame 504.06
Page 1 (1) Edition 1 7
23/30
900 rpm
Type L23/30 6cyl. 7 cyl. 8 cyl.
Min. level 2 (mm) 275 275 275
Max . level 3 (mm) 325 325 325
Min. litre 2 540 685 706
Max. litre 3 657 814 859
06.39 - ES1
MiB DieseI!
DescripIion
Specific Lubricating Consumption - SLOC 504.07
Page 1 (2) Edilion 03
GeneraI
Engine type SLOC [g/kWh]
16/24 100011200 0.4 - 0.8
L21/31 90011000 0.4 - 0.8
L21 /3 1CR 90011000 0.4 - 0.8
L23/3 0 72017501900 0.6 -1.0
L27/38 7201750 0.4 - 0.8
L28/32 7201750 0.6 - 1.0
V28/32H 7201750 0.6 - 1.0
V28/32S 7201750 0.4 - 0.8
L32/40 7201750 0.8 - 1.0
Please note that only maximum continuous rating 2:

(
(kW)) should be used order evaluate the Lubricating il evaporation
SOC. Lubricating l leakages
Lubricating l losses at lubricating l '
Please note, during engine running-in the SLOC may exchange
exceed the values stated.
The lubricating l density, @ 15' C must be known
The foll owing formula is used calculate the order convert the present lubricating il
SOC: temperature the base Irame. The lollowing lormula
is used calculate :
SOC [g/kWh) =
r OOcal;ngo;I {kg/m3j =
(Iubrjcating ojJ added - 1 - 2 [dm3~PIUbrcat1l'9oi1 f..1sLm3L "
run.hrs period * MCR [kW]
order evaluate the correct engine SLOC, The engine maximum continuous design rating ( MCR)
th e following circumstances must be noticed and must always be used order be able compare
subtracted from the engine SLOC: the individual measurements, and the running hours
since the last lubricating l adding must be used
: the calculation. Due inaccuracy .) at adding
Desludging interval and sludge amount from the lubricating l, the SLOC can only be evaluated
lubricating l separator (or automatic lubricating l after 1,000 running hours or more, where only the
filters). The expected lubricating il content ! the average values a number lubricating l addings
sludge amount is 30%. are representative.
The following does also have an influence Note ')

the SLOC and must be considered the SLOC deviation ol 1 mm with the dipstick measurement
evaluation: must be expected, witch corresponds ll 0.1
g/kWh, depending the engine type.
08.20 - ESO
Descrition 504.07
Page 2 (2) Specific Lubricating Consumption - SLOC Edition 03
GeneraI
Plant / Ship
Lube 011 consumDtion
Engine type: Eng ine #:
Lube l brandltype:
Density@15 C: [kg/m3]
Date Run. hrs Add. Lube l 1 + 2 L.O.Temperature SLOC Remarks

[h] [dm' ] [dm' l [OC] [g/kWh]
- ~
_.
- - - -
- -
- - -
-
~ - .
-
-
- -
08.20 ESO
,, lifMAN DieseII
Description
FueI Specifcation
504.20
GeneraI
Marine Gas l (MGO) Marine Diesel Ol (MDO)
MGO is a medium class distillate l which therefore is offered as heavy distillate (CIMAC) as
must ! contain any residual components. a blend distillate and small amounts residual
l (C IMAC) exclusively marine appl ications.
The key property ratings refer to CIMAC #2 1 The commonly used term the blend, which is
/2003. dark brown to black colour, is Blended .
is produced from crude l and must be free from
organic acids.
Units Value
Densily at 15C min. kg/m3 820.0 The key properties are based the test methods
rnax. kg/m3 890.0 specified.
Kinematic Viscosily
l 40C mm2fs >1.5
mm2/s <6.0
ProperIy Units Value
Flash ! c >60
CIMAC #2 1 12003 DB DC
WaIer conlenl % by volume <0 .05
Densityal15C kg/m 3 :s 900 < 920
SuIphur conlent % by weight <1.5
Kinematic Viscosily
Ash % by weigh! <0.0 1 at 40C c$I (mm2Js) <11 <14
Carbon residue (10% /) % by weight <0.30 Flash l C >60 >60
Waler content % by volume <0.3 <0.3
Minimum injection viscosity at entering the engine Sulphur conlenl % byweight <2.0 <2.0
>1.5c5t. Ash conIent % by weighl <0.01 <0.05
Carbon residue % by weighl <0.30 <2 .5
Vanadium mglkg - <100
Aluminium + Siliciurn mg/kg - <25
Minimum injection viscosity at ente ri ng the engine

>1.5 c5t.
05.37 - ES 1
IIi'( MAN DieseI/
504.20 Description
Edition 05 FueI Specification Page 2 (5)
GeneraI
Heavy Fue! ! (HFO)

Properly Unils Value
Commercially available luel oils with a viscosity Densityal15C kg/m 3 S 991'

to 700 cSt at 50 C corresponding to 55 cSt at 100
Kinematic Viscosity
C can be used lor & lour-stroke medium al 100' C cSI < 55
speed diesel engines. al 50 "C cSI S 700
Flash ! 'C > 60

For guidance purchase, relerence is made to ISO
8216/17, BS 6843 and to CIMAC recommendations ! 'C < 30
regarding requirements lor heavy luel lor diesel en-
Conradsen
gines, #21 12003. From these maximum accepted Carbon Aesidue % (m/m) S; 22
grades are RMH 55 and 55.
Micro Carbon Residue <22
It means that engines can be operated the same Ash % (m/m) :5 0. 15
luel oils as & two-stroke low-speed diesel
engines. Total Sedimenl after
Ageing % (m/m) < 0.10
Th e data the HFO standards and specilications Waler % (/) :S 1.0
reler to the same l uel type as delivered to the ship,
Sutphur % (m/m) :5 4.5
i.e. belore on-board cleaning.
Vanadium mg/kg < 600
order to ensure effective and sufficient cleaning
Aluminium + Silicium mg/kg < 80
the HFO, i.e. removal olwater and solid contaminants,
the luel l specilic gravity at 15 C (60 F) should be CCAI
below 991 kg/m'. Higher densities can be allowed l
Asphaltenes :s 213 carbon
special treatment systems are installed. residue
Current analysis inlormation is not sufficient lor es- FIA CeIane Number ...
timating the ignition and combustion properties
the l . This means that service results depend
l properties which cannot be known belorehand. m/m = mass VN=volume
This especially applies to the tendency th e l to
lorm deposits combustion chambers, gas pas- ') May be increased to 1.01 (kg/m' ) provided
sages and turbines. adequate cleaning equipment is installed, and
modern type centriluges.
Guiding Heavy Fue! ! Specification ") 1I the CCAI value exceeds 840 it is recom-
mended to have the FIA index measured
Based our general service experi ence we have, revealing l ignition and combustion problems
as a supplement to the above-mentioned standards, mayarise.
drawn the guiding HFO-specilication shown
below. 1I the CCAI value exceeds 840 ignition and
combustion problems can occur.
Heavy luel oils limited by this specilication have, to
the extent the commercial availability, been used "') 1I the FIA value is below 20 increasing ignition
with satisfactory results & four-stroke and combustion problems may be loreseen at
medium speed diesel engines. lw load operation.
The data reler to the fue l as supplied, i.e. belore any

on-board cleaning.
05.37 ES1
Oescription
Fuel il Specification
504.20
General
1I heavy luel oils, with analysis data exceeding the 1I the sodium content is lower than 30% the vana-
besides ligures, are be used, especially with regard dium con tent, the ri sk high-temperature corrosion
viscosity and specilic gravity, the engine builder wll be small. It must also be prevented that sodium
should be contacted lor advice regarding possible the lorm sea water enters the engine together
changes the luel l system. with the intake air.
1I sodium content is higher than 100 mg/kg, an

Blends increase salt deposits is be expected the
combustion space and the exhaust system. Thi s
Fuel il containing used lubricating l ( ) has condition wll have an adverse ellect engine
comply with the CIMAC #21/2003 luel l specilica- operation (among others, due surging the
. turbocharger).
The admixing used engine l the luel involves Under certain conditions, high-temperature corrosion
a substantial danger because the lubricating l addi- may be prevented by a luel additive that raises the
tives have an emulsilying effect and keep dirt, water melting temperature the heavy luel l ash.
and catfines linely suspended. Therelore, th ey impede
preclude the necessary cleaning the luel. We
ourselves and others have made the experience that Ash
severe damage included by wear may occur the
engine and turbocharger components as a result. Heavy luel oils with a high ash content the lorm
loreign particles such as sand, corrosion elements
The admixing non-mineral l constituents (such and catalyst ln es (catfines) heavy luel oils coming
as coal l) and residual products Irom relining Irom catalytic cracking processes. most cases,
other processes (such as solvents) is harmlull these catfines w ll be aluminium oxides, silicium
the engine! The reasons are, lr example: the ides, which causes high wear the injection system
abrasive and corrosive eIIects, the adverse combus- and the engine.
properties, a poor compatibility with mineral oils
and, last but least, the negative environmental
effects. The ord er letter lor the luel should expressly Sulphuric Acid Corrosion
mention what is prohibited, as this constraint has
yet been incorporated the commonly applied The engine should be operated at the cooling water
luel specilications. temperatures specilied th e operating manual lor
the respective load. 1I the temperature the com-
The admixing chemical waste materials (such as ponent surlace exposed the acidic combustion
solvents) th e luel is lor reasons environmental gases is below the acid dew , acid corrosion
protection prohibited by resolution the Marine can OCCOUf.
Environmental Protection Committee 1 Jan. 92.
Fuel il Condition, when entering the

Vanadium Sodium gine
Should the vanadium/sodium ratio be unlavourable, As practically all luel l specilications including the
the melting temperature the heavy luel l ash may above standards reler the same luel type as sup-
drop the range the exhaust valve temperature plied , the luel supplied a ship has be treated
which l l result high-temperature corrosion and board belore use. For running the l quality
deposits build up. precleaning the heavy luel l mentioned above is necessary that equipment ex-
the settling tank and the centrilugal separa- ists board, which can treat, respectively clean and
tors, the water, and with the water-soluble sodium preheat, the luel l with optimum efficiency.
compounds can be largely removed.
05.37 - ES1
504.20 Descriplion
Edition 05 Fuel il Specification Page 4 (5)
General
11 00 "Cleaning RecommendaIions" TemperaIure controller

recommendalions are outlined.
If Ihis melhod is chosen l demands a laboralory
For economical HFO operalion Ihe luel l condilion apparatus enabling Ihe slaft 10 lesl Ihe luel l sam-
al engine ll should be as recommended below. ples a regular basis and sel Ihe lemperature
conlroller accordingly. The Irequency is dependenl
Ihe homogenily Ihe luel . how often charges
are received and how well Ihese are blended Ihe
Properly Unils Value
l anking syslem.
Waler % by volume maX.0.2
Th e reason being Ihal Ihe charg es Ihe luel oils
may vary considerably properlies eg. Iraclions,
Solid
viscosily indexes, elc.
parlicles ppm (mg/kg) maX.20
Parli cle size Micron maX.5

ViscosiIy regulaIor (ViscoraIor)
Viscosily cSI Rang e 12-18
1I Ihis melhod is chosen Ihe viscosily Ihe luel l
is monilored conlinuously and Ihe lemperature is
adjusled al Ihe sel value depending Ihe qualily
healing elemenls and Ihe conlrols Ihese.
For luels above 180 cSV50 C a pressurerized luel
l syslem is necessary 10 avoid boiling and loaming Th ere are Ihe principle dillerenl melhods
Ihe luel. moniloring Ihe viscosily Ihe luel:
The prehealing charl page 5 illuslrales Ihe expecl- - True measuremenl (pressure drop a cali-
ed prehealing lemperature as lunclion Ihe specilic braled tube)'
luel l viscosily. - Ultrasonic vibralion
The viscosily leaving Ihe healers should be 10-15 ') The difticulty Ihis melhod is Ihal Ihe equip-
cSI and approx. 12-18 cSI enlering Ihe engine. menl has 10 be mainlained and calibraled
regularly. However Ihis melhod is by lar 10 be
prelerred.
ViscosiIy Adjustment
enable a proper injeclion viscosily and a 10 prevenl

overloading Ihe luel equipmenl l is essenlial 10
mainlain a conslanl viscosily wilhin Ihe Iimils slipu-
laled, see prehealing charl page 5.
vessel healed eilher by sleam eleclricily adjusls

Ihe viscosily Ihe luel. There are means
adjusling Ihe power supply 10 Ihe vessel:
- Eilher by measuring Ihe lemperature Ihe

media, or
- by measuring Ihe viscosily Ihe media
05.37 ES1
Description 504.20
Page 5 (5) FueI Specification Edition 05
GeneraI
Fuel il - prehealing charl
. viscosily
aher preheater
Temperaure
sec.
cSI Rw.
after preheater C
7 43
170
160
10 52
150 12 59
140 15 69
130 20 87
120
30 125
110
100
90
80
70
60
50 Approx . pumping lmit
40
30
,
Log scaIes 10 15 25 35 45 1 55 cSV100' C
30 60 100 180 380 700 cSV50' C

200 400 800 1500 3500 7000 sec . Rw/ 1000 F
~
,,;
q Viscosity of fuel
~
m
f;j
~
J:~ This chart is based inlormation Irom l suppliers regarding typical marine luels with viscosity inde 70-
:g 80.
Since the viscosity after the preheater is the controlling parameter, the preheating temperature may vary, de-
pendent the viscosity and viscosity ind e th e luel.
05.37 - ES1
Description 504.25
Page 1 (3) Fuel l Qualty Edition 03
General
General Considerations Combustion Quality
The quality of a fuel l is stated, in analysis data, in Combustion quality is the ability of the l l to
terms of physical and chemical properties, which are ignite and burn in a way. The ignition quality,
decisive the suitability of the fuel l for different combustion IntensIty, and length and completeness
applications. For diesel engine fuels the combustion combustion are properties influenced bythe chemical
quality, the content of impurities and the handling composition and structure of th e l l.
properties are the main quality criteria.
Ignition quality relates ignition delay, . . the time
Since residual fuels are traded and designated ac- elapsed between the start of injection and the start
cording viscosity, has become common practice of combustion.
associate viscosity with quality. This practice can
be very misleading, especially with modern residual Ignition quality is epressed by the cetane number,
fuels, as a fuel l of lw viscosity can often be just diesel ind e cetane ind e. In all cases th e higher
as bad, even worse, than other fuel oils of very the value, the better the ignition quality. For diesel l
high viscosity. the ignition quality is ep ressed by the cetane number
determined by a specified method in a standard
The quality of refinery residues is dependent on the engine running under standard condi tions.
origin of the crude il, the grade of utilization when
refining th e crude l, and the refinery technique Fordistillatefuels the ignition qualitycan be epressed
used. by the diesel inde cetane inde, both be cal-
culated from physical properties such as the aniline
Some of the residues used in fuel l production point, specificgravity and mid-distillation temperature.
are of a viscosity requiring visbreaking, a process The cetane number, diesel inde cetane ind e of
which w ll reduce the viscosity without improving a certain fuel l w l l show reasonable correlation
the quality at all . between the numerical values.
When producing residual fuels from visbreaked, For residual fuels ignition quality is an even more
cracked residues and from "straight run" residues, Important parameter. The reason why does not
the final adjustment of viscosity fulfil the require- appear in the international specifications is that a
ments of the different grades of intermediate fu els standardized testIng method is non-eistent. There-
is achieved by adding gas l . fore, parameters such as the Qalculated Qarbon
Aromaticity jnde (CCAI) are resorted as an aid
However, must be noted that considerable reduc- which is derived from determinable fuel parameters.
tion of the viscosity is achieved by adding a relatively According our eperience, only a rough assess-
small amount of gas l, which w ll give only a minor ment of th e igniti on quality of the heavy fuel l is
improvement of the quality of the blend. This means possible with the help of this method.
that the quality a major etent depends on resi-
dues present in the blend. Therefore the quality also However, the CCAI has become so well-known in
depends on the density. widespread publications that, in spite of the reserva-
tions menlioned above, we were compelled toclassify
As a consequence of the possible variations in the Ihe respective & Diesel AJS, four-slroke
quality of residues and the influence of adding gas engines according 10 CCAI-rating, 100, see also 11
l , the quality of blended fuels can vary, even for "Nomogram lor Determination CCAt".
fu el oils of equal nominal viscosity.
FIA cetane number test is also good for evalualion
of the combustion qualily.
04 .46 - ES1
DieseII
504.25 Descrilion
EdiIion 03 FueI Ol QuaIity Page 2 (3)
Genera!
Fuel ignition analyser FIA 10014 measure- However, the inlormation about the differences
ments the luel behaviour makes possible to see the el-
lects the luel composition the ignition and
the FIA 100 instrument, the ignition delay is delined the heat release patlern which may may have
as a time delay ( millisenconds, msec.) Irom the any impact the particular engine.
start injection, l the pressure has increased
0.2 bar above the initial chamber pressure. The engine load also influences the performance
the luel' l load operation, ignition must take
The start the main combustion phase is delined place at lower temperature. This increase the
as being the time ( msec.) Irom when the pressure demand lor ignition quality and l the lighter luel
has increased 3 bar above the intial chamber Iractions are highly aromatic, lw load combustion
pressure. problems may be lound.
The start the combustion is used establish the As mentioned above, the longer time the engine has
ignition quality a tested luel expressed as a FIA ignition, the less sensitive the engine is the
CN (Cetane Number). The basis FIA CN isa rele r- ignition delay quality the l .
ence curve lorthe instrument question showing the
ignition properties mixtures the rele rence luels This consideration has been proved lately a small
15 and 22 from PhiIIips Petr. l This reference number ships with auxiliary engines and main
curve establishes the re lationship between ignition engine operating th e same luel. lgnition problems
quality, recorded miIIiseconds, and Cetane Number have been observed the auxiliary engines during
the diffe rent mixtures the reference fuels. For lw load operation only, having effect the
heavy luels, the ignition properties range from CN stroke low-speed engine.
=18.7 above CN = 40.
The combustion condi tion the l oils is normally
The rate heat release ( ) is used evaluate evaluated Irom Conradson Carbon residue and the
the combustion properties the l. asphaltene contents.
FIA compared with CCAI Content of Impurities
Comparing th e FI A test and CCAI, the FI A gives a The content impurities diesel engine fuels should
relative picture ignition qualities fuels, which be kept as lw as possible. Harmful and unwanted
may be use the ship operator before buying th e impurities should, be removed the pre-treatment
l . The CCAI does provide sufficient inlorma- system order to minimize wea r and corros ion
and has some tests shown very inconsistent engine components. Impuriti es derive from the
indications, .. the FIA test should be carried out crude l itself, Irom processes and from
when the CCAI value is higher than 840. handling and storage oils. The amount water
and solid impurities can be reduced by centrifuging
and filtration.
Conversion of FIA 10014 test result actual
engine performance Sand, rust, metal oxides and catalyst particles can
be lound as solid particles l l.
When using the FIA 100/4 test conditions tem-
perature and pressure, the differences between the Fuel-related wear and corrosion diesel engines
dilferen t luels are more pronounced than what would take th e form mechanical wear and chemically
actually be seen the engine, and the results must induced corrosion, the latter the form high and
l temperature corrosion.
be seen this context and relation the engine
types question.
04.46 - ES1
DescripIion 504.25
Page 3 (3) Fuel l Quality Edition 03
General
Th e solid impurities and particles produced during The Ilash ! is related the volatility the amount
combusti on, co llectively kn own as ash, cause me- and nature ollighter lractions theluel oi l, and might
chanical wear engine components. thu s be used estimate the propensity gasilication
non-pressurized parts the luel system.
Especially catalyst particles, silicone and aluminium
oxides and silicates the lorm sand are very abra- The pour ! delines the temperature at which wax
sive. From sulphur, vanadium and sodium corrosive crys t a ll zation will take place and prevent the luel l
ash the lorm oxides, carbonates and sulphates, Irom Ilowing and Irom being pumped.
is created during combustion.
Therelore, the pour ! must be taken account
Further the sulphur content a luel l may lead when deciding the presence and capacity heating
low temperature corrosion combusti on cham- coils bunker tanks.
ber components and the lor ma t on deposits
these. The corrosive effect is due the lormation
sulphuric acid.
Quality FuelOil EffecIs
Sea water the luel l may lead several detri - Crileria CharacIerisIics
mental effects to the l uel system and th e diesel
Combuslion Conradson carbon Ignilion ability.
engine general by giving rise mechanical and
quality asphaltenes + Combustion condiIion.
corrosive wear, as well as louling. FIA test Fouling of gasways.
Sulphur Corrosive wear. Cold

HandIing Properties orrosion.
Vanadium Formation deosits

Handling the luel, . . storage, pumping and Sodium exhaust valves and turbo-
treatment, is affected mainly by physical properties chargers.
such as viscosity, density, Ilash ! and pour , High temperature corrosion.
but other luel properties such as stability, emul-
Sea water Disturbance of combustion
silication tendency, viscosity index and the nature process.
and amount water and solid impurities will also Increased heat-Ioad com-
influence the h a ndlng system. Content of bustion chamber como -
impuriIies nenls, fouling of gas ways,
mechanical and caviIa
The nominai viscosi ty is decisive lor the preheating
l of I injection sysIem.
temperature necessary to achieve adequate viscosity
lor pumping , settling, centriluging and injection . Ash Mechanical and corrosive
of combuslion
The density inlluences the gravitational settling chamber components.
Formation of deposils.
water and solid contaminants settling tanks.
Catalysl fines Mechanical wear fuet -
Specilic gravity is also an important parameter jecIion system, cylinder
the centriluging process. The Ilash ! is, lr salety lners nd pislon rings.
reasons, lmted a minimum 60C (140F) by
classilicati on societies and other authoriti es. Viscosily Temperatures, pressures,
Density and capacities of fuel
Handling l systems for storage,
properIies pumping and pre-IreaIment.
Flash ! Safe!y requiremen!s.
able 1. Fue/ properties affecting dieseI engine and (I sys-

tems.
04.46 ES1
Descriplion
Nomogram for Determination of CCAI
504.26
General
D CCAI
800 800
820 810
840
820
2 860
Normal
830 operating condition
880
3 ~
4 900
840
t ;
=>

5 850 Difficullies
920 =>
may be !f-
encountered ,
860 '
210
+
~
10 E~
870 !D
~

"-
~"-
20 Increased difficulties _m
880 "'-'"
30 10 engine 2"
",
damage after -
LLU)
50 1000 a short time
890
1020
900
1040
910
920
Legend
930
V Viscosity, mm'is (cSt) at 50 C.
D Density, kg/m 3 at 15C.
CCAI Calculated Carbon Aromaticity Index.
Fig 1 Nomogram for determination ( CCA/.
Example: and viscosily (180 c81) a heavy lue l l resulls

CCAI (859). From CCAI , conclusions may be derived
Vi scosily: 180 c81 al 50 C w ilh regard 10 Ihe ignilio n qualilies.
Densily: 990 kg/m 3 at 15 C
CCAI may be calcu lated wilh th e aid Ihe lottow ing
The co mbining slraighl lne across density (990 kg/m 3) lormula:
CCAI = D - 141 109 (109 ( + 0.85)) - 8 1
04.25 - ES1
,.f DieseI!
Description 504.27
Page 1 (4) AnaIysis Data Edilion 02
GeneraI
Comments Analysis Data for Fuel Oils Asphaltenes also inlluences the lubricating properties
olthe luel l and, in extremecases, high asphalteness
Carbon Residue content may lead to luel injection pump sticking.
The carbon residue a luel l indicates its coke- Fuel oils with a high asphalteness content ll have
lorming tendency and can be used to determine the a tendency to lorm sludge, especially l the water
tendencyto lorm deposits in the combustion chamber content is also high. The asphaltenes content a
and gasways. The higher the carbon residue value, luel l is inlluenced by pre-treatment. The heaviest
the higher the louling tendency. semi-solid asphaltenes, and asphaltenes bound to
water as sludge, can be separated by centriluging.
Some changes in the combustion process, requ ir-
ing adjustment the maximum pressure, may also
be attributed to a high carbon residue content. The Diesel lndex
value is measured by standardized tests, such as
the Conradson Ramsbottom tests which give Diesel index is a calculated value to determine the
similar results. ignition quality a l uel oil. Th e ignition quality is re-
lated to the hydrocarbon composition, paraffin being
The non-vaporized residue Irom the carbonizing test high quality, n-heptanes moderate quality and
consists carbonaceous materi al and inorganic im- aromatics low quality.
purities and is expressed as percentage weight ol the
luel sample tested. Carbon residue and asphal tenes With certain exceptions the properties the aniline
con tent generally move in parallel, both in relati on to point and the specilic gravity rellect the hydrocarbon
the carbon-to-hydrogen ratio, with increasing values composition a l uel oil, and are therelore used in
lor a higher ratio. the lollowing simple lormula as an expression
ignition quality:
The carbon-to-hydrogen ratio and thus also the
carbon residue depends on the source the crude Diesel index = (aniline point F gravity)
l and the type relinery processing used. 0.01.
The effect carbon residue is impossible to coun- The aniline point is the lowest temperature at which
teract by pre-treatment the luel oil, as centriluging equal volumes the luel and aniline become just
only inlluences solid inorganic contaminants and miscible. The test relies on the lact that aromati c
hard asphalts, which are only small amounts the hydrocarbons mix completely with aniline at compara-
percentage weight called carbon residue. tively low temperatures, whereas paraffin s require
considerably higher temperatures belore they are
completely miscible.
Asphaltenes
high aniline point thus indicates a highly paraffinic
Asphaltenes is delined as the part a luel l sam- luel, and consequently a luel l good ignition qual-
ple which is insoluble in heptane. The content ity. Similarly, a high gravity number denotes a
asphal teness is expressed as percentage weight low specilic gravity and high paraffinicity, and again
the luel l sample tested. a good ignition quality.
Aspha ltenes, which is aromatic, slow-burning, semi- The diesel index provides a reasonable idea the
solid hydrocarbon compounds dispersed in the luel ignition quality, but generally gives ligures slightly
oil , has a similar ellect on th e combustion process above the cetane number.
to the carbon residue, the main impact being louling
gasways. The stability the luel l is related to Fuel oils with poor ignition quality and a low diesel
the asphaltenes content. index might in particular cause problems in startIng
diesel engines and running at low load.
02.16 - ESO - G
,,' DieseII
504.27 Description
Edition 02 AnaIysis Data Page 2 (4)
Generai
In addition starting difficulties, a prolonged ignition Especially l the weight ratio sodium vanadium
delay may give rise alternations in the maximum exceeds t :3, ash with a very l w melting poinI and
pressure, leading increased mechanical or ther- stiction temperature is lormed , giving rise high
mal load. temperature corrosion exhaust valves and deposit
10 rm aon in turbochargers.
Furthermore, luel oils with poor ignition quality may
cause reIarded combusIion and subsequent louling is possible reduce the tendency lor 10rm aon
gasways. detrimenIal vanadium-sodium ash by effective
centriluging, which ll remove sodium salts
geth er with water. 1I a very l content sodium is
Sulphur ensured, a relatively high vanadium content might
be acceptable.
Sulphur is present in luel l , mainly as organic
compounds, the amount present being expressed
as percentage weight an l sample tested. 1I Iree Water
sulphur is present may cause corrosion in the luel
system. The main problem caused by sulphur is l w The water content luel l is measured by a
temperature corrosion . During combustion, sulphu r sIandardized disIillaIion test and is expressed as
oxides are produced in the lorm gases. Since percentage volume the sample Iested. Water in
humidity is also present sulphur and sulphuric acid the luel l may lead several detrimental effecIs
may be lormed on components in the combustion on the l uel l system, and corrosion and cavitation
chamber and in the gasways, where the temperature luel injection pumps and luel valves, and cause
is below that the dew point lor sulphuric acid. louling exhaust systems and turbochargers.
Th e deIrimenIal effect sulphur in luel l is coun- Due its content sodium, salt water in combina-
teracIed by maintaining an adequate temperature tion with vanadium conIribuIes th e 10rmaon
th e combustion chamber components and by using low-melting corrosive ash , which attacks exhaust
alkaline lubricating l neuIralize the sulphuric acid valves and turbochargers. When disturbs the luel
produced during combustion . atomization, water ll lead poor combustion,
resulting in higher heat load on the combustion
chamber components.
Vanadium and Sodium
is possible reduce the water content a luel l
Vanadium and sodium are consti tuents the ash primarily by centriluging, and this should be done
content. The amounts these are measured by th e widest possible extent in order avoid the
analyzing the residue Irom the combusIion test used deIrimenIal effecIs water in the luel .
lor deIerminaIion the ash content. The amount
vanadium and sodium present is epressed in ppm,
parts per million, by weight in relaIion the luel l Ash
sample being tested lor ash content. Vanadium de-
ri ves Irom the crude l itsell and, being l soluble, Ash content is a measure the non-combustible
cannot be removed Irom the luel l by convenIional material present in the luel l. The ash content is
pre-treatment. Sodium derives Irom th e crude l, and determined by a combustion test and is expressed
also Irom contamination with salt water during storage as a percentage weight residue Irom complete com-
and transport the luel l. Sodium is water- soluble bustion the l sample tested.
and, regard less derivation, tends combine with
the water present in the luel l. Ash-Iorming materials are present in the luel l as
natural components crude l and due exIernal
Owing iIs water solubility, is possible remove contamination the luel l.
or reduce the amount sodium present in the luel
l . During combustion, corrosive ash is lormed Irom
vanadium and sodium .
02.16 - ESO - G
DescripIion 504.27
Page 3 (4) Analysis Data EdiIion 02
General
Ash-forming materials exist both as solid contami- Viscosi ty Marine Gas l (MGO) and Marine
nants and soluble compounds. The solid contami- Diesel l (D) are expressed centi stokes (cSt)
nants may lead abrasive wear the fuel injection at 40 C.
system. Ash formed during combustion may lead
abrasive as well as corrosive wear combustion Viscosity is an important parameterin connection with
chamber components and give ri se formation pumping, pre-treatmentand injection offuel l, since
detrimental deposits. is therefore essential, the the possibility and efficiency these processes a
greatest possible , reduce the amount large depend adequate viscosity.
ash-forming materi als by centrifuging.
Adjustment viscosity adequate values is possible
Solid contaminants such as sand, rust, certain by taking advantage ofthe interdependence between
metal oxides and catalyst fines can be removed by the temperature and viscosity index the fuel l.
centrifuging, and the same goes for water-soluble
salts such as sodium. The nominal viscosity a fuel l is the factor de-
termining the preheating temperatures necessary
Some the components included th e ash content obtain adequate viscosity for pumping, centrifuging
have been found be particularly harmful and are and injection the fuel l , and thus also the factor
therefore stated individually the analysis data. determining the capacity ofthe preheating equipment
the l il system.
Silicium and AIuminium Oxides

Density
Residual fuels produced by refineries using fluid
catalytic cracking may be contaminated by catalyst Density is defined as the mass a ! volume
parti cles the form silicium and aluminium oxides. and is expressed g/cm 3 at a temperature 15C
Any catalyst particles are shown by the ash content (59F).
value. Separate values for silicium oxide content and
aluminium oxide content are measured by analyzing Specific gravity is the ratio the mass a given
the ash content. volume liquid at 60F (15.6C) and the mass
an equal volume water at the same temperature.
The amount silicium and aluminium oxides is For a given liquid, the specific gravity ll generally
pressed ppm relation the weigh t the original give the same numerical value as th e density.
fuel l sample being tested for ash content.
gravity is an arbitrary scale calibrated de-
As catalyst particles are very hard and abrasive, grees and related specific gravity by the following
they can cause extreme mechanical wear the fuel formula:
injecti on system, cylinder Iiners and piston rings. 141.5
gravity = specific gravity/500F + 131.5
Catalyst particles, being solid and insoluble, can be
removed from the fu el l. The guidelines for dimen-
sioning the centrifuge size are based the fact As the formula indicates, the gravity is inverse
that approx. 1/3 the catalyst particles terms
density and specific gravity.
weight is removed.
Density is an important parameter the centrifuging
process, where separating water and water-d issolved
Viscosity impurities from the fuel l is based th e difference
densities. the density the l l approaches
Basically viscosity is a measure ofthe internal fricti on that water, centrifuging thus becomes less effec-
resistance a Iiquid flow. , necessitating a reduced l w rate and therefore
increased centrifuge capacity.
02.16 - ESO - G
504.27 DescripIion
Edilion 02 Analysis Data Page 4 (4)
General
The water separation ability luel l is increased Pour
by preheating the luel l centriluging since
the densities luel l and water change with the The pour point is the lowest temperature at which an
temperature at different rates, thus making possible l ll Il orcan be poured. The , point is meas-
to optimize density differences. ured under specilic test conditions. Fuel l must be
stored, handled and pumped at temperatures above
some extent the quality a luel l can be judged the pour point avoid wax crystallization, which may
by the density, since this is directly proportional the result in precipitation in storage tanks, blocking
carbon-to-hydrogen ratio, which again is indirect pro- l ilters and lines and prevention pumpability.
portion aromativity, carbon residue and asphaltene Normally, the pour point residual luel l does not
content, but in reverse ratio calorilic value. create any problems, since the temperature needed
reduce the viscosity to pumpable levels l l be
adequately in excess the pour point.
Analysis Dala for Fel l5

Flash
Carbon Residue % weight
Asphaltenes %weight The Ilash point an l is delined as the temperature
Dieset Index at which gives off sufficient vapour create an
Engine- FIA
inllammable mixture with air. This mixture ll ignite
Relevant Ash %weight
Properties Sulphur % weight or fiash under Ihe inlluence an open Ilame, but
% volume ll nol support combuslion ilself. The Ilash poinl
Vanadium ppm luel l is normally lesled by Ihe Pensky-Marlens
Sodium ppm closed-up melhod.
Silicium Oxide ppm
Aluminium Oxide ppm
In order 10 provide a sufficienl margin salely Irom
Viscosily cSV50C l re risk duri ng slorage, handling and Iransporlalion,
Installation- Density g/ml l uel oils lor shipboard use musl meel Ihe classilica-
RelevanI Flash ! C l o n socielies' req uiremenls Ilash poinl , l mled 10
Properties ! C a minimum 60C (140F) .
Table 2 Analysis data fueJs.
02.16- ESO - G
DieseII
DescripIion 504.30
Pag.' (2) FueI il CIeaning Edition
GeneraI
Purification Recommendations Especially fuels above 180 cST/50'C (1500 sec.
RW/1 OO' F) th e highest possible temperature 98'C
Fuel oils are always contaminated and should there- (208' F) should be maintained in the centrifuge l
lore be cleaned thoroughly solid as well as liquid preheater.
con taminants belore use. The solid contami-nants
in the fuel are mainly rust, sand, dust and re-linery The fuel is kept in the centrifuge lor as long as pos-
catalysts. Liquid contaminan ts are mainly water, i.e. sible by adjusting the Il rate through the centrifuge
either Iresh water sea water. so that ! corresponds to the amount luel required
by the engine without excessive re-circu lating. Con-
The impurities can cause damage to luel injection sequently, the centrifuge should operate lor 24 hours
pumps and l uel valves, result in increased cylinder a day except duri ng necessary cleaning.
lner wear and cause th e exhaust valve seats to
deteriorate. Increased fou ling gasways and tur- Taking today's fuel qualities into consideration the
bocharger blends may also result Irom the use need to clean centrifuges ("shooting freq uency")
inadequately cleaned luel oils. should not be underestimated. Correct choice and
adjustment the regulating screws and/or the grav-
Effecti ve cleaning can only be ensured by means ity discs are special importance lor efficient water
a centrifug e. We recommend that the capacity removal. The centriluge manual states the disc
the centrifuges installed be at least according to screw adjustment which should be chosen on the
the centrifuge maker's recommendati ons. obtain basis the specific gravity the l uel.
opti mum cleaning ! is the utmost importance to
operate the centrifuge with as lw a viscosity the Normal practice is have at least two centriluges
fuel l as possible and to allow the fuel l to remain available lor fu el cleaning. Results from experimen-
in th e centriluge bowl lor as long as possible. tal work on centrifuges, treating today's qualities
residual fuel, have shown that the best cleaning ef-
fect, especially as regards re moval catalyst fines,
is achieved when the centrifuges are operated in
CIeaning of HFO by Centri fuging
series, in purilier/clarifier mode.
Single centrifuge as purifier.
Operating Therefore series operation centrifuges to ensure
opIions centrifuges parallel.
cenrrifuges series.
maximum saIety is a ll accepted alternative to the
previously recommended parallel operation, provided
OpIimum OperaIing ConfiguraIions the operating capacity each individual centrifuge
can handle the total amount fuel required by the
WaIer content Paral l eloeralion engine, without exceeding theflow rate recommended
below 1 % i Purifier by the cen tri fuge maker the operating mode in
Normal question .

condilons
Density at 15"C Series operation
below 0.991 Purifier + Clarjfjer the centrifuge capaci ty installed is on the l w side,
corresponding to the speci fi c viscosity the fuel
Water content il used, and l more than one centriluge is avail-
below 1 % Parallel operaIion able, parallel operati on may be considered in order
to obtain an even lower Il rate. However, in view
Extreme DensiIy at 15C Purifier Purifier the above results and recommendations serious
conditions below 0.991 considerati on should be given to installing new equip-
ment in accordance with today's luel qualities and
High conlent Series operalion l recommendations.
cataryst fines + Clarifier
Table 1. Ceaning of HFQ.
97 .40 - ESO
',l,l$'( MAN DieseII
504.30 Descriplion
Edilion FueI CIeaning Page 2 (2)
GeneraI
determine centriluging capacity we generally

advise to lollow the recommendations the cen- FIow Rate
triluge maker, but the curves in lig . 1, can be used Related 10 Rated Capacity of Centrifuge
as a guideline. %
100
homogenizer may be installed in the luel oil sys- 80

tem as a supplement to the centriluges in order to 60 '''1
homogenize possible water and sludge still present 40
~~
~
"',"
in the fuel after cen trifuging . 20
Separation Temperature
'F 'C
212 100
194 90
176 80
158 70
140 60
122 50
104 40
Log scales

15
30 60 80

25

45

75

180 380600
200 400 600 1500 3500 6000 sec.

-
cSV80"C
cSTl50C
RI/ 100"F
Fig. 1 Ffow rate Ihrough centrifuge refated 10 nominal capa-

city of centrifuge.
97.40 ESO
Descriplion
Page 1 (5) Freshwater System Treatment 504.40
Edition 02
General
Protection against Corrosion n Freshwater Cleaning agenls emulsilied waler as we ll as slightly
Cooling System alkaline cleaning agenls can be used lor Ihe degrea-
sing process, whereas ready-mixed cleaning agenls
The engine Iresh waler mus/ be carelu lly Irealed , which l Ihe risk lre musl obviously l be
mainlained and monilored so as avoid corrosion used. For descaling wilh acid, especially producls
or Ihe lormalon deposits which can result insul- based amino-sulphonic acid, cilric acid, and l ar-
lcenl heattransler, l is necessarylolreal Ihe cooling laric acid are recommendable, as Ihese acids are
waler. & W recommend Ihal Ihis Irealmenl is usually oblainable as solid substances, easily soluble
carried l according the lollowing procedure: waler, and do l emil poisonous vapours.
The cleaning agenls should be directly admixed,

- Clean Ihe cooling water syslem. bul should be dissolved waler and Ihen added
the cooling water syslem.
- Fill wilh deionized or dislilled cooling waler
(Ior example Irom Ihe Ireshwaler generalor) Normally, cleaning can be executed wilhout any dis-
wilh corrosion inhibitor added. mantling the engine. We Ihal Ihe waler
should be circulated Ihe engine achieve th e
- Carry l regular checks Ihe cooling water best possible resull.
system and Ihe condilion Ihe cooling wa-
ler. As cleaning can cause leaks become apparent
poorly assembled joints or partly del ective gaskels,
inspection should be carried ! during the cleaning
Observance ollhese precautions, and correcl venling process. The acid content Ihe system l should
Ihesyslem, wll reduce service difficulties caused also be checked immediately after cleaning, and 24
by Ihe cooling waler a minimum. hours afterwards.
Cleaning the Cooling Water System Cooling Water - Inhibitors
Belore slarling Ihe inhibilion process, any exisling The lilling-up with cooling water and the admixlure
deposils l me or rusl, or any l sludge, should be Ihe inhibitor is be carried directly aller Ihe
removed order 10 improve Ihe heal Iransler and 10 cleaning order prevent lormation rust Ihe
ensure unilorm proleclion Ihe suriace by means cleaned suriaces.
Ihe inhibilor.
RawWaIer
The cleaning should comprise degreasing 10 remove
l sludge, and descaling wilh acid afterwards 10 The lormalon l me stone cylinder ln ers and
remove rusl and l me deposils. cylinder heads may reduce the heat transler, which
w ll result unacceptably high temperatures Ihe
Ready-mixed cleaning agenls, specially made lor malerial.
cleaning the cooling water syslem, can be oblained
Irom companies specializing cooling water Ireal- Therelore, ! is recommended that deionized ordistil-
menl. These companies offer assislance and conlrol led water (Ior example Irom the Ireshwater genera-
Ihe Irealment all major porls. number Ihese tor) is used as cooling water. However, account
companies are menlioned Ihe enclosed lisl. We its lack hardness, this water w ll be relatively
l l Ihal Ihe directi ons given by Ihem should corrosive, and a corrosion inhibitor should therelore
be closely lollowed. It is parlicular imporlance 10 always be added.
Ilush Ihe syslem complelely after cleaning.
OO. 11-ES1
504.40 Freshwater System Treatment
Description
Page 2 (5)
Edition 02
General
1I deionized distilled water cannot be obl ained, Checking the C ooling Water System and
normal drin king water can be used exceplional the Cooling Water during Service
cases. 1I so, the total hardness th e water must
l exceed 90 dH (German hardness degrees). Th e 1I the cooling water is conlaminated during service,
chloride, chlorine, sulphate, and silicate contents sludge deposits may lorm. The condition the
are also be checked . These contents should l cooling water system should therelore be regularly
exceed th e lollowing values: checked, especially l deionized distilled water is
used. 1I deposits are lound the cooling spaces,
Chloride 50 ppm (50 mg/litre) these spaces , l necessary, Ihe system
Chlorine 10 ppm (1 mg/litre) should be cleaned.
Su lphate 100 ppm (100 mgIIitre)
Silicate 150 ppm (150 mgIIilre) According experience, a zinc galvanized coating
the Ireshwater cooling sysl em is often very suscep-
There should be sulphide and ammonia contenl. tible corrosion, which results heavy lormal on
Rain water must be used, as may be heavily sludge, even l the cooling water is correctly inhibited.
contaminated. Th e initial descaling with acid l l , a greal ,
remove Ihe galvanized coating . Generally, therelore,
should be noted th at softening water does advise against the use galvanized piping the
reduce its sulphal e and chloride conl ents. Ireshwal er cooling sysl em.
Corrosion Inhibitors The quality Ihe cooling water is be checked re-

gularly, l possible once a week. Basicallythe inhibitor
protect Ireshwaler cooling systems marine concentration, the value and th e chlori de concen-
diesel engines against corrosion, various types Iralion should be accord ance with l m t s stated by
Inhibitors are available. inhibitor manulacturer. For Ihis purpose the inhibitor
manilactures normally supply simple lest kits.
Generally, only nitrite-borate based inhibitors
are recommended. As a general guidance values the value should be
7-1 measured at 200 C and th e chloride concentra-
number th e products marketed by major compa- should exceed 50 ppm (50 mg/litre).
nies are specilied th e enclosed list, together with
the necessary dosages and admixing procedures. The water sample lor these tests is be taken Irom
We recom mend that these direclions are strictly th e circulaling syslem, and Irom the expansion
observed. tank the lead ing l.
Treatment ofthe cooling wal er with inhibting oils is The concentration inhibilor must under
recommended, as such treatment involves the risk circumslances be allowed lall below that
l adhering 10 Ihe heat transmitting surfaces. recommended by the producer, as Ihis would
increase Ihe risk corrosion,
Chromale inh ibilors musl l be used planls
connecled 10 a Ireshwater generalor. clear record all measuring results should be kept,
so that th e actual condilion and trend th e sysl em
Evaporated cooling water is be replaced with may be cu rrenlly ascerlained and evalualed.
noninhibited water, whereas a loss water Ihrough
leakage must be replaced wi th inhibited water. sudden gradual increase the chloride content
Ihe cooling water may be indicative salt water
When overhauling individual cylinders, a new dosage leakages. Such leakages are 10 be traced and repai-
inhibitor must, l necessary, be added im-mediately red al the lrs t .
after completing the job.
OO .1 1 ES1
Description
Edition 02
General
chloride content the cooling water higher than The cooling water system must not be kept under
the 50 ppm specified might, exceptional cases pressure.
be tolerated. However, that case the upper limit
specified by the individual inhibitor supplier must Check, and repair any leaks.
be exceed.
Drain the system and l ll completely with clean
clear record all measuringresu lts should be kept, tap water, order flush any l grease from
so that the actual condition and trend the system the tank.
may be currently ascertained and evaluated.
Circulate the water 2 hours, and drain again.
sudden gradual decrease value, an
increase the sulphate content, may indicate
haust gas leakage. The value can be increased DescaIing with Acid SoIution
by adding inhibtor; however, major quantities are
necessary, the water should be rep laced. Fill with clean tap water and heat 70-750 C.
Every third month a cooling water sample should be Dissolve the necessary dosage acid compound
sent ashore laboratory analysis, particular a clean drum with hot water.
ascertain the con tents inhibtor, sulphate, and ,
as well as the total salinity the water. Fill the drum half with water and slowly add the
acid compound, while stirring vigorously. Then ll the
drum completely with hot water while continuing
CIeaning and Inhibiting Procedure stir (e.g. using a steam hose).
The engine must be run ning during the cleaning Be careful - use protective spectacIes and
procedure, as this may l the risk overheating gloves.
when draining.
For engines which have been treated before the trial
,
the lowest concentration recommended by the
Degreasing supplier ll norm ally be sufficien t.
Use clean tap water fill ing-up. The cooling water For untreated engines, a higher concen tration - de-
the system can be used, does contain pending the condition the cooling system - ll
inhibitors. normally be necessary.
Heat the water 600 C and circulate the water Drain some water from the system and add the acid
continuously. solution via the expansion tank.
Drain lowest water level expansion tank. The cooling water system must not be under
pressure.
Add the amount degreasing chemical specified
by the supplier, preferably from the sucti on side Keep th e temperature th e water between 700 C
th e freshwater pump. and 750 C, and circulate it constantly. The duration
the treatment l l depend the degree ul
Drain lowest water level the expansion tank ing. Normally, the shortest time recommended by
directly afterwards. the supplier l l be sufficienI engines which are
treated before the trial . For untreated engines,
Ci rculate th e cleaning chemical the period speci- a longer time must be reckoned with. Check every
fied by the supplier. hour, example wi th pH-paper, that the acid th e
solution has been used up.
00." - ES ,
',I,HM'iMAN DieseI!
504.40 Freshwater System Treatment
Description
Page 4 (5)
Edition 02
GeneraI
number descaling preparations contain colour Adding of InhibiIors

indicators which show the state the acid solution.
1I the acid content is exhausted, a new acid solution Fill the cooling water system with waler Irom th e
can be added, which case, the weakest recom- evaporator to the lowest water leel the expan-
mended concen trati on should be used. sion tank.
The solubility acids water is often limited. Weight ! th e quantity inhibitors specilied by th e
Therelore l, exceptional cases, a large amount is supplier and dissolve a clean drum wilh hot
required, descaling can be carried ! two stages water from the evaporator.
with a new solu ti on compound and clean water.
Normally th e supplier w ll specily the maximum Add Ihe solution via the expansion tank to the system.
solubility. Then lll to normal water l l with water from the
evaporator.
After completing the descaling, drain the system and
Ilush with water. Acid residues can be neutralized ll w the engine to lor ! less than 24 hours
with clean tap water containing 1 kg soda per ton ensure that a stable protection the cooling surfa-
water. Circulate the mixture lor 30 minutes, then ces is lormed.
drain and Ilush the system.
Subsequently, test the cooling water with a test
The cooling waler syslem musl l be l under kit (available Irom the inhibitor supplier) to ensure
pressure. that an adequate inhibitor concentration has been
obtained.
Continue to flush until water used is neutral (
approx.7). This should be checked week.
The acid content the system l is to be checked

directly after the descaling with acid, and again 24
hours afterwards.
OO.11 ES 1
Oescription
Edition 02
General
NiIriIe-boraIe corrosion inhibiIors

for cooling waIer IreaImenI
Maker's minimum
Company Name Inhibitor Delivery Form Recommended
Dosage'
CasIrol Limited Castrol Powder 3 kg/1000

Swindon SolvexWT4
Wiltshire, England Castrol Liquid 20 1/1000
SolvexWT2
Drew Ameriod DEWT-NC Powder 3.2 kg/1 000

Marine Liquidewt Liquid 81 /1000
Boonton, N.J./U.S.A Maxiguard Liquid 161/10001
Houseman Scandinavia Cooltreat 65 1 Liquid 51/1000

3660 Stenl"se
Denmark Cooltreat 652 Liquid 5 1/1000
Nalfleet Marine Chemicals Nalfleet Liq

Northwich, (9-108) Liquid 3 1/1000
Cheshire CW8DX, England Nalfleet 9-131 C Liquid 10 1/1000
Nalfleet 9-111 Liquid 101/1000
Nalcool 2000 Liquid 101/10001
Rohm & Haas 11 PROSIM Powder 3 kg/1000

( l) 25 PROSIM Liquid 501/1000
Paris, France
Rochem Dieselguard Powder 3 kg/1000

Marine Chemicals Rocor Liquid Liquid 101/10001
Oslo, Norway
, Initial dosage may be larger
The list is for guidance only and must be consid- The suppliers are l sted alpabetical order.
ered complete. We undertake responsibility for
difficu lties that might be caused by these other Suitable cleaners can normally be supplied by
water inhibitos/chemicals. these firms.
00. 11- ES1

5ection 505
Cylinder Head
Description
Cylnder Head 505.01
Working card
Dismantling of Cylinder Head 505-01.00

Inspection of Inlet Valve, Exhaust Valve and Valve Guide 505-01 .05
Reconditioning ofValve Spindle Seatand Valve Seat Ring 505-01.1
Valve Rotator 505-01.15
Replacement of Valve Guide 505-01.20
Indicator Valve 505-01.26
Replacement of Sleeve for Fuel Injector 505-01.30
Replacement of Valve Seat Ring 505-01.35
Mounting of Cylinder Head 505-01.40
Inspection of Cylnder Head Cooling Water Space 505-01.45
Plates _ _ ~ _______________ ----
Cylinder Head 50501-10

Valve Spindles and Valve Gear 50502-01
Indicator Valve 50508-01
Cylinder Head, Cover 50510-01
'il@"'lMANDieseII
Descriplion
CyIinder Head
505.01
Page 1 (1)
Edition 01
23/30
Cylinder Head ll and ExhausI Valves
The individual cast-iron cylinder heads, for each The l and ehaust valve s indles are identical
cylinder , are equied with a centrally situated and therefore interchangeable.
fuel injection valve, l valves, ehaust
valves and indicator cock. Th e valve s ind les are made heat-resistant ma-
terial. Hard metal is welded the valve sindle
The head has a thi ck, bore-cooled flame late for seats.
satIsfactorycontrol ofmechanical and thermal loads
and stress. The valve sind l es are fitted with valve rotators
which turn the sindles a lttle each time the valves
The cylinder head is attached by means 4 nuts .
and 4 studs screwed dee bosses the engine
frame late. The nuts are tightened by means The cylin der head is equ i ed with relaceab l e
hydraulic Iools. seat rings for l and eha ust valves.
The sea ting surfaces are hardened order mi-

nimize wear and dent marks, the l
seat by induction hardening , the ehaust seat
by hard metal armouring.
95.50 - ESOU-G
',, DieseII
Working Card
DismantIing of CyIinder Head
505-01.00
23/30
Safely precaulions: Special lools:
Stoped engine Plate Item Note

Shut-off startIng air
Shut-off cooling water 52021 011 l injector,
Shut-off fuel l 52021 011 (Complete)
Shut-off cooling l
Stopped lb. l circul.
52021
52021
52021
501
513
155
4 pieces
1 piece
52005 014
52021 25 1 Hydraulic tools
Descriplion:
Dismantling ! cylinder head for inspection

and/or overhaul.
Hand lools:
Slarling posilion: Ring and open-end spanner, 17 mm.

Ring and open-end spanner. 19 mm.
Cooling water has been drained from engine. Ring and open-end spanner, 27 mm.
Allen key, 8 mm.
Relaled procedure:
Dismounting piston and connecting

rod 506-0 1.00
Dismounting and inspection l valve,
exhaust valve and valve guide 505-01.05
Dismantling , ove r hai and test
pressure ! l l valve 514-01. 10
Manpower:
Replacemenl and wearing parls:
Working time 1 hour
Capacity 2 men Plate Item Qty/
Dala:

Data for torque moment (Page 500.40)
95.50 - ESOS
f,J,IIM DieseII

EdItion 01 DismantIing of CyIinder Head Page 2 (2)
23/30
Draining cooling water, di sconnection

pipes etc.
1) Open the drain cock and vent cock cool -

ing water.
2) Take 011 the cover.
3) Take 011 the ! cover which gives access

the injection pump.
4) Disconnect the lel l high-pressure . ,

5)
pe.
Disconnect the rocker arm lubricating l
,
/'--
6) Remove the thermometer attachment bran-
ch (cooling water tl! ).
Fig2
7) Remove the exhaust Ilange screws.

Mounting Lifting Tool with the Fuel Injection
8) Remove the cylinder head nuts, see Fig 1, Valve is Removed from the Cylinder Head.
by means hydraulic jacks. See working card 520-
01.05. 12) the two-distance pieces the studs.
13) ! the lifting l by means the nuts.

See Fig 3.

.
FIg 1
,
Mounting Lifting l while the Fuellnjection ,

')::;
Valve is Placed the Cylinder Head.
9) Disconnect the nuts which is holding down

the lelinjection valve. 1';g3
1 ) Remove the distance pieces.

14) Attach the hook th e Iifting l and lift the
11) the lil ting l by means the nuts. cylinder head away.
See Fig 2.
95.50 - ESOS
'( DieseII
~~~~91 ~;;d Inspection of In Iet VaIve, Exhaust VaIve and VaIve Guide 5~~I~~~5
23/30
Safely precaul ions: Special 10015:
Stopped engine Plate no. item . Note.

Shut-oll starting air
Shut-oll cooling water 52005 014
Shut-oll luel l 52005 05 1
Shut-off cooling l 52005 254/30 1 E t r a tools
Stopped lub. l circui . 52005 553
De5criplion :
Dismounting l ! and eha u s t valve, inspec-

valve guide and mounting l ! and
e ha us t valve. Hand 10015:
Ring and open-end spanner, 24 mm.

Smali screwdriver.
Slarling posil ion : Measuring tools.
Cylinder head, dismantled Irom

engine 505-0 1.00
Relaled procedure:
Reconditioning valve spindle seat

and valve seat ring 505-0 1.1 0
Valve rotator 505-0 1.15
Replacemen t valve guide 505-01.20
Replacement valve seat ri ng 505-01.35
Mounting cylinder head 505-01.45
Manpower: Replacemenl and wearing parl5:
Workin g time hou r Plate Item Qtyl

Capacity man
60501 363 4/cy l.
Dala:
Data lor pressure and tolerance (Page 500.35)

Data lor torq ue moment (Page 500.40)
95.50 - ESOS
505-01.05 Inspection of Inlet Valve, Exhaust Valve and Valve Guide WorkIng Card
EdillOn 01 Page 2 (3)
23/30
Dismantling Inlet and Exhaust Vale Spind-

les
1) Land and laslen Ihe cylinder head Ihe

special work lable and remove Ihe lifting 1001.
Or as an Allernalive:
Land Ihe cylinder head Ihe Iloor wooden

supports and remove the lilting tool.
2) l Ihe supporling devices lor Ihe valve

spindle heads the work lable.
Or as an allern alive: FIg2.
Place wooden blocks under Ihe valve spindle 9) Remove valve rolator and springs.
heads.
10) Remove the supporling devices under Ihe
3) back Ihe rocker arm and remove Ihe work lable and lake Ihe valve spindle.
11) Repeat poinl 4 - 1 10 remove Ihe olher

valve spindles .
.__.-
Inspection ValvesNalve Seats
slight grinding valve/valve seal can be carried

out by means the handle as shown, see fig 3.
If the valve seal is heavily burnl scarred, l should

be ground using Ihe valve seal grinder, see working
card 55-. .
FIg 1.
spring-Ioaded valve bridge over Ihe valve spind-

les.
4) Ihe 1001 lor mounling af valves, see fig

2.
5) Compress Ihe valve springs by lightening nut

, see fig .
6) Remove the cone ring s, see fig 2.
7) Release Ihe springs again . Fg3.
8) Remove and Iraverse , see fig .
95.50 - ESOS
',tlM"I MAN DieseII
Working Card
Page 3 (3) Inspecti on of InIet VaIve, Exhaust VaIve and VaIve Gu ide 5~~;~~5
23/30
Inspeclion VaIve Guide
much clearance between valve spind le and

spindle guide may cause: Max inner diameter,
---- see page 500. 35.
increased lub. l consumption.
fouling of the spindle guide and thus give
the risk of a sticking valve spindle.
much clearance also means insufficient guid-

ance of the valve spindle, and thus bad alignment
between spindle head and valve seat ring .
In connection with overhaul olthe cylinder head, the

valve spindle guides should be cleaned, inspected
and measured for wear.
1I the inner diameter the valve spindle guide

exceeds the tolerance, see page 50035, the valve
spindle guide must be replaced. See working card
505-01.20.
Mounling VaIve SpindIe
Fig4.
12) For mounting valve spindle lw the in-
structions in point 4 - 10 in reversed order.
95.50 - ESOS
DieseI!
WorkIng Card Reconditioning of VaIve SpindIe Seat 505-01.10
and VaIve Seat Rin
L23/30
Safely precaulion5: Special 10015:
Stopped engine Plate Item Note

Shut-off cooling water 52005 408 Grinding machine
Shut-off fuel l for valve spindle.
Shut-off cooling l 52005 350 Grinding machine
Stopped lub. l circul. for valve seat ring
(etra tools).
De5criplion:
Reconditioning of valve spindle seat and valve

seat ring, with special gri nding machine.
Hand 10015:
the hand tools and new stones are included

the tools bo for grinding machine.
Slarling posilion:
Valve spindle has been removed 505-01.05
Relaled procedure:
Mounting of valve spindle 505-01.05
Working time 6 hours Plate Item Qty!

Capacity man
Dala:

Data for torq ue moment (Page 500.40)
Declaration of weight (Page 500.45)
95.50 - ESOS
505-01,10 Reconditioning Valve Spindle Seat WorkIng Card
EdiIIon 01 Page 2 (3)
and Valve Seat Ring
23/30
Reconditioning VaIve Seat Ring I-Iowever, when theseat 'S' has been ground such
an extent that the recess 'R' disappears, see Iig 1,
Reconditioning of valve seat rings by machining is the valve seat ring has be scrapped and a new
carried by means of a grinding machine, the must be installed, see working card 505-01.35
l spindle of which is be mounted the valve
spindle guide. Foroperation the grinding machine,
see separate instructions. Reconditioning VaIve Spindte
Reconditioning by machining is carried with the

Grinding VaIve Seats valve spindle being rotated a turning lathe and a
special grinding machine mounted the l post
Grinding valve seat rings shouId be carried the turning latch.
according the lollowing sequence:
1) Grind the seating surlace with a leed at an Grinding VaIve SpindIe

angle " " of 300 ~ 10"
For operation the grinding machine, see separa-
2) Continuethe grinding l a clean and unilorm ted instructions.
surface condition has been obtained.
1) Grind the seating surface with a leed at an
3) Carry the linaI grinding with a feed the angel '' 300 g.".
direction inside and outwards. Normally, the best
surlace quality is obtained this way. 2) Continuethe grinding l a clean and unilorm
surlace condition has been obtained.
3) Check the height '1-1' 1 after completing the

grinding, see fig 2.
'1-1'1 has as a minimum be as indicated page

'S'
500.35.
1I measured be less, the spindle has be scrap-

ped.
Fig 1. Valve Seat Ring

/
Scrapping VaIve Seat Rings
'"
~L
' 30" 8:s'
Normally, the valve seat ring can be recondition ed
several times.
Fig 2. Va{ve Spind/e
95.50 - ESOS
,' Dieserl
Working Card Reconditioning of VaIve SpindIe Seat 505-01"10
Page 3 (3) EdiIIon 01
and VaIve Seat Ring
23/30
4) Alter assembling the valves, check - account

the valve motion - that distance " "2 between the
upp er edge the cylinder head and the upper edge
the valve spindle, see fg 3, does eceed the
maimum value, see page 500.35.
"2
Fig3.
95.50 - ESOS
+$' DieseI!
Worklng Card 505-01.15
Page 1 (2) VaIve Rotator EditIon Q1H
23/30
Stopped engine Plate no Item no Note

Shut-off cooling wa ter 52005 051
Shut-off fuel l
Shut-off cooling l
Stopped lub. l circul.
Descriplion:
Dismantlin g, inspection and mounting valve

rotator. Hand lools:
Small screwdriver.
Ring and open-end spanner 24 mm.
Slarling posilion:
Relaled procedure:
Mounting valve spi ndles 505-0 1.05
Manpower: Replacemenl and wearing parls:
Working time 1/2 hour Plate no Item no Qtyl

Capacity 1 man
Dala:

95.50 - E50S
l$% DieseI!
505-01.15 WorkIng Card
Editfon 01 VaIe Rotator Page 2 (2)
23/30
Inspection Rotocap ! Having assembled the valve rotator dry

condition should be placed clean lubricating
especially the ball pockets due residues l lor a short period time.
theoil (abrasives, combustion products) , can cause
the individual parts become stuck, and hinders
the movement the balls.
Rotocap valve rotators need servicing under

normal operating conditions.
Rotator perlormance is satislactory when the valve

rotates visibly and evenly.
Dismantling Rotocap
FIg /.
See work;ng card 505-01.05, po;nl 3 10 9.
Oerhaul RoIaIor Mounting Rotocap
1) Clean the valve rotator. See work;ng card 505-01.05, po;nl3 10 9, Oppos;le
d;recl;on.
2) Inspect lor wear and ball impressions.
3) Remove the retaining ring and disassemble

the individual parts.
4) Replace parts showing wear grooves de-

pressions lormed by the balls.
5) Insert the balls and the tangential springs.
! balls the incl ined racesol the ball pockets

must the same direction , see (;g. 1.
The ring the spring washer should rest

the retainer bod y.
95.50 - ESOS
Page 1 (2) Replacement of Valve Guide Edilion 01
L23/30

Shut-off cooling water
Shut-off luel l
Shut-off cooling l
Stopped lub. il circul.
Descriplion:
Dismantling and mounting olvalve guide lor l

and exhaust valve. Hand lools:
Hammer.
Nitrogen (,). similar.
Mandrel lor 'knocking out the valve guide.
Slarling posilion:
Relaled procedure:
Mounting valve spindles 505-01.05
Working time 3/4 hour Plate no. Item no. Qtyl

Capaci ty 1 man
50501 363 4/cyl
Dala: 5050 1 218 4/cyl

Declarati on weight (Page 500.45)
95.50 - ESOS
f,J,I'MI.lfMAN DieseI!
EdiIIon OSH RepIacement VaIve Guide Page2 (2)
23/30
When 10 RepIace Ihe VaIve Guide 4) Belore mounling - cool down the new valve
guide 10 approx. -70"C with nilrogen or similar.
Illhe cIearance exceeds Ihe max. Iimil , see page
500.35, Ihe vaIve guide musl be repIaced. 5) Inserl Ihe valve guide the bore.
6) Knock slightly wilh Ihe mandrel and a ham-

Dismounling VaIve Guide mer.
Nole! The shoulder Ihe valve guide musl bear
1) Knock Ihe valve guide l Irom Ihe bollom against Ihe cylinder head, by knocking slightl y with
the cylinder head, by means a mandrel , which Ihe mandrel and a hammer.
has a shoulder turning th at lits Ihe valve guide,
see fig .
Valve seat rIng
M andrel
Fig2.
Valve guide
7) Belore mounling Ihe valve spindle inserl a
O-ring Ihe valve guide.
Correcl mounling can easily be done by Ihe use

valve spindles as mounting 1001 , spindle 10
Fig 1. be used as supporl and the olher spindle 10 be used
lor pushing Ihe O-ring downwards.
2) Clean th e bore the cylinder head careluIIy. Screw-drivers or other sharp lools should never be
used lor Ihis purpose.
3) Inspect lor marks th al can prevent mounting
valve guide. 8) For mounting valve spindle, see working
card 505-0. 05.
95.50 ESOS
WorkIng Ca rd
Indicator Valve
505-01.26
23/30

Stopped engine
Shut-off cooling wa ter
Plate Item Note
Shut-oll luel l
Shut-olf cooling l
De5criplion: Hand 10015:
Dismounting, inspection and mounting indi- Ring and open-end spanner 1 mm

cator valve. Ring and open-end spanner 27 mm
Steel brush
Copaslip
Slarling 05:
Relaled procedure:
Man power: Replacemenl and wearing parl5:
Working time 1/2 hour Plate Item Qty./

Capacity 1 man
50508 037 1/Cyl.
Dala:

Data lor torque moment (Page 500.40)
95.50 - ESOS-G
,, DieseII
505-01,26 Worktng Card
EditIon 01 Indicator VaIve Page 2 (2)
23/30
MainIenance
Under normal working conditions the indicator valve

requires very l ttle maintenance except inspection
in connection with the normal cylinder cover over-
haul.
1
Inspection the IndicaIor Valve
1. Disassemble the indicator valve. 2

2. Check the valve seat and the cone for ' burning
through' .
If the valve seat the housing is 'burned', the entire

valve is be replaced. 1. Indicator valve, complele
2. ConneclIng ptece
3. Clean and l u br cate all components before
remounting .
Fg 1 /ndIcator va/ve.
4. EnsLl re that the spindle is in ' position
when assembling the valve.
: Otherwise, cone and seat may be dama-

g ed.
95.50 - ESOS-G
I+I@,!"iMANDieseI!
Working Card
RepIacement of SIeeve for FueI Injector
505-01.30
Page 1 (2) Edition Q1H
23/30
D Stopped engine Plate Item Note

D Shut-off starting air
D Shut-off cooling water
D Shut-off fuel l
D Shut-off cooling l
D Stopped lub. l circul.
Descriplion:
Dismounting, inspection and mounting sleeve

lor fue l injector. Hand lools:
Brass mandre).
Hammer.
Lub.oil.
Slarling posilion: sma)) screw-d rivers.
Loctite 572.
The cylinder head has been dis-
mounted Irom engine 505-0 1.00
The fue l injector has been removed 514-0 1.1 0
Relaled procedure:
Mounting fuel valve 514-01.10
Working time hour Plate lIem Qty/

Capacity man
50501 039 1/cyl.
Dala: 50501 040 1/cyl.
50501 052 1/cyl.
DeclaraIion weight (Page 500.45)
96.19 - ESOS
Edillon 01 Replacement of Sleeve for Fuel Injector Page 2 (2)
23/30
Dismounting Sleeve for Fuel Injector 4) Coat the sealing ring the bore with
grease l b. l.
1) Remove the snap ring by means screw-
drivers.
2) The sleeve can be driven out the bo-
~
- snaPjng
by a brass mandrel and a hammer.
~ / O-lng
Sleeve
LocIIte 572
Fig2.
5) Install new sealing rings the sleeve.
6) Coat the sealing surfaces the sleeve with

Fig 1. l octte 572.
7) Insert the sleeve the bore.

Inspection Bore Cylinder Head and Mount-
ing the Sleeve: 8) the snap ring.
3) Clean and inspect the bore the cylinder

head. Any marks which could prevent mounting
the sleeve, should be gently smoothed.
96.19 - ESOS
Wo(king Card
Replacement of Valve Seat Ring
505-01.35
Page 1 (4) Editlon 01
23/30

Shut-off cooling water 52021 011
Shut-off luel l 5202 1 501 1 piece
Shul-off cooling l 52005 457 El r a
lools
Stopped lub. l circul. 52005 504 Etra lools
52021 466 1 piece
Descriplion:
Replacement valve seal ring for inlet and

valve.
e h aust
Slarling posilion:
Inlel and ehausl valves have been Hand lools:

removed 505-01 .05
Ring and open-end spanner, 36 mm
Hammer.
Loctite, 572.
Lub.Oil.
Relaled procedure:
Mounling of valve spindles 6505-01.05
Working time 1 1/2 hours Plale Item Qty

Capacity 1 man
5050 1 351 4/cyl.
Dala: 5050 1 064 2/cyl.
50501 076 2/cyl.
Dec laralion of weight (Page 500.45)
05.02 ESO
505-01.35 Replacement of Valve Seat Ring
Working Card
23/30
Dismounting Valve Seat Rings Dismounting a Vatve Seat Ring is Carried

According the Fotlowing Procedure
When reconditioning a valve seat ring longer is
possible due dimensions exceeding the scrapping 1) means the guide (7) the guide disc
criteria, the seat ring has be replaced. (5) is led ver tically through the valve seat ring. Then
the guide disc (5) is llted with the guide (7)
Dismounting a valve seat ring is carried out by l the laer is guided by the valve seat ring. The
means a special extractor tool set comprising the stud (1) is then screwed l rests the valve
components, see fig 1. guide.
10
6
5 .
[~-'

1 Stud 6 Eye screw Fig 2.

2 Collar U hexagon 7 Gide
3 Guide dIsc 8 Valve guIde
4 Disc 9 Hydraulic jack
5 GUIde disc 1 Valve seal rIng 2) The guide disc (3) is positioned so that
bears against the bottom the cylinder head, and
the hydraulic jack is clamped with the disc (4) and
Fig 1. the collar hexagon (2), see fig 1. The hydraulic
jack is the one used lor main bearing caps.
05.02 - ESO
.i( DieseI[
WorkIng Card 505-01.35

Page 3 (4) RepIacement of VaIve Seat Ring Edition 01
L23/30
3) pumping Ihe pack, see working card 3) facililale mounling Ihe valve seal ring is l
520-01.05 for Ihe use ! hydraulic lools, Ihe valve cooled down, however, a min. of -25C olherwise,
seal is pressed l max. 6 mm, and Ihe pressure is Ihe o-ring can be damaged.
released again. The collar nut heagon is lighlened
and Ihe operalion is conlinued unlil Ihe valve seal 4) Place Ihe o-ring on Ihe valve seal ri ng and
ring can be removed. coal wilh oil/loclile as shown in Iig 4, jusl before
posilioning l in Ihe bore.
Mounting Valve Seat Rings
1) 10 mounling ! a new valve seal ring, Ihe

bore musl be cleaned Ihoroughly and inspected for Coatwith
IOCIIte 572
marks. Marks thal can hinder mounting of the valve
seat ring musl be removed.
Valve seat ring
2) Tools for ru ntng of valve seal ring s

shown in Iig 3. O-ring
Coat Witt1 01 1
Fig4.
5) The valve seal ring is posilioned in Ihe bore,

Ihe handle wilh stud is inserled as shown in Iig 5,
and Ihe washer wilh screw is screwed light.
1 Handle 2 Std
Fig3. Fig5.
05.02 - ESO
Editlon 01 Replacement of Valve Seat Ring Page 4 (4)
23/30
6) kn ocking on the handle and at the same

time tightening the nut (4), the valve sea t rin g slides
in place in Ihe bore and l is lell on Ihe knocks when
l bears in Ihe bore.
7) 10 mounting Ihevalve spindle Ihevalve

seat ring must be ground , to ensure correctcentering
al the valve guide and the valve seal ring. This can
be done according /0 working card 50.5-0. 1.0.5
50.5-0.1.10.
05.02 - ESO
WorkIng Card
Mounting of Cylinder Head
505-01.40
Page 1 (2) EdiIion 01
23/30

11
Stopped engine
Sht-oll starting air
Plate Item Note

Sht-oll cooling water 52021 011
Shut-off lel 52021 501 4 Pieces
Sht-oll cooling l 52021 155
11 Stopped lb . circul. 52005 014
52010 011
52021 251
Descriplion:
Mounting cylinder head alter inspection and/or

overhaul.
Hand lools:

Slarling posilion: Ring and open-end spanner, 17 mm.
Cylinder head is completely l ub. l and copaslip.
assembled 505-01.05 505-01.35
Valve gear respective cylinder is right posi-
(valve closed)
Control the surlace the
cylinder l er 506-01.45
Relaled procedure:
Adjustment valve clearance 508-01.1 0

.;
~ Working time 1 1/2 hour Plate Item Qty/
~
~ Capacity 2 men
~
50501 338 2/cyl
3
> Dala: 505 10 075 1/cyl
506 10 079 8/cyl
Data lor pressure and tolerance (Page 500.35) 51202 024 2/cyl
Data lor torque moment (Page 500.40) 51625 097 1/cyl
Declaration weight (Page 500.45) 5 1625 132 1/cyl
95.50 - ESOS
Edilton QIH Mounting of Cylinder Head Page 2 (2)
23/30
Check 10 be Done belore Lifting Place Ihe spacer ring around Ihe nls wilh Ihe slol

1) Check Ihe joinling surlaces Ihe cylinder such a posilion thallhe lommy bar can be used.
head/cylinder ler see thal they are clean and
wi l hol damage marks, see working card 50.6-0.1.45. Tighlen Ihe hydraulic jacks and make sure that Ihe
Fit new O-rings Ihe waler passage, lbrcale the cylinder Ihe jacks bears lirmly againsllhe spacer
O-rings with a lllle l. ring . Tighlen aII Ihe nuls, see page 50.0..40. For
using (he hydraulic (ools, see working card 520.-
2) Check aII conlacl laces Ihe cylinder head 0.1.0.5
and nuts, including threads, and make sure Ihat
Ihese are level and smoolh and absolutely Iree Irom
loreign parlicles.
Mounling Cylinder Head
3) Allach Ihe lilting 1001, see fig 1, 10 the cylinder

head thal has been made ready lor instaIIation, and
posilion careluIIy the cylinder l.
Fg2.
7) 1I new slds nls have been lilted . the nuls

musl be tighlened and loosened Ihree limes, order
compensate lor delormation the Ihread and
order 10 ensure a sale minimum load Ihe slds
Ihrough the lightening.
Adjuslmenl Vale Clearance

FIg 1.
) Adjusllhe valve clearance, see working card
50.8-0.1.10..
Tighlening Cylinder Head Nuls
9) Fit Ihe pipes lor lel l, lb. l, cooling water
4) Make sure Ihat Ihe nuls easi ly Ihe and th e Ilange lor exhaust .
Ihreads and Ihat Ihey bear their l contacl
surlaces.
Belore Slarling
5) Coallhreads and conlact laces wilh copaslip
belore lilling Ihe nuls. 10) slarting check lor leakages. Afler
sl arti ng check lor leakages and l Ilow.
6) Screw nuls l Ihe slds and lighlen lightly
wilh Ihe lommy bar. 11) l th e cover lor rocker arm and the I
cover lor lel pump.
95.50 ESOS
Page 1 (2) Inspection of Cylinder Head Cooling Water Space Edition 01
23/30

Shut-off fuel l
Shut-off cooling l
D Stopped lub. l circul .
Descriplion:
lnspection cyl inder head cool ing water

space. Hand lools:
Steel brush
Slarling posilion :
The cylinder head dismantled

from engine 505-01.00
Relaled procedure:
Working time v.hour Plate Item Qty/

Capacity 1 man
Dala:

95.50 - ESOS
EditIon 01 Inspection of Cylinder Head Cooling Water Space Page 2 (2)
23/30
Inspeclion Cylinder Head CooI. Waler Space
1) Inspect the cooling water inlet at the bottom Cooling

and the cooling water outlet at the the cylinder water, outlet
head. see lig 1.
2) Remove all possible deposits.
3) , water into the cooling water l and

make sure that water is coming all the cooling
water inlet bores at the bottom the cylinder
head.
4) necessary. clean the cooling water inlet and

outlet by means a steel brush. Flush the cooling Cooling
water space after cleaning. water, InleI
5) Should the cylinderhead cooling water space.

contrary epectation. be blocked with deposits. =ig . CY/Inder Head
please contact & Diesel . Holeby ' further
instructions.
,.

95.50 - ESOS
1,j,j@'.ifMANDesel
Plate
Page 1 (2) CyIinder Head 50501-10
23/30
255i~
363
2~279
243 039 ____- 267
231 292
147
1 59~

:::~
637
35 1
~k--- 076
064
649
338-_
160
015
172
184 ~
196 :=----e
184 ---------..
07.32 - ESO
Plale
50501-10 Cylind er Head Page 2 (2)
L23 / 30
Ilem Item
. Qty. Designalion Benrevnelse . Qty. Designalion 8enrevnelse
015 I/C Cylinder head (as 649) Cylinderdreksel (som 363 4/C O-rlng 0 - 9
with brackels 80d 649) monlere! med
rocker arms insIalled bukke og . 637 1/C Cylinder hea d with Cylinderdceksel mon-
valve guide sIeeve for !l med spindelslyr,
039 I/C Sleeve Forlng fuel l and l forin9 for br. venlil 09
seat r ings venlilscederinge
040 /C - -
649 1/C Cyllnder head (as 637) Cylinderdcekse l (som
052 I/C Snap ring L~sering wlth valve splndles, 637). monterel med
spring and rotocap venlilspindler, fjeder og
064 2/C Valve seat ring, VenIllsredering, installed rolocap
(ll) (indstr0mning)
076 2/C Valve seat 9. Ventlsredering,

(ehausl) (udst0dning)
111 2/C Plug screw Propskrue
123 2/C Sealing Treln in gsring
135 8/C l screw Propskrue
147 8/C Seal ing ring Tretnlngsring
159 2/C Spring Fjederstilt
160 I /C Water guide jacket K01ekappe
72 4/C Screw Skrue
184 8/C O- rlng O- rlng
196 4/C Cooling con - K01evandsove rgang

neclion
218 4/C l Guide Veotilstyr
231 2/C SlUd .
243 2/C Dis tance Afs tandsstykke
255 2/C M0trik
267 2/C S lUd
279 2/C M0trik
292 3/C SlUd .
302 2/C Thrust piece Trykstykke
338 2/C - -
351 4/C O- rlng - (1
When orderng spare parts, also page 500.50. Ved besIilling al reservedele, se ogsf side 500.50.
Only avail able as part of a spare parts kit. Kun lilgc:engelig som del af l reseredelsset.
Oty./C = OtyJCyllnder Antal/C = Antal/Cylinder
07.32 - ESO
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-01
23/30
286 262 249

See l ate
\\
50501
453
607 178
095 '"
V a
083
- - 130 298
022 1--- 071

286 117 : : J 034 ~ 117
105 046 ~
105
465
573 477
441 298 477
453 489 -~ 489
~- 490
See l ate
50501
512
512
02.38 - ESO
Plate
50502-01 Vale Spindles and Vale Gear Page 2 (2)
23/30
Item Ite m
. Qty. Desig nation Bencev nelse . Oty. Designation Benre vnelse
010 2/C Vale brIdge , compl. Ver1!rJl)rQ kllet rnkl. 489 4/C Inner s prlng Illdvendig fjeder
incl.item022,034, 046, Ilem 022, 034, 046. 07 1,
071,083,095,105,117, 083,095,105,117,129 490 4/C Outer sprlng Udvendig fjeder
129 a nd 130 og 130
512 4/C Valve splndle, Inlet Ventilsprndel, rnds. og
022 2/C Valve bridge Ventilbro and outlet uds.
034 2/C Spring Fjeder 524 28/C Spring FJeder
046 2/C 8all guide Kuglestyr 536 28/C Ball Kugle
071 2/C Thrust piece Trykslykke 548 4/C Spring washer Fjederskive
083 2/C Thrust screw I"rykskrue 573 2/C Bearing bu sh Lejeb0sning
095 4/C M0trik 585 4/C Retalner ring Lasering
105 4/C hrust piece Trykstykke 607 lIC Rocker arm shaft Aksel vippearm
117 4/C Clrc llp Fjeder ring
129 2/C Thrust plece Trykstykke
130 4/C Spr/ng Fjeders!ift
178 1/C Rocker arm 8uk for vrppearm

bracket
201 1/C Plug
237 1/C Rocker arm, exhaust, Vippearm udst. kompfet

compl. Incl. Item 095, inkl. ilem 095, 249, 262.
249, 262, 286, 298, 286, 298 og 585
585
249 I/C Rocker arm, exhaust Vippearm, udSI0dning
262 4/C Plug
286 2/C Thrust piece Trykstykke
298 2/C hrust screw TrykslHue
345 1/C Rockerarm inlet,com- Vippearrn inds. komplet

plete incl. Item 095, inkJ. Ilem 095, 249, 262
249, 262, 286, 298, 286. 298 og 585
585
357 1/C Rocker arm, Inlet Vippearm, indsugning
441 2/C Di sc Skive
453 2/C Securing ring Si kr ingsrIIg
465 4/C Conical ring 212 Konisk ring 2/2
477 4/C Rotocap, compl. Rotatronsgive r, kom-

plet
When ordering spare parts, see a lso page 500.50. Ved bestilIing af reservedele, 5 ogsa side 500.50.
Only available as part of a spare parts kit. tlg cen g e l i g som en del af reservede lssc.el.
OtyJC OtyJCylinder Anta l/C = Antal/Cylinder
OtyJ = Oty./lndividual Anta l/ = Antal/lndividuell
02.38 - ESO
Plate
Page1 (2) Indicator Va l e 50508-01
23/30
052
051
050
049
Handwheel for indicator
valve, see plate 52005
0 37 -
~
013
025~
. ,
... ,
"'.,,',
...
.'., , ..
06.41 - ESO
Plate
50508-01 Indicator Valve Page 2 (2)
23/30
Item Item
. Oty. Desfgnation Bencevnelse . Oty. Des lgnatlon Bencevnelse
013 1/C Connectlng plece Forbindelsesstykke
025 31C Gasket Gasket
037 1/C Gasket Gasket
049 1/C Indl cator va lve IndikaIorvenlil
050 1/C Screw cap
051 1/C Chain
052 1/C In sul ation cover
When ordering spa re parts, see al50 page 500.50. Ved bestilling af reservedele, 5e ogsA side 500.50.
Only avallable as part of a spare parts kit. Kun Iilgcengelig som del af et reseredelsscet.
Oty./C = OtyJCyllnder AntalfC = Antal/Cylinder
06.41 - ESO
,],
. Diese~1
Plate
-
Page 1 (2) Cylinder Head, Coer 50510-01
~
23/30
94.22 - ESOS
f,J+tNIIMAN DieseI[
Plate
50510-01 CyIinder Head, Cover Page 2 (2)
23/30
Item Item
. Q,y. Designation Bencevnelse . Qty. Designation Bencevnelse
014 I/C Coamlng Karm
026 I/C Gasket PaknIf1g
038 13/C Screw Skrue
051 4/C Spring Fjederstift
063 I/C cover lopd<:eksel
075 I/C Gasket PaknIng
087 3/C Handle Handtag
099 3/C O-rlng 0-rln9
110 3/C Nu' M01rik
122 13/C Washer SkIve
When ordering arts , see al so page 500.50. Ved bestilling af reservedele, se ogsf side 500.50.
Only avallable as part of a spare parts kit. t Hgengelig som del af et reservedelssceI.
Q'y./C = Q'y./Cyl1nder Anlal/C = Antal/CYIInder
94.22 ESOS
Section 506
Pstoo, Connecting Rod and CylinderUner
Description
Piston, Connecting Rod and Cylinder Liner 506.01
Working card
Dismounting of Piston and Connecting Rod 506-01.00

Separation of Piston and Connecting Rod 506-01.05
Piston 506-01.10
Connecting Rod 506-01.15
Criteria for Replacement of Connecting 506-01.16
Big-end and Main eag Shells
Mounting of Piston and Connecting Rod 506-01.20
Tightening and Check of Connecting Rod Screws 506-01.25
Hydraulic Tightening of Connecting Rod Screws 506-01.25
ln-situ lnspection of Connecting Rod Big-end eag 506-01.30
lnspection and Honing of Cylinder Liner 506-01.35
Replacement of Cylinder Liner 506-01.40
Gdng of Seal Face Cylinder Uner and Cylinder Head 506-01.45
Dismantling of Piston and Cylinder 506-01.50
Linerat Oerhaul Heights
Plates _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.1
Piston and Connecting Rod 50601-01

Piston and Connecting Rod 50601-02
Piston and Connecting Rod (Hydraulic Tightened) 50601-05
Piston and Connecting Rod (Hydraulic Tightened) 50601-06
Plates
Cylinder Liner 50610-01

Cylinder Lner 50610-02
Cylinder Liner 50610-05
Description
Piston, Connecting Rod and Cylinder Liner 506.01
Page 1 (1)
EdiIion 0 1
23/30
Piston Connecting Rod
The piston, which is oil-cooled and the monobloc The connecting rod is die-Iorged. The big-end has
type made nodular cast iron, is equipped with 3 an inclined joint in order lacilitate the piston and
compression rings and 1 scraper ring. connecting rod assembly 10 be withdrawn through
the cylinder liner. The joinl laces on the connecting
use a combination compression rings with rod and the bearing cap are serrated ensure
different barrel-shaped proliles and chrome-plated precise location and prevent relative movement
running surface on all rings, the piston ring pack is Ihe parts.
optimized lor maximum sealing effect and minimum
wear rate. The big-end bearing is the trimetal type, .. steel
shells lined with tin-aluminium lead-bronze coa-
The piston has a cooling l space close 10 the pisl on ted with a running layer. Designed as plain type
crown and the piston ring zone. The heat transport, rillenlype. The bearing shells are the precision
and Ihus the cooling effect are based on the sha- type and are Iherelore be fitted without scraping
ker effect arising during the piston movement. l any other kind adaption.
Irom the engine's lubricating l system is used as
cooling l. The small-end bearing is the trimelal type and is
pressed into the connecting rod.
The piston is provided with a turned edge at the
due the Ilame ring mounted in the cylinder liner.
Cylinder Liner
Piston The cylinder lner is made offine-grained, pearlite cast

iron and is fitted in a bore in the engine frame. Repla-
The piston pin is lully Iloating which means th al l ceable cast iron sealing rings are fitted between the
can turn Ireely in th e pin bosses the piston as liner and the cylinder head and belween Ihe lner and
well as in the connecting rod bush. The piston pin Ihe Irame. The lner is clamped by the cylinder head
is turned in place upwords in axial direction by w and is guided by a bore al Ihe botlom Ihe cooling
circl ips (seeger rings). waler space Ihe engine frame. The lner can Ihus
expand Ireely downwards, when healed during Ihe
ru nning Ihe engine. Sealing lor the cooling waler
is oblained by means silicone rubber rings which
are litled in grooves machined in the liner.
The cylinder ln er is the socalled "stepped cylin-

der" Iype, provided wilh flame ring inserted in the
l Ihe liner.
96. 19 ESOU
Working Card
Dismounting of Piston and Connecting Rod
506-01.00
23/30
Stopped engine
Shut-off 8tarting air
Plate Item

Shut-off fue l l 52006 033
Shut-off cooling l 52006 094 2 pieces
Stopped lub. l circul. 52006

52006
52010
224
273
011
80-360 Nm
De8criplion: l combinaIion lor dismounting connecting

rod screw, see working card 520-01.20.
Dismounting piston and connecting rod as-
sembly, lr inspection and!or overhaul.
Slarling 08: Hand 10018:
Cylinder head has been dismounIed Threaded 1 2.

Irom engine 505-01.00 Open-end spanner 24 mm.
Crankcase open. .
Scraper similar.
Small adjustable spanner.
Relaled procedure:
Separation piston and connecting

rod 506-01 .05
Inspection and honing cylinder
ln e r 506-01 .35
Working time 1 hour Plate Item !

Capacity 2 men
Dala:

DaIa lor torque moment (Page 500.40)
96.20 - ESOS
Edition 01 Dismounting of Piston and Connecting Rod Page 2 (3)
23/30
Preparations belore Dismounting 2) Remove the gangway, l any installed , order

improve the access conditions.
1) Clean the upper part the cylinder. 1I , the
piston may get stuck during removal the carbon 3) Turn Ihe crankshaft 10 bring Ihe crank Ihrow
deposited this area. concerned a posilion approx. 50 degrees
belore TDC.
a) Turn the piston the buttom.
This position is identiliable by the connecting rod
b) Place a used piston ring the piston. shaff beng very close the cylinder I shrt,
see lg. 1.
c) th e tube (Ior holding down the cylinder
l ' duri ng the piston withdrawal) the 4) Clean the Ihreaded hole the pislon lop, and
cyl inder head studs, screw the and tighten mounl Ihe eye screw.
slightly.
5) l the tube (' holding down Ihe cylinder
d) Turn th e piston top, order push the l nerduring Ihe pislon wilhdrawal) Ihe
flame ring th e cylinder by means the piston cylinder head studs, screw the l and tighlen l
ring. slightly.
l: is th e used piston ring which pushes the 6) Attach a wire rope the eye bolt by means
flame ring out the cylinder. a shackle, hook the 10 a tackle and ll Ihe
wire rope light.
NoIe! If minor adjustments th e crank Ihrow posi-

l appear necessary ' access 10 Ihe connecting
rod screws, Ihe wire rope must be slackened belore
turning Ihe crankshaft and lighlened again
Ihe crank throw posilion.
Fig 1. Mounting of tooJs (lacing). Fig 2. Remoa/ bearing cap.
96.20 - ESOS
',,,,II DieseI!
Page 3 (3) Dismounting of Piston and Connecting Rod EdiIion 01
L23/30
--l
- - ~ ---~

@
@
Fig 3. Remova/ of upper big-end bearing sheJI.
DismounIing Bearing Cap
7) Unload theconnecting rod screws and unscrew

one the upper screws.
8) the guide lor Ihe bearing cap

one the threaded holes and l a screwdriver or
similar the hole Ihe guide , and unscrew the
screws. Fig 4. Lft af piston and connecting rod assemb/y.
! The purpose the guide is prevent

any damage crank journal, laces or bearing
surface 10 occur during dismounting the beari ng DismounIing Upper Big-end Bearing Shell
cap, and lac l tate easy handling when removing
the bearing cap Irom the crankcase. 11) ll the piston and connecting rod assembly
upwards and remove Ihe upper big-end bearing shell,
9) Remove the screwdriver Irom the guide , see fig 3.
and dismount the bearing cap by sliding along
the guide , see fig 2. 12) Lift the piston and connecting rod assembly
through the cylinder lner and the engine,
1) Remove the guide Irom the connecting see fig 4.
rod.
96.20 - ESOS
Page 1 (2) Separation of Piston and Connecting Rod Edition 01
23/30
Sa/ety precautions: Special tools:

Shut-oll cooling water 52006 021
Shut-off luel il 52006 033
Shut-off cooling l 52006 200
Description:
Separation piston and connecting rod lor

spection or/and overhaul.
Assembly piston and connecting rod after
inspection or/and overhaul.
Starting position: Hand tools:
Piston and connecting rod are dismounted Open-end spanner, 24 mm.

Irom engine 506-01 .00 Wooden wedge, 2 pieces.
Wooden support.
Wire.
Related procedure:
Inspection or/and overhaul piston 506-01.1

Inspection or/and overhaul
connecting rod 506-01. 15
Inspection connecting rod
big-end bearing 506-01 .16
Manpower: Replacement and wearing parts:
Working time 1/4 hour Plate Item Qty/

Capacity 1 man
Data:

95.50 - ESOS
DieseI!
506-01.05 Separation of Piston and Connecting Rod
Working Card
EdiIion 01 Page 2 (2)
23/30
Land ing Piston and Connecting Rod Separation Piston and Connectin g Rod
1)
Land the pisIon and connecting rod carelu lly 6) Take the securi ng ring, (seeger circlips),
wooden supports damage piston push oU the piston and l the connecting rod
and scraper ring, see fig 1. away.

Assembly Piston and Connecting Rod
7) For assembly piston and connecting rod,
see t 1-6 reversed order
8) Lubricate the piston belore assembling.
Fig 1. Landing of Piston and Connecting Rod.
2) The beari ng cap should be mounted with the

screws tightened only by hand, order protect the
serrated joint laces during handling the assembly,
see fig 1.
3) Remove the shackle and eye screw from the

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

upright position resting the lace olthe piston
crown, see fig 2.
Note: Wooden wedges should be used the

connecting rod Irom swinging oU and thus impact the
piston skirt duri ng the lifting upright posi ti on.
5) Place a around the big-end the con-

necting rod. Attach a tackle and tightenthe ,
Fig 2. Removal Connecting Rod and Piston .
see fig2.

95.50 - ESOS
I I1 ' DieseII
P_ge 1 (4) Piston Edilion 01
L23/30
Stopped engine Plate no Item no

Shut-off cooling waler 52006 141
Shut-off luel il 52006 153
Shut-oll cooling l 52006 165
Cleaning and inspection piston. Control piston Tools lor cleaning pisIon, steel brush,
ring, scraper ring and ring grooves. scraper etc.
Slarling posilion:
Piston has been dismantled Irom

connecting rod 506-0 1.05
Relaled procedure:
Mounting piston and

connecting rod 506-01.20
Working time 1/2 hour PlaIe no Item no I

Capacity 1 man
Dala:
DaIa lor pressure and tolerance (Page 500.35)

95.50 - ESOS
Edition 01 Piston Page 2 (4)
23/30
Removal Pislon Ring lnspeclion Pislon
For removal piston rings, which are be used 1) Remove the piston and scraper rings.
again, and lor all mounting rings, only the special
ring opener which prevents local over stressing 2) Clean and examinethe piston rings todetermine
the rings should be used. l reuse is acceptable, see page 3.
Straps 10 expand the ring gap or tools working 3) Clean the piston the outside and the
Ihe same principle must not be used, as this would inside.
result permanent delormation which might cause
blow-by or broken rings. 4) Inspect the piston ring and scraper ring grooves
lor wear, see page 3.
95.50 ESOS
,,I( DieseI!
Workin g Card 506-01.10
Page 3 (4) Piston Edition 01
23/30
The piston has be scrapped :

Pislon and l ring
Ring grooves.
sc raper ring. grOQves.
Max. wear l m
Nomina/ size. Tolerances.
) The wear lm the testing mandrel is ex-
ceeded , see fig 1
Piston ring New +0.14
4.0 mm 4.43 mm
1 4.0 mm +0. 12

Pislon rin g New +0.11

) The clearance between the new piston/scraper 4.0mm 4.43 mm
2 4.0 mm +0.09
ring and ring groove is exceeded, see fig 1.
Piston ring New +0.11
4.0mm 4.43 mm
3 4.0 mm +0.09
Note! each piston overhau/:
New +0.10
he piston and scraper ring must be ex- Scraper ring 7.Qmm 7.43 mm
7.Qmm +0.08
changed.
he cy/inder Iner must be honed according Tabfe 1. Nomina/ siz, new ring groove toferance and wear
Iimit (or ring grooes.
the instructions.
) Testing Mandrel for Ring Grooes ) Clearance Ring/Grooe
the wear li m (2 mm mark) the testing

mandrel is exceeded, the specified max. wear
lims are exceeded , and the piston must be
scrapped.
0.45 mm
Wear lm l .
Ma i mum vertical clearance

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

with th e nominal size.
Fig 1. Wear Iimits (, ring grooes.
95.50 - ESOS
Edition 01 Piston Page 4 (4)
23/30
Position of Piston and Scraper Rings
Piston Ring 1:
marked wi th ident.
"top 881500-3"
''0946''.
Piston Ring 2:
marked with ident.
" 881502-7"
''0947'',
Piston Ring 3:
marked wi th ident.
' 881501-5"
''0945'',
Scraper ring:
marked with ident.
" 881503-9"
''0120'',
Marking of Piston and Scraper Rings
Identification marks 10 face upwa rds against Ihe pislon crown when mounted.
Note! The marking may include olher figures than mentioned above, for instance trade mark and
production codes.
95.50 ESOS
~Orkjng Card 506-01.15
Page 1 (4) Connecting Rod Edition 01
L23/30
Salely precaulions: Special lools:

Shut-oll cooling water 52006 273 80-360 Nm
Shut-off luel l 52006 618 225-250 Nm
Shut-oll cooling l
Descriplion:
Cleaning, inspection and test measurement

connecting rod.
Hand lools:
Slarling posilion: Inside micrometer (195 mm).

Feeler gauge 0.15 - 0.20 mm.
Connecting rod I,as been
dismantled from piston 506-01.05
Relaled procedure:
Mounting piston and

Working time 1/2 hour Plate Item Qty /

Capacity 1 man
Dala:

95.50 - ESOS
f,j,J,$H'fMAN DieseII
506-01.15 Connecting Rod
Working Card
Edilion 01 P_g.2 (4)
23/30
CIeaning Connecting Rod Measurement Big-end Bore
1. CIean aII machined surfaces the connecting For check ovalness the bearing cap has be
rod. mounted onto the big-end bore without bearing
sheIis.
2. Degrease the serrated jointlaces, tapped hoIes
and connecting rod screws with a voIatiIe soivent and Note !! The ident. the connecting rod and the
bIow dry with working air. bearing cap must aIways be the same, see fig 3.
VisuaI Inspection Serraled Faces
3. Inspect the serrated joint laces.
Damages, the lorm visibIe wear marks and

tings even cracks, may be the serration due
reIative movements between the surfaces.
Wear marks and cracksare visible, but perceptibIe

with a lingernaiI. Pittings and impact marks are both
visibIe and perceptibIe.
Note!! Handle the connecting rod with care.ln case

damaged serrati on caused by improper handIing,
the bearing cap can longer be tightened tothe con-
necting rod without ovalness the big-end bore.
4. Register observed damages the scheme

"Connecting Rod fnspection" ' historic use only.
See page 4.
Fig. 1. Point of measurement
5. Carelully smooth singIe raised spo's the

serra'ion caused by pitting and impact marks wi'h a 8. Moun' the bearing cap onto the connecting rod
fiIesmal1. by means 'he connecting rod screws.
9, Tighten the screws with the prescribed torque,

fnspeclion Connecting Rod Screws see working card 506-01.25.
6. Inspect the connecting rod screws ' seizures 10. Measure different diameters the middIe
the threads and pittings the contact surfaces the boring, see fig 1.
the screwheads.
11. Register the measurements the scheme
7. Turn 'he connec'ing rod screws bottom "Connecting Rod Inspection". See page 4.
posi'ion th e threaded screw hoIes by hand.
12. Calculate the maximum ovaIness as the dif-
screws Then lerence be'ween biggest and smaIlest diameter
measured.
have seizures Renew the screws
threads or pittings 13. Check maximum ovalness is exceeded, see
contac' surface page 500.35.
cannot be turned Renew the screws

bottom position by hand
95.50 - ESOS
Page 3 (4) Connecting Rod Edition 01
23/30
Then For connecting rod 2 the maximum ovalness

is 0.125 mm and Iherefore the connecting rod is
maximum ovalness is Renew the complete rejected.
exceeded connecting rod, screws
and bearing shells.
Inspection Connecting Rod Bush
maximum ovalness is Reuse theconnecting rod
exceeded 1. Inspect the surface the piston and the
connecting rod bush.
2. Measure the clearance between the piston

and bush.
ConnectIng Rod Inspectlon for L2330
---
~oo_
~t.ou.!O<....-.gf<J
....
.
,
-0,5 -3,0
,
3. Check max clearance is exceeded, see page
500.35.
the specified clearance is exceeded, contact

~- ,,,
2,0 - 7,0
-
111110 .....
- 1,5 5. & Diesel NS, Holeby replacement.
..5,0 +5,5
0 1 9S_ . 3. .3.
~'IId1_
~OI_._
.... _
-
~!O< ___ o -~
0-
00_
0 --0- 0 """- ""
0-
...,.,
0-
..""
Inspection Bearing Shells lr Big-end
Criteria replacement connecting rod big-end
~ Son."",
0 :::;- O~' 0::;-'
bearing, see working card 506-01.16.
r\K 0 ..- ...... 0 - - 0 - -

~,
"""
~
-
-~
reused ,eIectod
_m
-,--.., ........... -
-"' ................ MfWog
~""",,,,,.,,,,,. ,,,,,,
Fig 2. Connecting od Jnspection-.
Example Measurement Results
Th e example, see fig 2, shows measurements and

damage observations connecting rods the
Connecting rod
scheme "Connecting Rod Inspection" ( case the Ident
speci fi ed maximum ovalness is exceeded, con tact
& Diesel NS, Holeby overhaul) .
For connecting rod 1 the maximum ovalness is

0.07 mm and thus reuse is acceptable. Fig3.
95.50 ESOS
Z~ "SO'P6/09l9H/OO-Sl080
"
~w
~
u- PlantlShip: Engine Type: ~
0>" .,.;
~ ~ '"
~
Connecting Rod Inspection for 23/30 Engine . : Running Hours:
~ "-
Sign.: Insp. Date:
Cylinder . 1 2 3 4 5 6 7 8
Connecting rod ident. .
Running hours connecting rod

~~-
1{100 mm 8
C
Nominal D
diameter
0195 mm
Ovalness: Diff. between min Jmax .
' Condition serration Serration < SerraliQ < Seation Dseation < Serration Serri1tion < Serration Serration

Tghtening l measurement see
: instruclion.
Wear Weat Wea.t Wear Wear Wear Wear Wea,
Crac Cracks OCclCkS Cracks
Cracks
D CrilCks
Coro$ionl "".,..,.,
OCr3C1<S
Deorosiool
Cracts
CorroSIO\'
-
DI DCcos,onl CorfO$loI\' Dcorrosionl Corros,onI
::: Pitling PinIng Pitting Pirung Pittng PItting Prg Pit!Irg
Impnct mark Impac marl. Impact mark ImpaC1 mark Impac mark Impac: mark Impact mark Impac! mark
u
~

:::
:::
U

Serration

/'
~ f D
Remark.s: Remark.s: Remark.s: Remark.s: Remark.s: Aemark.s: Remarks: Remark.s:
YJ'y.
+
J Connecting rod
Ident. .
Lt
""' ::::: Note! The ident. . the con
,....' 0-
necting rod and the beang
9 .
<D:a ~
C'II
cap must always be the same.
o w ...
Lt
Working Card Criteria for Replacement of 506-01.16
Page 1 (8) Connecting Rod Big-end and Main Bearing Shells Edilion 01
23/30

Shut-off fuel l
Shut-off cooling l
Stopped lub . l circul.
Descriplion:
Inspection bearing shells.

Hand lools:
Magnifier (30).
Slarling posilion:
Bearing shells removed Irom engine:

Big-end bearing, 506-01.00 and 506-01.30

Main bearing , 510-01.05

Guide bearing, 510-01.10
Relaled procedure:
Mounting al bearing shells:

Big-end bearing , 506-01 .20 and 506-01.30
Main bearing, 510-01.05
Guide bearing, 510-01.10
power: Replacemenl and wearing as:
Working time 1/4 Hour Plate no. Item no. Qty. 1

Capacity 1 man

Data lr torque moment (Page 500.40)
91.07 - ESOS-G
I,,l$'IMAN DieseII
506-01.16 Criteria for RepIacement of Working Card
Edilion03H Connecting Rod Big-end and Main Bearing Shells Page 2 (8)
23/30
Thi s paper gives inlormation about the evaluation Wear the bearings running surface starts primarily
the connecting rod big-end and main bearing shells the soft overlay, where the overlay the slots is
when wear appears the running surface under reduced approx. 0.001 mm. Th e dillerence between
normal operating conditions. the light-alloy metal and the overlay is by lurther
wear almost constant, .. approx. 0.005 mm.
Bearing damages caused by incorrect running con-
ditions, like Th e gravity the running surface's wear must be
determined with a magnilier ( 30), hereby the over-
Scoring the running surface due loreign lay can be seen as the dark area and the light-alloy
particles the lubricating oil. metal as the light area.
Cavitation.
Corrosion The ratio between the width the light-alloy metal
Overloading, overheatin g a.s .o. and the width the slot as we ll as th e dimension
the worn area are important lor determining the wear
are described this paper. the bearing.
In these cases, the bearing shells must be exchang- Th e bearing can also operate although part the
ed, course, and order avoid lurther bearing overlay is missing the slots. Practi ce has shown,
lail ures, th e cause the la lure must be lound and th at bearings with partly empty slots can run without
eliminated. any negative inlluence the operation the bea-
ring.
determining th e condition the bearing shell, the

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

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

approx . 75 % galvanic overlay and approx. 25 %
light-alloy metal, see lig. 1.
91.07 ESOS-G
',,4'I DieseII
Working Card Criteria for RepIacement of 506-01.16
9 3 (8) Connecting Rod Big-end and Main Bearing SheIIs Edition 01
L23/30
1.1. Bearing ShelJs Reuse. 1.2. Bearing SheIIs Re-use.
Condit ion: The sIot geometry corresponds a Condit ion : The overlay is equally worn, approx.
bea ng
shell. The ove~ay the slots is fu lly preser 0.005 mm the slots. The lightal)oy strips show
ved, see fig 2. wear, see fig 3.
Dark spots are mainly l coke remains. Dark spots are mainly l coke rema ins.
VaIuation: The between lightalloy metal and VaIuation : Due running surface the light
overlay is 75 % 25 %. Reuse! alloy strips are sIightly widened. Reuse!
Fig2. Fig3.
91.07 ESOSG
506-01.16 Criteria for Replacement of Working Card
Edition 01 Connecting Rod Big-end and Main Bearing Shells Pag84 (8)
23/30
1.3. Bearing Shells for Re-use. 1.4. Bearing Shells for Re-use.
Condition: Small particles all overthe overlay. The CondiIion: The overlay has been dragged and
lighlalloy melal shows changes importance. smudged over the light-aIIoy metal. These are only
see lig 4. partly visible, see lig 5.
Valuation : Re-use the shell . as the particles are Valuation: Re-use the shell.
wedged the slots.
Fig4. Fig5.
91.07 - ESOS-G
+ DieseI!
Worklng Card Criteria for RepIacement of 506-01.16
Page 5 (8) Connecting Rod Big-end and Main Bearing SheIIs Edition 01
23/30
2. Limiting Case - Wear Condition: The bearing shell is locally so worn , that
th e ratio between th e light-alloy metal and the
lay is 1:1, see fig 6. The width the light-alloy metal
has increased from 100 % (new bearing shell)
175 %. the slots some overlay is still left, see fig
7.
Valuation: Th e bearing can operate with wearof the

below listed size, see fig 8 og 9. Ifthe wear limits are
exceeded the bearing shells must be exchanged due
safety precausions.
Fig8.
Fig6.
175%
100%
......
..... ............. :: :
, ............ ... .
.....
.. , .... .......
. ... ... .
Fig9.
Fig 7.
91.07 ESOS-G
,', Dieserl

Edition 03 Connecting Rod Big-end and Main Bearing Shells Page 6 (8)
L23/30
3. Limit Ca5e Levelling Val uation: Ihe limils shown fig. 11 and 12 are
e cee ded Ihe bearing shells musl be ec hang e d .
Condition: The 5101s are locally tolally levelled as
shown fig . 10.
max. 10% widlh
Fig. 70.

~

L()

max. 10% width

max. 5 mm
u Fig. 12.
11
Fig.1 1.
91.07 ESOSG
,, DieseI!
Working Card Criteria for RepIacement of 506-01.16
Pag. 7 (8) Connecting Rod Big-end and Main Bearing SheIIs Editon 01
L23/30
4. Limil Case Permanenl Breakage Ihe Condilion: Breakage the overlay due 10 local
Running Surlace overload, as shown fig 13 and 14.
Valuaton: If the limits as shown below fig 15 and

16 below are exceeded with totally partially empty
slots, the bearing shells must be exchanged.
Fig 15.
ma 10% width
ma. 10 mm
LJ
Fig 13.
.6
~~
i.t :>;:
j~
ii!
:
)~:
:(
:t
:;;;
: ,:
:~~
,~:
,'' !
@
W ~:
~ i:"
~
\
n
Figl4. Fig 16.
91.07 ESOSG
iIJ,i,gNIfMAN DieseI!
Edilion 03H Connecting Rod Big-end and Main Bearing SheIIs Page 8 (8)
23/30
5. Limit Case - Empty Slots ValuaIion: If the limits shown the belowfig. 18 and
19, are exceeded, the bearing 5he l1 5 mU5t be
Condition: l 50me areas there is overlay the changed.
510t5, see fig . 17.
-- -- ------- max. 10% !
r-
width
~
max. 5 mm

\ LlgtI moInl
Fig. 17.
max. 30% ~ width

-
IU
c

Fig.19.

,

<f'-
'.
~ .-
'"
~
'"

n
.-
Fig. 18.
91.07 - ESOS-G
Page 1 (4) Mounting of Piston and Connecting Rod Edition 01
23/30
Stopped engine
Plate Item Note

Shut-off luel l
52006
52006
021
033

Stopped lub. l l. 52006 141
52006 224
Descriplion:
Mounting piston and connecting rod assembly,

after overhaul and/or inspection.
Slarling posilion: Hand lools:
Piston mounted the connecting rod, crank-shaft Open-end spanner 24 mm.

turn ed the right position and the cylinder l Clean lubricating l .
is , see working card 506-01.35.
Relaled procedure:
Tightening connecting rod screws 506-01.25


~
.;
"
~
~
Working time 1 1/2 hours Plate Item Qty/
~
Capacity 2 men
~
50601 093 1/cyl
Dala: 50601 103 1/cyl
:;
50601 11 5 1/cyl
"
Data lor pressure and tolerance (Page 500.35) 50601 127 1/cyl
"
95.50 ESOS
506-01.20 Mounting of Piston and Connecting Rod
Working Card
23/30
Mounting olTools Note: crank Ihrow positi on appro 50 degrees

belore TDC w ll ensure Ihis and also be suilable lor
1) the lilting device comprising eye screw, Ihe lurlher mounling procedure.
shackle and wire rope the piston.
2) L the piston and conn ecting rod and Mounting Big-end Bearing
mount the piston and scraper ring s, see 14,
and working card 506-01.10. 6) Lower the piston lurlher down, l ubr cate the
ends Ihe bearing shells (as fig. 2) wilh copaslip,
3) Remove Ihe backstop lor cylinder Iiner and molycole pasla similar and mounl Ihe upper shell
place Ihe pislon guide ring l Ihe cylinder Ihe big-end bearing.
liner, see fig 1.
r-~~~--- -
Fig 1.
Fig2.
Lowering Piston and Connecting Rod

7) Coal Ihe crank journal wilh clean lubricaling
4) When Ihe pislon approaches Ihe guide ring, l .
slop lhe lowering, coatguide ring, pislon, pislon rings
and scraper ring, wilh clean lubricaling il order ) Lower Ihe pislon and connecling rod slowly
10 minimize Iriclion during Ihe subsequenl lowering correcl landing Ihe journal.
Ihe assembly.
During Ihis the connecling rod musl be guided by
5) Make sure Ihal Ihe crank Ihrow is a posilion hand 10 ensure correcl approach and landing Ihe
allowing Ihe connecling rod 10 go clear bolh crank journal, see fig 3.
journal and cylinder liner skirl during fu rlher lower-
ing.
95.50 - asss
- '' DieseII
Page 3 (4) Mounting of Piston and Connecting Rod Edition 0 1
23/30

Note: The ident. . the connecting rod and the
bearing cap must always be the same, see fig 4.

1) Lubricate threads and contact face of the con-
necting rod screws with copaslip, molycote pasta
similar.
11) the screws and tighten them slightly

using end spanner.
12) Slacken the tackle and dismount the eye

screw/shackle from the piston.
Fig3.
Mounting Bearing Cap
9) th e bearing cap with inserted lower

shell
of th e big-end bearing, using the guide , see fig
4.
Fig5.
Tightening Connecting Rod Screws
13) Tighten the screws according "Tightening

Procedure forConnecting Rod Screws", seeworking
card 506-0 1.25.
Fitting Piston and Scraper Rings
14) Piston rings should only be removed from and

fitted the piston by th e use of a special tool, the
Con. Rod . IdenI .
socalled piston ring .
Fig4.
95.50 - ESOS
,,],,6' DieseII

Edition 01 Mounting of Piston and Connecting Rod Page 4 (4)
23/30
1I the rings are opened lurther than necessary there Belore l itting th e coil spring loaded scraper ring, the
is a ri sk overstressing , which means that rings w ll coil spring is dismantled Irom the ring by removal
become permanently distorted and wll not conlirm th e joint pin.The coil sprin g is placed and assembled
to the inner running surface the cylinder. in the ring groove. Then th e scraper ring is litted in
the groove in such a way that the ring joint is approx-
The piston rin gs should be installed with the identi- imately 180 offset to th e spring joint.
lication mark, which is stamped into the ring close
to the ring joints, lacing upwords, see working card Ascertain correct assembling by checking the back
506-01.10 "Pis/on". clearance.The back clearance is sufficient when the
lace the ring is below the groove edge when the
ring is pressed against the bottom the groove.
When installed on th e piston th e rings should be

Joint for pushed back and lorth in the grooves to make sure
coil spring Joint coil spring 10 be
pla~~d_opposite ring joint that they can move Ireely. It is also advisable to insert
1>':--
"- .- --:::.,
- a leeler gauge adequate thickness between ring
, and groove.
\
,
'/ Adequate clearance is present so the leeler gauge
\, .:;:~: : :~
. gjOint can be moved all th e way round.
prevent gas leakage through coinciding ring joints

th e piston rings should be turned into positions off-
setting the ring joint 180 to each other.
Fig6.
95.50 - ESOS
Working Card
Tightening and Check of Connecting Rod Screws
506-01.25
23/30
Safety Precautions: Special ools:

Shut-off cooling water 52006 273 80 - 360 Nm
Shut-off fuel l
Shut-off cooling l lcombinations lor tightening connectin g rod
Stopped lub. l circul. screws, see working card 520-01.20.
Description:
Tightening procedure lor connecting rod screws.

Check connecting rod screws, tightening
condition.
StartIng Position: Handools:
Piston, connecting rod, bearing shells Open-end spanner, 24 mm.

and bearing cap preassembled. 506-01 .20
Related Procedure:
Man Power: Replacement and Wearing Parts:
Working time 1/2 Hour Plate Item Oty./

Capacity 2 men
Data:

95.50 -ESOS
506-01.25 Tghtening and Check of Connecting Rod Screws
Working Card
23/30
lcombinations lor tightening connecting rod 1-

screws, see working card 520.-0.1.20.
Tightening of Connecting Rod Screws
1st Step:
Mark
5crew collar
Tightening the screws tightening order, illustrated
fig 1, using an initial torque 250 Nm . Mark
bearing cap
Fig2.
4th Step:
--
<
Check the screw tightening prescribed order using
a torque 325 Nm.
Proper tightening condition is present, the screws

are turn ed lurther during thi s test.
--
5th Step:
Check that th e bearing can easily be moved th e

journal.
3 4
Checkof Connecting Rod Screws,Tightening
Condition:
Fg 1. Check the tigh tening condi ti on connecting rod

screws has be executed within a short running
period alter remounting/mounting the connecting
rod.
2nd Step:
This check can be fullill ed after only a le running
Once more, tightening the screws prescribed hours at max. rpm at fu llload, but has be fulllled
tightening ord er, still using a torque 250 Nm. later than 200 runn ing hours after star ting-up.
3rd Step: The ti ghtening condition is checked with a torque

325 Nm, executed prescri bed screw tightening
Mark the screws and the bearing cap I- , order, see fig 1.
illustrated fig 2.
Proper tightening condition is present, the screws
Tightening order by turning through a 600 20 angle, are turned further during the test.
. . l the marks the screw collar and the con-
necting rod coincide radially.
95.50 - ESOS
Page 3 (3) Tghtening and Check of Connecting Rod Screws EdiIian 01
23/30
order ensure observation any movement, the Any turning Ihe screws during Ihe 325 Nm lest
screws and Ihe connecling rod should be applied wilh indicates insufficient tightening condition, and this
coinciding l- marks the test, see fig 3. case Ihe big-end assembly has 10 be dismantled and
invesligated lor evaluati on and correction la lure.
As parl recommended overhaul and l work,

the tightening condilion connecling rod screws
should also be checked, at cerlain running hours
inlervals, see page 500.24.
Mark
screw callar
Cainciding
mark
bearing cap -
Fig3.
Fig4.
95.50 - ESOS
f,!,j,tH'lMAN Dieserl
Page 1 (2) Hydraulc Tghtening of Connecting Rod Screws Edilion 04
23/30
Safety Precautions: SpeciaI TooIs:

Shut-off cooling water 52021
Shut-off fuel il
Shut-off cooling l
Description:
Ti g htening proced ure for con nec ting rod

screws. HandTooIs:
Check of connecting rod screws, tightening
condition.
Starting Position:
Piston, connecting rod, bearing shellsand bearing

cap preassembled. 506-01 .20
ReIated Procedure:
Man Power: RepIacement and Wearing Parts:
Working time 1/2 Hour Plate Item Qty./

Capacity 2 men
Data:

00.28 -ESO
/ i( DieseII

Edition 04 HydrauIic Tghtening Connecting Rod Screws Edition 2 (2)
23/30
1) Screw the stu ds pos. 3 down by hand into the

connecting rod body pos. 1.
2) Fit the upper part the connecting rod pos. 2

and hold ! with nuts pos. 4.
Note. Remember to l ! the bearing shells (unless

the mounting is carried ! lor linish-machining).
3) Screw the studs to the bottom. Check the

distance 8 1 Irom surlace upper part pos. 2 to the
end th e studs pos. 3 and hand-tighten the nuts
pOS.4.
4) ! the hydraulic jacks pos. 5.
Note. the thrust piece the jack so that the 7

slots lor the ball handle pos. 6 are unloaded when
pressurizing the jack.
5) Connect the jacks to the hydraulic system!

pumpby using the angle piece pos. 7.
6) Load the studs wi th the hydraulic pressure and

tighten the nuts with the ball handle pos. 6
7) Relieve the tool pressure.
8) Re-apply the tool pressure.

5
9) Tighten the nuts again.
Note. Item 8 and 9 are carried ! order to elemi-

nate any harmlul stresses.
1 ) 1I any clearance is still visible and the ! can

be turned, then repeat item 7, 8 and 9.
Fig. 1 Hydraulc tightening of connecling (00.
11) The pressure to be relieved and the tool to
be dismantl ed.
00.28 - ESO
',,,.J DieseII
Page 1 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edilion 01
23/30

Shut-off l l
Shut-off cooling l
52006
52006
224
273 80-360 Nm
lcombination for tightening connecting

rod screw, see working card 520-01.20.
Descriplion:
In-situ inspection and/or replacement con-

necting rod big-end bearing, dismounting and
moun-ting.
Hand lools:
Open-end spanner 24 mm.

Slarling posilion:
Fuel injection valve dismounted, 514-01. 10

Crankcase open.
cover fo r cylinder head removed.
Relaled procedure:
Inspection connecting rod

big-end bearing 506-01. 16
Tightening and check connecting
rod screws 506-01.25
Manpower: Replacemenl and weari ng parls:
Working time 1 1/2 hours Plate Item Qty/

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

96.30 - ESOS
EdiIion 01 In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)
L23/30
Turning the Piston Correct Position
1) Turn the crankshaft a position allowing the

connecting rod 10 be losened .
2) Turn the crankshaft a position allowing the

connecting rod bearing cap be dismounted, see
fig 1.
Fig 1. Fig2.
Dismounting Bearing Cap 7) L the piston/connecting rod Irom the bearing

journal.
3) Remove the luel injector.
Note: the pislon/connecting rod should be lfted
4) Insert the long-eye bolt and screw the lurther then, just 10 allow dismounting the upper
thread hole the piston, see fig 2. bearing shell, see fig 2.
5) Tighten slightly by means a tackle, see fig

2. lnspection Bearing Shells
8) Inspecl Ihe bearing shells, see working card

Removal Bearing Shells 50.6-0.1.16.
6) Dismount the bearing cap and bearing shell.

For use guide , see working card 50.6-0.1.0.0.
96.30 - ESOS
Page 3 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 01
23/30
11) Ascertain that the crank throw concerned is

a posi ti on of appro 50 degrees before TDC.
12) Coat the journal with clean lubricating l and

lowerthe piston and connecting rod assembly slowly
correct landing the journal .
While lowering the connecting rod, must be guided

by hand ensure a correct approach and landing
the journal, see lg 4.
13) Lubricate the ends of the bearing shells (as

fig 2) wi th copaslip, molycote simular.
Mounting Bearing Cap

...
14) the bearing cap with inserted lower
big-end bearing shell, using the guide .
15) Lubricate threads and contact face the con-

necting rod screws with copaslip similar.
16) the screws and tighten them slightly

using an open-end spanner.
Fig3.
17) Slacken the tackle and dismount the eye screw

from the piston crown.
Cleaning Components before Mounting.
9) Clean aII components, see workng card 506- Tghtening Connecting Rod Screws
01.20.
18) Tighten the screws accordng 10 "Tighlenng
Procedure lor Conneclng Rod Screw", see workng
Mounting Upper Bearing Shells card 506-01.25.
1 ) The bearing sheIi is placed the bore, the

con tact surfaces th e shells to be parallel to the
contact surface of the connecting rod and the bearing
cap respectively.
96.30 - ESOS
''!: DieseI!
Working Card
Inspection and Honing of Cylinder Liner
506-01.35
23/30
Stopped engine
Plate Item Note
Shut-oll cooling water

Shut-off fuel l
52006
52006
488
51 1

Shut-off cooling l 52006 606 275-300 mm
Descriplion:
Inspeclion and honing cylinder ler with ho-

ning brush.
Hand lools:
Drilling machine 60-180 rpm.

Honing l.
Slarling posilion: Gas l.
Piston and connecting rod is

removed 506-01.00
Relaled procedure:
Mounting piston and

Replacement cylinder l e r 506-01.40
Grinding seal lace cylinder
head and cylinder l er 506-01 .45
Working time 1/2 hour Plate lIem Qty/

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

96.04 - ESOS
'}'i DieseI!
506-01.35 Inspection and Honing of CyIinder Liner
Working Card
Edilion 01 Page 2 (4)
23/30
Measurement Cylinder Diameter honing, deposits coke and possible wear

edges the the l must be removed by
While the piston is removed Irom the cylinder, the scraping .
latter is measured record the wear. The measure-
ments are taken by means an inside micrometer, 1I the cylinder is th e Ilame ring type, the used
with measuring points at TDC-position lr upper- Ilame ring has be cleaned water. Subsequently,
most piston ring, hallway down and at the bottom the Ilame ring is remounted th e cylinder belore
the cylinder l , see lig 1 and page 4. carrying out the honing process.
Note: After the honing process has taken place

the used Ilame ring is discard ed. Ilame ring
is always mounted the cylinder when replacing a
piston ring.
80 160 rpm.
Fig 1.
The measurements should normally be taken !, . . . -.-.-.~
transverse as well as longitudinal direction. ._----~
When measuring, take care that the measuring l

has the approximately same temperature as th e l .
When the wear a cylinder ln er exceeds the value
indicated page 50.0.35, .. when it becomes
troublesome maintain satislactory servi ce
conditions, the cylinder ln e r question should be
exchanged.
Fig2.
Honing the Cylinder Liner

Th e honing is made by means a Ilex-honer wi th
lnene ss grains 80-120. l speed between
The renovati on can be made either with dismantled
ln e r th e workshop with lner mounted the 80 and 160 rpm is chosen.
engine Irame and by the use th e belonging l
nel.
96.04 - ESOS
Working Card
Inspection and Honing Cylinder Liner
506-01.35
page 3 (4) Edition 01
23/30
In order to achieve the required angle belween th e

honing grooves, see fig 2, the vertical speed is ad-
justed to about 1 mtsec . which corresponds to about
2 sec. for one double movement (the flex- honer is
led from below and down in 2 sec. )
The procedure is to be conlinued until the cylinder

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

with honing l cutting l.
Fig3.
After the honing, the ln e r is carefully cleaned with
gas l. Make sure that all abrasive particles have
been removed .
96.04 - ESOS
"80' tr6/0SZSH/OO-BZOSO
<J)
C>
<J)
> W
<n;;t
0- g
0> "- <ri
c
Engine type Report . >
:tg
~.
Measurement of Cylinder Liner Engine . EncI. .
Running hous Insp. date

Plant Fuel Sign.
Cy. . 1 2 3 4 5 6 7 8
Cyl.liner den .
...

Running hours
L
e

c: n
:::
...
I ~ :< J
9
t
h
w
C
"

c: .,. s
e
>- ~
-
U

c:
~

C
r

s
s
w

c:
s
e
::::
C lner
"
c: temp.
'c
a:
c: Remarks ...
a.
n
c:
J
~
:: .n
::::
.~
,.... C>
05
~ ~
~
~
ow C\I
..J
.n
. !+!iM'MAN DieseI!
Page 1 (2) RepIacement of CyIinder Liner EdiIion 01
23/30
SafeIy precauIions: Special lools:


Shut-off l l
Shut-off cooling l
Descriplion:
Replacement cylinder l.
Hand lools:
Adjustable spanner.
Slarling posilion:
Cylinder head and piston/connecting rod dis-

mantled,working card 505-01.00 and 506-
01.00.
Relaled procedure:
Mounting piston and

Grinding seal lace cylnder
head and cylinder l 506-01.45
Working time 11/2 hours Plate Item Qtyl

Capacity 2 men
50610 079 8/cyl
Dala: 50610 031 1/cyl
506 10 043 2/cyl
Data torque moment (Page 500.40) See also plate 50610.
96.27 - ESOS
IM",, MAN DieseI[
506-01.40 Working Ca rd
Edition 01 RepIacement of CyIinder Liner Page 2 (2)
23/30
Dismounting Cylinder n
1) mounling Ihe lifting 1001 and dismoun-

ling Irom Ihe Irame, l musl be ensured Ihal Ihe liner
and Irame have been marked 10 malch, lr Ihe sake
t
a possible remounling Ihe liner, see fig 1.
Fig 2.
Hole for rolIer guide house

\ Mounting Cylinder n
Marking scraIch frame \\ 6) Check Ihal Ihe sealing surfaces on engine

\ Irame, cylinder liner, and sealing rings are perfectly
Marking scratch lner clean.
7) Mounl Ihe lifting 1001, attach a lackle hook 10

Fig 1. Ihe eye nul 10 Ihe in Ihe cross bar and l ll Ihe
liner.
2) Mounl Ihe lilling 1001 as shown, see fig 2.
8) Check Ihal Ihe O-ring grooves are clean. Mounl
the O-rings and lbrcale wilh a lttle l .
3) Turn Ihe lifting eye nul 10 ll out Ihe lner unlil
Ihe edge Ihe lner le aligned againsl Ihe
9) Lowerl he cylinderlinercarelully inlo Ihe engine
copper prolecling pieces Ihe cross bar.
Irame.
4) Allach a lackle hook 10 Ihe eye nul Ihe
When Ihe lirsl O-ring louches Ihe sealing lace,
and Ihe cross bar, and l Ihe lineroul Irom Ihe engine
align Ihe l ne r so Ihal Ihe scralch mark on Ihe ln er
Irame and l l down onlo wooden supporls.
Ilange poinls 10 the scralch mark on Ihe Irame as
illuslraled.
5) Clean all parls and inspecl lor damage and
wear according 10 Ihe descriplion. For measuremenl
1) Mounl Ihe pislon/connecling rod and cylinder
cylinder liner, see working card 506-01.35.
head according 10 working card 506-01.20 and 505-
01.40.
96.27 - ESOS
Working Card Grinding of Seal Face 506-01.45
Page 1 (2) Cylinder Liner and Cylinder Head Edilion 01
L23/30
SaleIy precautions: Special tools:

Shut-off sIarting air
Shut-off luel l
Shut-off cooling l
Description:
Grinding seal lace on cylinder lner and cylinder

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

Irom the engine 505-01.00
Cooling water guide jacket removed.
Related procedure:
Man power: Replacement and wearing parts:
Working time hour Plate no. Item no. !

Capacity man
50610 031 1!cyl.
DaIa:
DaIa lor pressure and Iolerance (Page 500.35)

95.50 - ESOS-G
506-01.45 Grinding of Seal Face Working Card
Edition 01 Cylinder Lner and Cylinder Head Page 2 (2)
23/30
Note! The grinding l iS used for both grinding the

groove in the ln er fl ange (1) and the sealing surface
on the cylinder head (2) , see Fig 1.
Grinding l
Fig3.
Fig 1.
3) After grinding , remove all traces ! abrasives

Grinding and grinding compound.
1) Loosen the sealing ring in linerflange and take 4) When having ground the contact faces, ! must
! !. be observed th at the gap between cylinder head
and Iiner is no less than 0.5 mm , . . the difference
2) Face-grind the sealing grooves in the cylinder between measurements and must not be less
lner flange, see Fig 2, and the sealing surface on than 0.5 mm, see Fig 4.
th e cylinder head, see Fig 3, with the use ! grinding
pasta and the grinding tool.
y -z= min . O.5mm

Fig 2.
do so, move the l back and forth and l !

from time time allow the grinding compound Fig4.
distribute evenly.
95.50 - ESOS-G
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 1 (2) Edition 0 1
at Overhaul Heights
23/30

Shut-off cooling water 52050
Shut-off luel il 52006 094 2 pieces
Shut-off cooling l
52006
52010
224
011 1I necessary
lcombination lor dismounting connecting

rod screw, 520-01.20
Descriplion:
Dismounting piston, connecting rod and cylinder

liner lor inspection and!or overhaul.
Slarling posilion: Hand lools:
Cylinder head has been dismounting Irom the Inside micrometer (195 mm).
engine. Feeler gauge 0. 15 - 0.20 mm.
Crankcase open.
Relaled procedure:
Separation piston and connecting rod.

Inspection and honing cylinder liner.
Working time 2 2hours Plate Item Qty !

Capacity 2 men
Dala:

03.34 - ESO
506-01.50 Dismantling of Piston and Cylinder Lner Working Card
01 Page 2 (2)
Edilion
at Overhaul Heights
23/30
Dismanlling Pislon al Overhaul Heighls Dismantling Cylinder Liner al Overhaul

Heights
1) Lift the piston and the connecting rod
through the cylinder lner l the piston is clear ! 1) Mount Ihe normal lifting 1001 for cylinder l
the liner. ners.
2) MounI the collar on the connecting rod , see 2) Carefully pull the cylinder l ner half-way
pfate 52050, item 045. Ihe frame.
3) Place Ihe pisIon wilh Ihe collar on Ihe cylinder 3) Mounl a special lifting 1001 for cylinder liners
liner. al lw overhaul heights, see pfate 52050, item
033.
4) MounI pull-lifts on Ihe collar.
4) Atlach puII-lifts on the lifting 1001 lor the cylinder
If Then liner, see pfate 52050, item 033.
Ihe overhaul height is dismounl Ihe pislon Irom 5) Take l the l ne r over the camshaft side.
100 lw 10 ll oul pislon Ihe connecting rod, re-
and connecling rod in move the piston and
one piece. Ihe connecting rod
by the pull-lifts.
the overhaul heighl is remove the piston and

sufficienl 10 pull l Ihe connecting rod by
pislon and Ihe connect- means the pull-lifts.
ing rod in one piece.
03.34 - ESO
'I DieseI!
Plate
Page 1 (2) Piston and Connecting Rod 50601 -01
23/30
72050
c _____ :::. 093
081
~~ 103
~ 115

127

020'
032
056
139
068
152
140'
97.05 ESOS
'+I,zM'iMAN Dieserl
Plate
50601-01 Piston and Connecting Rod Page 2 (2)
23/30
72050
Item Item
. Deslgnation Benrevnelse . aty. Deslgnatlon Bencevnelse
019 lIC Pi ston incl. Stempelpind inkt.

Item 020 pos. nr. 020
020 4/C Socket screw Kraterskrue
032 21C Retalning ring Sikringsring
044' 1/C Plug screw Propskrue
056 I/C Bush for Plejlstangs-

connectrng rod bosning
068 I/C Connecting rod Plejlslang inkl.

Incl. Item Nos pos. .
044,056,152,140 044, 056, 152, 140
081 I/C Piston Stempel
093 I/C Piston rl"g Stempelring
103 1/C Piston rl"g SIempelring
115 I/C Pi ston rln9 Stempelring
127 I/C l scraper rl"g Olieskrabering
139 I/C Connectlng rod Plejlstangs-

bearlng 212 leje 2/2
140 I/C Plug screw Propskrue
152 4/C Screw for PJejlslangs-

connectlng rod skrue
When ordering spare parts, see al50 page 500.50. Ved besti lling af reservedele, se ogs~ side 500.50.
Only avalJable part of a spare parts kit. Kun tilgoongeHg som en del af et reseredeIssoot.
QtyJC = QtyJCylinder AntaIIC = Antal/Cylinder
97.05 - ESOS
"'. DieseII
PIate
Page 1 (2) Piston and Connecting Rod 50601-02
23/30
900
093
103
115
127
056
139
152
140'
97.05 ESOS
',,/" DieseII
Plate
50601-02 Piston and Connecting Rod Page 2 (2)
23/30
900
Item Item
. Qty. Designation Ben ;ev nel se . . Deslgnatlon Benrevnelse
01 9 1/C Piston l incl. SIempelpind inkl.

Item 020 pos. nr. 020
032 2JC Retainlng rl"g Sikringsring
044' 1/C Plug sc rew Propskrue
056 1/C Bush for Plejlstangs-

connecting rod bsnng
068 1/C Connecting rod PlejlsIang inkl.

Incl. item Nos pos. nr.
044, 056,152, 140 044,056, 152,140
081 1/C PIston Stem pel
093 lIC Piston ring Stempelring
103 1/C Piston ring SIemelri n g
115 1/C P/stO" rl"9 Stempelring
127 1/C scraper rIng Olieskrabering
139 1/C Connectlng rod Plejlsl angs-

bearing 212 leje 2/2
140 1/C Plug screw Propskrue
152 4/C Screw 10r PlejlsIangs-

connecting rod skrue
When ordering spa re parIs, see al50 page 500.50. Ved besIiIling af reservedele, se ogso3 side 500.50.
= On ly available as part a spare parts kit. tilgrengelig som en del af et reseredelsscet.

QtyJC = QtyJCylinder Antal/C = Antal/Cyl inder
97.05 ESOS
l
50601-05 Piston and Connecting Rod (Hydraul ic Tightened) Page 2 (2)
23/30
72050
Item Ilem
. Oty. Deslgnatlon Benoevnelse . Oty. Deslgnatlon Benc:evnel se
019 1/C Piston incl. Stempelpind inkl.

Ilem 020 pos. nr. 020
032 21C Retalnlng ring Sikringsring
044* 1/C Plu g sc rew Propskrue
056 1/C Bu sh 10r PlejlsIangs-

connecting rod b0sning
068 1/C Connecting rod Plejlstang inkl.

incl. Ilem Nos os. "r.
044,056, 140,1 52 044,056,140.152
and 164 09 164
081 lIC Piston Stem pel
093 1/C Piston ring Stempelring
103 lIC Piston rln9 Slempelring
115 lIC Plston rlng Stempetring
127 1/C l scraper ring Ol ieskrabering
139 lIC Connecting rod Plejlsl angs-

bearing 212 l 2/2
152 2/C Connectlng rod Plejlstangs-

stud boll
164 21C Nut M01rik
When orderlng spare parts, also page 500.50. Ved bestil ling af reservedele, se ogsa side 500.50.
= Only aval lable as part of a spare parts kit. tilgrengelig som del af et reseredelssreI.
Oty./C = OtyJCylinder Antal/C = Antal/Cylinder
00.27 - ESO
.J DieseII
Plale
Page 1 (2) Piston and Connecting Rod (Hydraulic Tghtened) 50601-06
23/30
900
c ___ :>
103
115
127
044'
056
139
068 -
~140'
00.27 - ESO
Plate
50601-06 Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)
L23/30
900
Item Item
. Qy. Deslgnation Ben~vnelse . Qy. DesignaIlon Benaevnelse
019 1/C Plston l incl. Stempelpind inkl.

ttem 020 pos. nr. 020
020 4/C Socket screw KraIerskrue
032 2/C Retalnlng ring Sikringsring
044" 1/C Plug screw Proskrue
056 1/C Bush for Plejlstangs-

connecting rod bsn n g
066 1/C ConnectIng rod Plejlstang inkl.

lncl. Item Nos pos. nr.
044,056, 140, 152 044,056,140,152
and 164 og 164
061 1/C Piston Stempel
093 lIC Plston rl"9 SIempelring
103 1/C PIston rl"9 Stempelring
11 5 1/C Pi ston ring Stempelring
127 1/C 011 scraper rIng Olieskrabering
139 1/C Con necting rod Plejlstangs

bea ring 2/2 leje 2/2
152 2/C Connecting rod lej lstangs -

stud boll
164 2/C 1 M0trik
When ordering spare parts, see al50 page 500.50. Ved beslilling af reservedele, se ogsA side 500.50.
Only avallable as part of a spare parts kit. lilg .engel ig som en del af el reservede l ss.et.
QlyJC = QlyJCyllnder Antal/C = Antal/Cylinder
00.27 ESO
',I,I,.( DieseII
Plate
Page 1 (2) CyIinder Liner 50610-01
23/30
72050 RPM
031
043 ~
97.05 ESOS
M,l}H'(MAN DieseI!
Plate
50610-01 CyIinder Liner Page 2 (2)
23/30
72050
Item Item
. Oty. Designation Bencevnelse . Qty. Oesignation Benrevnelse
016 1/C Cylinder liner Cyl inderforing
031 1/C Sealing rlng Tcetningsring
043 21C O-rlng O-ring
When ordering spare parts, see al50 page 500.50. Ved beslilling af reservedele, 5e og5(\ side 500.50.
Only avallable as part a spare parts klt. tilgrengelig som del af reservedelssC'e1.
OtyJC = OtyJCyllnder AnIal/C = Antal/Cylinder
97.05 - ESOS
",, DieseII
Plate
Page 1 (2) Cylinder Liner 50610-02
23/30
900
043
97.05 - ESOS
Plale
50610-02 Cylinder Lner Page 2 (2)
L23/30
900
Item Item
. Deslgnation Benrevnelse . aty. Designation Bencevnelse
018 lIC Cylinder l Cylinderforing
031 1/C Sea ling ring el n ingsring
043 21C O-rlng O(lng
092 1/C Flame ring Flammering
When orderlng spare parts, see al50 page 500.50. Ved beslilHng af reservedele, se ogsI side 500.50.
= " available as part of a spare parts kit. Kun tilgrengelg som del af l reserede l ssret.
Qty./C = QtyJCyIInder Antal/C = Antal/Cylinder
97.05 ESOS
Plate
Page 1 (2) Cylinder Liner 50610-05
23/30
031
092 -~
-~-
018 - - - -
043 ~
~"
01.08 - ESO
+, DieseII
Plate
50610-05 CyIinder Liner Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Q. Designation Benrevnelse
018 1/C Cyl inder l ner Cylinderforing
031 1/C Sea llng rlng Trelningsring
043 2JC O-ring O-ring
092 1/C Flame r ing Flammering
When ordering spare parts, see a l50 page 500.50. Ved beslilling af reservedele, se ogsa side 500.50.
On ly avalfable as part a spare parts kit. tilgrenge1ig som del af el reservedelss<:eI.

QtyJC = QtyJCyllnder Antal/C = Anlal/Cylinder
01 .08 - ESO
Section 507
Camshaft and Camshaft Drive
Description
Camshaft and Camshaft Drie 507.01
Working card
Camshaft and Camshaft Drie 507-01.00

Inspection and Replacement of Camshaft Bearing 507-01.05
Adjustment of Camshaft 507 -01.20
Plates _ _~_ _ _ _ _ _ _ _ _~_ _ _ _ _.....
Intermediate Wheel 50701-01

Camshaft and Camshaft Bearing 50705-07
Camshaft and Camshaft Bearing 50705-17

Description
Camshaft and Camshaft Drive 507.01
Page 1 (1)
Edition 01
23/30
General The lubricating l pipes the gear wheels are

equipped with nozzles which are adjusted apply
The camshatt which con trols Ihe actation inlet the l at Ihe poinls where the gear wheels are
valves, ehaust valves and fuel injection pumps is mesh. The position the nozzles is determined by
driven by a gear wheel the crankshaft Ihrough an direction rotation the engine.
inlermediale wheel, and rotated by a speed which
is half that Ihe crankshaf t, see fig. 1.
The camshaft is located in a high level housing Engine seen from aft - fly wheel end
the engine frame.
The camshaft runs replaceable, identical, steel-
backed bronze bushings fitted borings th e
transverse girders the housing.
The camshaft is built-up sections, one each

cylinder !. Each section is equipped with fied
cams operation fuel injection pump, air inlet
valve and ehaust valve. The seclions are assem-
bled by bolting the ample dimensioned and pre-
cision made flange connections, which also act as
bearing journals.
Ecept the Ioremost and the aftmost ones, the

sections are identical and thereIore interchangeable.
The Ioremost section is equipped with a clutch
driving the fuel il Ieed pump ( mounled). The gear
wheel driving the camshaft as well as a gear
wheel connection governor are screwed the
aftmost section. Clockwise rolatIon direCIIQI1
-- -----'
FIg. 1. Infermediate wheef
94.26 - E50S
Page 1 (2) Check of Camshaft and Camshaft Drive EdiIion 01
L23/30

Stopped engine
Plate no
52006
Item no
261
Note.
20 - 120 Nm.
Shut-off fuel l
Shut-off cooling l
Descriplion:
Checking of gear wheels, bolted connections

and lubricating system. Hand lools:
AIIen key, 12 mm.

Ring and open end spanner, 19 mm.
Socket spanner, 19 mm.
Slarling posilion:
Relaled procedure:
Man power: Plate no Item no Qty./

.;
"
v
~
Working time 3 Hours 50705 099 1 Oeng.
m
Capacity 1 man 50705 146 6/eng.

m
'!' 50705 195 1/eng.
Dala: 50705 183 2/eng .

:f
i'i 50705 205 2/eng.
" Data for pressure and tolerance (Page 500.35) 51106 237 1/cyl.
Data lor torque moment (Page 500.40) 51106 058 1/cyl.
Declaration of weight (Page 500.45) 5 11 06 693
97.06 - ESOU-G
',Ji@,,,,i MANDieseII
EdiIIon 01 Check of Camshaft and Camshaft Drive Page 2 (2)
L23/30
1) Dismount the covers which give access the 3) Examine all lubricating l spray nozz
gear wheels, camshalt and crankcase. les.
Examine all gear wheels lor cracks, wear and delor- 4) Start the electrical lubricating l pump and
mations. While turning the engine enable inspec- check theoil I lw everywhere. Be particularly carelul
allover the circumlerence the gear wheels. check that the l jet hits the gear wheels correctly
at the points where the wheels mesh.
2) Check all screws, nuts and bolted connections.
including locking devices everywhere the gear
wheel housing, camshaft housing and crankcase
check that they have worked loose. Tightening
torques, see page 500. 40.
97.06 - ESOU-G
Page 1 (2) Inspection and Replacement of Camshaft Bearing Edition Q1 H
L23/30
11 Stopped engine Plate Item Note.

Shut-off cooling water 52006 261 20 - 120 Nm.
Shut-off luel l
Shut-oll cooling l
Descriplion:
Check roller path cams and check cam-

shalt bearing. Hand lools:
Replacement camshaft bearing.
Feeler gauge.
Slarling posilion: Big screw driver.
Cover lor camshaft and gear wheel has been

removed .
Relaled procedure:
Camshalt and camshalt dri ve, 507-01.00
Man power: ReplacemenI and wearing parls:
Working time 2 Hours Plate Item Qty./

Capacity 2 men
50705 038 1/eng.
Dala: 50705 051 1/eng.

95.02 - ESOS-G
EditIon 01 Inspection and Replacement of Camshaft Bearing Page 2 (2)
23/30

Check Roller Palh of Cams.
1) While urning Ihe engine, eamine the cam

Camshaft bearIng
discs and in parlicular, check Ihe roller palh all Hole for lubricaIing l
cams for cracks. crackles and ruffle. Also eamine
the rolle rs Ihe ro ller guides.
Nole: Ihere are flal spolS on Ihe roller and some

Ihe rollers may be blocked, Ihe roller musl be repla-

ced by a new one, see working card 50.8-0.1 .0.0.
Check Camshafl Bearings.
2) The wearing surface Ihe camshaft bear-

ings cannol be checked wilhoUl dismounting the LocatIng screw
camshaft. However, ab-normal wear or more
Frame
bearings ll become apparenl Ihe form burrs
while metal at the circumference Ihe camshaft
journal, and in Ihal case the bearing ll doubl
be discoloured, as well. Fig 1.
The bearing clearance is measured wilh a feeler

gauge, see data sheet 500.35.
l a new camshaft bearing in Ihe bore and make
sure thal Ihe hole for inserlion Ihe localing screw
Replace Camshafl Bearing. in Ihe beari ng is in a correcl posilion. Lock the bea-
ring by means Ihe localing screw, which is 10 be
3) If or several Ihe camshaft bearings provided wilh a new gasket. faci lilale Ihe fitling
should be replaced, Ihe camshafl musl be wholly Ihe bearin g l can be cooled down wilh CO
2
or partly dismantled.
Inspecl Ihe camshaft journal for seizures.
Dismounl Ihe fuel l feed pump, mounled, and
check Ihal Ihe camshaft seclions are marked If necessary, Ihe camshaft seclion must be entirely
relation 10 each other. Disassemble the camshaft aft removed from the engine, and Ihe journal concerned
(Ioward flywheel) Ihe bearing Ihal is to be replaced. musl be polished .
Dismounl all roller guides Ihal are localed forward
Ihe disassembling posilion, see working card Coal all the journals Ihe camshafl seclion wilh
50.8-0.1.0.0. and 50.8-0.1.0.5. clean lubricating l and push Ihe camshaft into
posilion, making sure Ihal Ihe marks on Ihe flanges
ll Ihe disconnecled seclions Ihe camshaft so coincide.
far a head thal Ihe bearing which is 10 be replaced
is free. Assemble Ihe seclions and l Ihe bolts (coaled wilh
copaslip or similar).
Take Ihe localing screw Ihe camshaft bearing
concerned and push Ihe bearing Ihe bore in Tighlen the nuts with a lorque spanner, see data
Ihe engine frame, see fig 1. sheet 500.40.
Check Ihe lubricaling l ducls 10 Ihe bearing for Mounl all roller guides as well as Ihe fuel l feed
free flow. pump.
95.02 - ESOS-G
Working Card
Adjustment of Camshaft
507-01.20
23/30
Safely precaul ions: Special lools:
liIII Stopped engine Plale Item Note.

Shul-off starting air
Shut-off cooling waler
11 Shut-off fuel l
Shut-off cocling l
11 Stopped lub. l circul.
Descriplion:
Nominal adjustment ! camshaft. (Adjustment !

camshaft relation crankshaft). Hand lools:
Depth gauge.
Slarling posilion:
Camshaft assembled as per timing order,

mounted frame and rol ler gear house.
Rel aled procedure:
Adjustment ! the maximum

combuslion pressure, 514-0501
Working time 3 hours Plate lIem Qty. /

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

Declaration ! weight (Page 500.45)
96.30 - ESOS-L
507-01"20 Adjustment of Camshaft
WorkIng Card
Edillon 01 Page 2 (2)
23/30
1I the intermediate wheel has been dismantled a

nominal adjustment the camshalt compared
the crankshaft (timing) must be made as lollows: "rnal size'
1) The crankshaft is turned TDC ( dead

centre) lor cy linder 1.
Cylinder numbering, see page 50.0. 11.
2) Roller guide lor ll l pump cylinder no. 1 is

mounted and the camshaft is turned in a position
where the roller guide rests the cicular part al
the cam, see Iig 1.
Roller guide
ehaust valve
Cam for fueJ .- FIg2.
l pump
4) The camshaft is turned - the engines direc-

rotation (see page 50.0. 12)- l the "nominal
size" (as described item 3) is reduced with the
lead, mentioned "Lead Fuel Pump'.
Seen from front edge
Note: "Lead luel pump" is shown the table "Ad-
jusment after the trail" the Shop Test Protocol.
Fig . 5) When items 1 - 4 are completed and correct the

intermediate wheel can be mounted and tightened
again (torque moment, $ page 50.0..40.).
3) Th e "nominal size' is measured with a depth
gauge, .. the distance Irom the edge the For adjustmen tol the single le l l pumps (separately
roller guide house the thrust gauge pressed and assembled), see working card 514-0.5.0.1.
the rolle r guide, see Iig 2.
96.30 - ESOS-L
I,I'l}g..'( MAN DieseI!
Plate
Page 1 (2) Intermediate WheeI 50701-01
L23/30
, 288
~ 181

144

048

168

132
264
" - 227
024
120 %------- 215
203
~- 239
215
061+
193
94.22 ESOS
",.f DieseII
Plate
50701-01 Intermediate WheeI Page 2 (2)
23/30
Item Item
. Qty. Design ation Bencevnelse . Oty. Designation 8encevnelse
024 1 / Gear wheel, complete Tandhjul, komplet

inCI.ite m 119, 120,132, inkt. Ilem 119, 120, 132,
144, 156 144, 156
046 1 / Axle journal Lejelap
061+ 31 Fitted bolt Pasboll
073+ 31 5elf locklng ! Selvlasende ffitrk
119 1/ Gear wheel Tandhjul
120 1 / Gear wheel Tandhjul
132 1 / Bearlng bush Lejebsning
144 4/ Fitted bolt Pasbolt
156 4/ 5elf locking nut SelvlAsende rneIrik
166 1 / Pipe Ror
161 6/ Locking plate Sikringsplade
193 21 Gasket Pakning
203 l Connectlon plece MellemsIykke
215 2/ Securing washer Sikke rhedsskive
227 1 / Nlpple plug Prop
239 1 / Ror
240 1 / l plug Prop
252 1 / Connection piece Mellemstykke
264 3/ Gasket Pakning
276 1/ Cover Dc:eksel
266 6/ Screw Skrue
+ Item . 061 and + Ilem nr. 06 1 09 073

073 requlre Indivi- krrever individuel
dual match ing, before tiipasning, monIe
mounting, contact ring kontakt & W,
B&W, HoIeby Holeby
When ordering spare parts, see also page 500.50. Ved beslilling af reservedele. se ogsa side 500. 50.
On ly avai lable as part a spare parts kit. Kun tilgrengelig som en del af et reservedelssret.
OtyJE = OtyJEnglne Antal/E = AntalfMotor
94.22 ESOS
',l+tN'iMAN DieseII
PlaIe
Page 1 (2) Camshaft and Camshaft Bearing 50705-07
23/30
'JL).j!.--------- 217
325 051
' ----/ -:::::..;;:~ --
337 063
349
350
026 362
229
230
242
063
026 --__
075 254
266
278
109
099
087
134
146 11
158 038
291
171 301
313
183
195
205
99.4 1 - ESO
1,:,:,'!III DieseII
PlaIe
50705-07 Camshaft and Camshaft Bearing Page 2 (2)
L23/30
Item Item
Designatlon Bencevnelse
Deslgnatlon Ben a!vnelse
026 4/ Camshaft, aftfnterme- Styreaksel agter/mel- 230 1/ Camshaft "aft" Syreaksel, agler
dlate. 5 cyI. englne lem, 5 cyl. motor 7 cyI. engine 7 cyI. rnolor
038 1 / Camshaft "fo re " SIyreakseI "Ior" 242 1/ Camshaft "aft" Sty reaksel, agter
5 cyl. englne 5 cyt. moor 8 cy. engine cyl. moIor
051 1/ Camshaft bearing Styreakselleje 254 4/ Camshaft , intermed- Styreaksel mellem

late, 6 cyl. engine 6 cyI. motor
063 Camshaft bearlng Styreaksetleje
5/ 5 cyl. engine 5 cyl. motor 266 5/ Camshaft Intermed- SIyreaksel meJlem
6/ 6 cy. engine 6cyl. motor iate, 7 cyl. engine 7 cyl. molor
7/ 7 cyl. eng ine 7 cyl. moIor
8/ 8 cyl. engl ne 8cyl. rnoIor 278 61 Camshaft , intermed- Styreaksel mellem
late, 8 cyI. engine 8 cyl. molor
075 1/ Gear wheel andhjU
291 1/ Camshaft "fore" Styreaksel "O ~
087 1/ Screw Skrue 6 cyl. engine 6cyl. motor
099 10/ Sprlng washer Fjederskive 301 1 / Camshaft "fore" Styreaksel "for"
7 cyl. engine 7 cyl. motor
109 1 0/ Screw Skrue
313 l Camshaft "fore" Styreaksel "Ior"
110 Self locking nut Selvl ~se nde m0trik 8 cyl. englne 8 cyl. motor
50/ 5 cyl. engine 5 cyl. motor
40/ 6 cyl. eng ine 6 cyl. moIor 325 1/ Camshaft complete, Slyreaksel komplet,
52/ 7 cyl. englne 7 cyl. moIor 6 cyl. eng, inci. item 6 cyl. molor Inkl. Item
66/ 8 cyl. engine 8 cyl. motor 109, 11 , 122, 134, 146, 109, 11 0,122,134,146,
158, 171 , 183, 195,205, 158.171,183,195,205,
122 1 / Hub Nav 229,254,291,374 229.254.291,374
134 6 Screw Skrue 337 1/ Camshaft complete, Slyreaksel komplet ,

7 cyl . eng. incl. Item 7 cyt. moIor Inkl. Ilem
146 61 Dlsc spring Fjederskive 109,110,122,134,146, 109. 11 0. 122, 134. 146,
158, 171 ,1 83 ,195,205, 158. 171, 183.195,205.
158 1 / Guide ring Sikrlngsring 230.266,301,374 230,266,301.374
171 Screw Skrue 349 1/ Camshatt complete, Slyreaksel komplet,

40/ 5 cyl. engine 5 cyl. motor 8 cyl. eng, inci. Item 8 cyl. motor inkl. Ilem
30/ 6 cyl. engine 6 cyl. motor 109,11 , 122, 134, 146, 109. 110. 122. 134.146.
42/ 7 cyl. engine 7 cyl. motor 158,171, 183,1 95,205, 158,171,183.195.205.
561 8 cyl. engine 8 cyl. molor 242,278,313, 374 242,278.313.374
183 2/ Spring n Fjederlap 350 GuIde screw Styreskrue

6 5 cyl. engine 5 cyl. motor
195 1/ Coupling Kobling 7/ 6 cyl. engine 6 cyl. motor
8/ 7 cyl. englne 7 cyl. motor
205 2/ Screw Skrue 9/ 8 cyI. engine 8 cyl. motor
217 1 / Camshaft, compl ete Styreaksel komplet, 362 Packlng rlng Pakningsring
for 5 cyl. engine, incl. 5 cyt. molor, inkI. Ilem 6/ 5 cyl. eng ine 5 cyl. moIor
item 026, 038, 109, 11 , 026.038. 109. 110. 122. 7/ 6 cyl. englne 6 cyl. motor ~
,.;
122,134,146, 158, 171 , 134,146,158,171,183, 8/ 7 cyl. engine 7cyl. moIor
183,195, 205, 374 195, 205. 374 9/ 8 cyl. engine 8 cyl. moIor
~'"
~

229 1 / Camshaft "aft" Styreaksel, agter 374 1/ Shaft Aksel ~
6 cyl. englne 6 cyl. motor 39

When ordering spare part5, see al50 page 500.50. Ved besIiJling af reservedele, se ogsa side 500.50.
Only avallabl e as part a 5pare parts kit. tilgcengelig som del af et reseredelsscel.
QtyJE = QtyJEngine Antal/E = AntalfMotor
99.41 - ESOS
,,:,:,,, MAN DieseII
PJaIe
Page 1 (2) Camshaft and Camshaft Bearing 50705-17
23/30
))J.J'----r- 217
325 051
337 063
349
350
026 362
229
230
242
063
026
075 254
266
278
109
099
087
134
146 11
158 038
291
171 301
313
183
195
205
05.24 - ESO
,:,:,:,l'[ DieseII
PIate
50705-17 Camshaft and Camshaft Bearing Page 2 (2)
23/30
Item Item
Oty. Designation Bencevnelse Oty. Oeslgnation Bencevne lse
026 4/ Camshaft,aft/lnterme- Slyreaksel agter/meI- 230 1/ Camshaft "aft" Styreaksel, agter

dl ate, 5 cyl. englne lem, 5 cy!. molor 7 cyl. engine 7 cy!. motor
038 1 1 Camshaft "fore" Styreaksel fo, 242 1/ Camshaft "aft" Styreaksel, agter
5 cy!. englne 5cyl' rnotor 8 cyl. engine 8 cy!. molor
051 1 / Camshaft bearing S I reakse l le e 254 4/ Camshaft , Intermed- SIyreaksel mellem

late, 6 cyl. engine 6 cyI. molor
063 Camshaft bearing Slyreakselleje
5/ 5 cyl. englne 5 cyl. moIor 266 5/ Camshaft intermed- Styreaksel mellem
6/ 6 cyl. engine 6 cyl. motor iate, 7 cyl. eng ine 7 cy!. molor
7/ 7 cyI. englne 7 cy!. rnotor
8/ 8 cy!. engine cy!. motor 278 6/ Camshaft , in termed ~ Styreaksel mellem
late, 8 cyl. englne cyl. motor
291 1/ Camshaft "Iore" Styreaksel "Ior"
087 1 01 Screw Skrue 6 cyl. engine 6 cyl. molor
099 1 / Sprlng washer Fjederskive 301 1/ Camshaft "fore" Slyreaksel "Ior"

7 cyI. englne 7 cyl. molor
109 101 Screw Skrue
313 1/ Camshaft "Iore" Styreaksel "10'"
110 Self locklng Selvlasende metrik cyl. englne cyl. molor
50/ 5 cyl. engine 5 cyl. molor
401 6 cyl. englne 6 cyl. motor 325 1 / Camshaft compiete, Styreaksel komplel ,
521 7 cyl. engine 7 cyl. motor 6 cyl. eng. Incl. Item 6 cyl. motor inkl. ilem
66/ cyI. engine cyl. motor 109,110,122,134,146, 109, 110,122,134,146,
158, 171, 183,195,205, 158,171 , 183, 195.205.
122 l Hub Nav 229, 254,291 , 374 229,254.291,374
134 6/ Screw Skrue 337 1/ Camshaft complete, Slyreaksel komplet,

7 cyl. eng. Incl. Item 7 cyl. motor inkl. ilem
146 6/ Disc sprlng Fjederskive 109, 110, 122, 134, 146, 109,1 10,122,134,146,
158,171 ,183, 195,205, 158,171,183,195,205.
158 1/ Gulde rJng Sikringsring 230,266, 301 , 374 230,266,301,374
171 Screw Skrue 349 1/ Camshaft complete, Styreaksel komplet ,

40/ 5 cyl. engine 5 cyI. motor 8 cyl. eng. Incl. Item 8 cyl. molor inkl. ilem
30/ 6 cyI. engine 6 cyl. motor 109, 110, 122, 134,146, 109, 11 0,122, 134,146,
4 21 7 cyl. engine 7 cyl. motor 158,171,183,195,205, 158,171 , 183, 195.205.
56/ 8 cyI. engine cyI. motor 242,278,313,374 242.278.313. 374
183 21 Spring Fjederlap 350 Gulde screw Slyreskrue

6/ 5 cyl. engine 5 cyI. molor
195 l Coup ling Kobling 7/ 6 cyl. engine 6 cyl. motor
205 21 Screw Skrue 9/ 8 cyl. engine 8 cyl. motor
217 1/ Camshaft, complete Slyreaksel komplel, 362 Packing ri ng Pakningsring

f 5 cyl. engine, Incl. 5 cyl. molor, inkI. Ilem 6/ 5 cyl. engine 5 cyl. molor
Item 026, 038, 109, 11 , 026,038,109, 11 0,122, 7/ 6 cyl. englne 6cyl. motor ~
122, 134,146,158,171, 134.146. 158.171. 183. 81 7 cyl. engine 7 cyl. motor .;
183,195,205,374 195,205,374 9/ 8 cyl. engine 8 cyl. motor "i!

~
229 1 1 Camshaft "aft" Styreaksel, agler 374 1 / Shalt Aksel
~
6 cyl. englne 6 cyl. motor '!'

:;;:

When ordering spare parts. see also page 500.50. Ved bestilIing af reservedele, se ogsA side 500.50.
= avai IabIe as part a spare parts kit. tilgrengelig som deI af reserede i ssaat.
OtyJE = QtyJEngine Anla1/E = Antal/Motor
05.24 ESO
5ection 508
Operating Gear for Vale and
Fuellnjection Pumps
Description
Operating Gear for Vale and Fuellnjection Pumps 508.01
Working card
Inspection of Vale Roller Guides 508-01.00

Inspection of Fuellnjection Pump Roller Guide 508-01.05
Control and Adjusting of Vale Clearance 508-01.10
Plates
Roller Guide and Push Rods 50801-07

',:,'i DieseII
Descrition
Operating Gear for VaIve and FueI Injection Pumps
508.01
Page 1(1)
Edilion 06
23/30
Roller Guides
The luel injection pumps and the rocker arms lor inlet
and exhaust valves are operated by the cams, the
camshaft through roller guides. The roller guides lor Valve bridge Rocker arm
luel pump, inlet and exhaust valves are located
bores a common housing for each cylinder, this
housing is bolted to the engine Irame.
The roll er runs a bush ltted a that is pres-

sed into the roller guide and secured by means
a lock screw.
Operating Gear for Fuellnjection Pumps

Valve spindle
The injection pumps which are mounted directly
the roller guide housing are activated via thru st
Push rod - - -1-
pieces Irom the roller guide.
The rolle r is pressed down to the cam by a spring, Roller guide

housing
which is lixed between the roll er guide and the loot
plate the luel injection pump.
Roller guide -------..
Operating Gear for Inlet and Exhaust Valves ----.----~
The movment Irom the rol ler guides lor inlet and Roller
ehaus t is transmitted via the push rods the rocker
Camshatt
arms and spring-Ioaded valve bridges to each
th e two valve seats. Th e bridge is placed between
the valve spindles and the one end it is provided
with a pressed-on thrust shoe and the other end Fig. 1. Vafve Operating Gear.
it is litted with a thrust screw for adjustment the
valve clearance.
its top the bridge is controlled by a spherical

thrust shoe the rocker arm and at th e bottom
by a guide which rests a spherical socket the
cylinder head.
08.17 - ESOS
,, DieseII

Page 1 (2) Inspection of VaIve RoIIer Guides Edition
23/30
11 Stopped engine Plate Item Note.

11 Shut-off starting air
Shut-oll cooling water 52006 261 20 -120 Nm

Shut-oll luel l
Shut-off cooling l
Descriplion:
Dismounting, inspection and!or overhaul, and

mounting valve roller guides.
Inspection roller guide housing. Hand lools:

Ring and open end spanner, 24 mm
Slarling posilion: Socket spanner, 19 mm.
Socket spanner, 1 mm
cover lor cylinder head and cover lor luel Allen key, 3 mm.
injection pump removed. Allen key, 1 mm
Ratchet spanner.
Hammer.
Drift.
Relaled procedure:
Inspection fuel injection pump

roll er guide, 508-0 1.05
Control and adjusting valve
clearance, 508-01.10
Manpower: Replacemenl and wearing parts:

Capacity 1 man
50801 185 4!cyl
Dala: 50801 220 2!cyl
50801 232 1!cyl
08.17- ESO
Mi.I(MAN DieseII
EdiIion Inspection VaIve Roller Guides Page 2 (2)
23/30
Dismounting Roller Guide. 5) Dismount the screws (3) which secure th e roller
guide coer, take off the coe r l out the roller
1) Turn the engine so that the roller, rests the guide (5).
circular part th e cam.
Disconnect any pipes that may be the way (Iub.
2) Unscrew the nuts which secure th e rocket arm l
and fu el l pipes).
brackets, and l off the rocker arm with brackets.
6) 1I the roller guide housing is be dismantled,
3) Remoe the push rods (1), see fig 1. the luel injecIion pump and the luel injection pump
roll er guide are to be dismounted, see working card
514-0 1.05 and a number al lubricating l and luel
l pipes are also be disconnected.
The roller guide housing (6) can not be dismantled

wi th the rolle r guides litted.
7) 1I the any marks or scores Irom sei-

zures, these must be polished away.
2
8) Inspect the spherical stud lor delormaIions
3 (replace as necessary) .
4 Examine the surface the roller lor marks and other

6 delormations.
Make sure that there is Iree ply between the roll er

and the bush and the shalt , an d replace the
bush, l necessary.
5 Replacement Roller, Bush and Shaft .
9) R emoe the lock screwwhich secures the roller

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

as required .
1 ) l th rough the lubricating ducIs rollerguide

and roller guide housing , and clean the lubricati ng
grooes.
Mounting Roller Guide.
Fig 1. 11 ) When assembling the parts, which is carried

the reerse order the aboe ca re must be
exercised to damage the o-rings when mounting
4) Loosen the lock screw lorthe push rod protec- the proctecting tube.
ting tube, see p/ate 50801, item 207, the roll er
guide coe r and l and remoe the protecting 12) Adjusting ale clearance, see working card
tube (2). 508-01.10.
08.17 ESOS
+ DieseI!
Working Card
Inspection of FueIInjection Pump RoIIer GUde
508-01.05
23/30

Stopped engine
Plate Item Note
Shut-off fuel l
Shut-off cooling il
Descriplion:
Dismounting , inspection and/or overhaul , and

mounting af roller guide for fuel injection pump. Hand lools:
Allen key, 3mm.

Hammer.
I.
Slarling posilion:
Cover for fuel injection pump removed.

Fuel injection pump has been
removed , 514-01.05
Relaled procedure:
Adjustment and/or check max.

combustion pressure, 514-01 .20
Manpower: Replacemenl and wearing parts:

Capacity 1 man
Dala:

96.03 - ESOS
DieseI!
508-01.05 Inspection of FueIInjection Pump RoIIer GUde

Working Card
23/30
Dismounting Roller Guide. 3) Inspect the spherical stud lor delormations

(replace as necessary).
1) Remove the support ring (1) and spring (2)
and take the roller guide (3), see fig 1. Examine the surface the roller lor marks and other
delormations.

Make sure that there is Iree ply between the roller
and the bush and the shaft , and replace the bush
l necessary.
Replacement , Bush and Shalt .
4) Remove the lock screw which secures the rol ler

guide shaft and push the shaft .
The roller, shalt , and bush can be replaced

as requi red.
5) Blowthrough the lubricating ducts rollerguide

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

the reverse order.
Fig 1.
7) For adaption the thrust piece the roller
guide, see working card 5 14-01.20.
Inspection Gu ide.
2) the event any marks scores Irom sei-

zures, these must be polished away.
96.03 ESOS
Working Card
Control and Adjusting of Valve Clearance
508-01.10
23/30

Stopped engine Plate no Item no. Note
Shut-off cooling water 52008 022 Ehaust
Shut-off fuel l 52008 010 Inlet
Descriplion:
Control and/or adjusting valve clearance.

Hand lols:

Big screw driver.
Slarling posilion:
Cover lor rocker arm are removed.

indicator valves open.
Relaled procedure:
Manpower: Replacemenl and wearing as:
Working time 1/4 hour Plate no Item no Qtyl

Capacity 1 man
Dala:
Data lor pressure and tolerance (Page 500.35) See also plate 50502.
96.38 - ESOS
Edition 01 Control and Adjusting of Valve Clearance Page 2 (3)
L23/30
-------
Adjusting Inlet Valve Clearance.
1) Turn the engine so that th e roller. rests the

ci rcular part the cam. .. the l valves and the
exhaust valves are closed.
2) Loosen the adjustment screws valve bridge

and rocker arm, see fig 1.
Fig2.
The leeler gauge is remain this position when

adjusting the clearance th e other valve.
6) Place another leeler gauge, at the same size

0,50 mm above the other valve spindle, see fig 2.
Fig.1.
7) Adjust the clearance beIween valve bridge and
valve spindle by means th e adjusment screw
the valve bridge, and tighten the lock , see fig
3) Clearance beIween valve bridge and valve 2.
spindle, see page 500.40.
8) Checkthatthe clearance is correct simuItaneo-
4) Place the leeler gauge marked with "correct" usly at both valve spindles.
0,50 mm above the valve spindle nearest the
rocker arm bracket, see fig 1.
5) Adjust the clearance beIween valve bridge and

valve spindle by means the adjustment screw
the rocker arm (above the push rod) and tighten the
lock .
96.38 - ESQS
,, ,,,t MAN DieseII
Working Card
Contro! and Adjusting of VaIve CIearance
508-01.10
23/30
Adjusting af Exhaust Valve Clearance.
9) Carry adjustment in the same way as

described for the inlet valves, but using the feeler
gauge for exhaust valve clearance 0,90 mm.
1 ) The fee ler gauges for checking the clearance

have w gauges which are marked "incorrect" and
"correct", the latter be used when adjusting the
valve clearance, see fig 3.
After tightening the counter nuts rocker arms

and valves bridge, be sure that the feeler gauges
marked "correct" can be inserted into th e w clear-
ancessimultaneously as where it mustnot be possible
insert the gauges marked "incorrect" .
Fig3.
96.38 - ESOS
ptate
Page 1 (2) Roller Guide and Push Rods 50801 -07
L23/30
268
293 303
268
185
173
185
090
219
11 2
197
124
207
089
148
100
281
028
077
053
041
053
065 065
~ 244
.; 256
"
v
~ 016+
~
~
161
'!
136 232
"
"
08.16 - ESO
Plale
50801-07 Roller Guide and Push Rods Page 2 (2)
L23/30
Item Iteln
. Qty. Designation Benmvnelse . Qty. Deslgnatlon Benc:evnelse
016+ 1/C Housing for Hus ' 315 1/C Valve gear complete, Vent il bevegelse
roHer guides rulleslyr as s hown plate komlet, som visl ~
50801 exce pt Item plale 50801 undtagen
028 1/C Roller guide for Rulleslyr 'or pu me 161 ,173, 185,220,232, ilem 161,173,185,220,
pump 244,256,303 232,244,256,303
041 31C l Tap
053 31C Bush Foring + Item 016 requlre + Ilem . 016 krever
IndIvldual match- individuel tilasning
065 3/C Roller Rulle ing before mounting, f0r montering, konlakt
contact Dlesel Diesel
077 31C Lock screw Pinolskrue
089 1/C Thrust Tryklap
090 1/C Washer for spring Skive (or fjeder
100 1/C Spring Fjeder
112 1/C Thrust Tryktap
124 1/C Washer Skive
136 2fC Screw Skrue
148 2fC 8all Kugletap
161 81C Washer Skive
173 2fC Protectlng tube SkcermrOf
185 4/C O-ring
197 2fC Cover Dreksel
207 2fC Lock sc rew Pinolskrue
219 4/C Screw Skrue
220 2fC Gasket Pakning
232 1/C Gasket Pakning
244 2fC Guide l SIyresIift
256 8/C Screw Skrue
268 4/C Thrust Tryklap
281 2fC Roller guide 10r Rulleslyr 'or ventil

valve
293 2fC Push rod SI0dstang
303 2fC Push rod comp., incl. St0dsIangkomplet. inkl.

Item 268 and 293 ilem 266 09 293
When orderlng spare parts, see also page 500.50. Ved beslilling af reservedele, se ogs~ side 500.50.
l aval lable as part of a spare parts kit. lilgeng e li g som del af el resered el sse l.
QtyJC QtyJCyllnder Antal/C = Anlal/Cylinder
08.16 - ESO
Section 509
Control and Safety Systems
Description
Control and Safety Systems 509.01

lnstruments and Automatics 509.05
Lambda Controller 509.10
Starting 509.35
Conerter for Engine- and Turbocharger RPM Signal 509.40
Working card
Functional Test and Adjustment of Safety, 509-01.00

Alarm and Monitoring Equipment
Functional Test and Adjustment of Oerspeed 509-01.05
Adjustment and Test of On/Off Pressostate 509-05.00
Adjustment and Test of On/Off Thermostate 509-05.01
Function and Test of Leel Switch ( 25) 509-05.02
Adjustment and Test of Analogous Pressure Transmtter 509-05.03
Adjustment and Test of Analogos Temperature Transmiller 509-05.04
Lambda Controller 509-10.00
Plates
Goernor and Goernor Drie 50901-21

Regulating Deice 50902-06

Regulating Deice 50902-07
Oerspeed Deice 50903-02
lnstrument Panel 50905-07
lnstruments 50905-17
Plates
Thermometer 50907.09
Lambda ControIIer 5090802
PreIubricating AIarm ( 25) 5091901
LeveI Switch Sump (L 28) 5092013D
LeveI Switch Sump (L 28) 5092013
LeveI Switch Sump ( 28) 5092014
LeveI Switch Sump (Dipstick ) 5092015
FueI Leakage AIarm ( 42) 5092508
LocaI Stag 1 5093511
LocaI Stag 2 5093512
LocaI Stag 2 (incl. high Iub. temp.) 5093513
Engine ControI 5093513
TerminaI 5093620
Motor ControI 5094801
Cveer 5095601
Oescltion 509,01
Page 1 (2) Control and Safety Systems Edition 01
23/30
Governor Should a fuel pump plunger seize its barrel, thus

blocking the regulating guide, governing ! the re-
The engine speed is controlled by a hydraulic go- maining fuel pumps may continue unimpede owing
vernor. The purpose the governor is regulate to the spring-Ioaded Iinkage between the blocked
the rate delivery Irom the luel pumps, so that the pump and the regulating shaft.
engine speed is kept within certain limits, indepen-
ding the load.
Stop Screw for Max. Delivery Rate
Info rmation aboutthe design, luncton and operation
the governor is lound the special governor The bracket for stop cylinder/lim iting cylinder is litted
instruction book. with a stop screw which prevents the fuel pumps
from being set a higher delivery rate than what
The governor is mounted the Ilyheel end ! corresponds the permissible overload rating.
the engine and is driven Irom the camshaft via a
cylindrical gear wheel and a set ! bevel gears. This is effected by the arm the regulating shalt
being stopped by the stop screw, see lig. 1.
Pick-up for Engine

Mechanical Overspeed (SSH 81)
The pick-up for transfer ! signal the tachometer
instrument for engine RPM is mounted the fl yhee l The engine is protected against overspeeding th e
end cover the engine. of, for instance, governor lailure by means
an overspeed .
signal varying proportionally engine RPM is
created th e pick-up by the rotating toothed im- The engine is equipped with a stopping device
pulse wheel mounted the camshaft end. which starts operate l the maimum permissible
l number is exceeded.
Pick-up for Turbocharger The overspeed tripping device is fitted the end
cover th e lubricating l pump and is driven
See Urbocharger instruction book, section 5 12. through this pump.
1I the pre-set tripping speed is exceeded , the spring-

Regulating Shaft loaded flyeight (1), see lig. 1, wll move outwards
and press down the arm (2).
The governor movements are transmitted through a
spring-Ioaded pull rod the fuel pump regulating The arm is locked its bottom position by the lock
shalt which is fitted along the engine. (3) which is pressed by the spring (4).
The spring-Ioaded l l rod permits the governor the same time th e arm (2) presses down the
give ll deflection the stop cyli nder ! the spindle (5), and the pneumatic valve (6) opens,
manoeuvring system keeps the fuel pump regulating whereby compressed air w ll be led th e Lambda
shaft at 'no fuel' position. cylinder. see descri ption 509. 10, which th e piston
is pressed lorward and, through the arm, Urns the
Each fuel pump is connected the common , lon- luel pump regulating rod STOP position, thereby
giudinal regulating shaft by means ! a two-piece, the engine stops, the spring-Ioaded ll rod con-
spring-Ioaded arm. nection the governor being compressed.
96.38 - ESOS-G
509.01 OescrIption
Editlon 01
Control and Safety Systems Page 2 (?)
23/30
The engine can be stopped manually by pressing

down the button (7), seefig. 1, which wll activate the
springloaded fly weight (1) through the lever (8),
If the overspeed has been activated the overspeed

must be reset before the engine can be started.
Reset is done by means of the button (1 ).
The overspeed alarm (SAH 81) is activated by means

of the micro switch (9).
1. Flyweight
2. Arm
3. Lock
9
4, SprIng
5, Spindle
6. PnemalIc valve
Overspeed
actIvaled 7. ul
8, Lever
9. micro swIlch
10. t
2 5 3 4 10 10
Fig ,. MechanIcaf overspeed (SSH 81).
96.38 . ESOSG
Desc r ptIon 509.05
Page 1 (3) Instruments and Automatics Edition 01
L23/30
Main Instrument PaneI
As standard the engine is equipped with an instru- The instrument panel is mounted flexibly rubber
ment paneI, comprising instruments visual indi- elements and aII manometer connections are con-
cation the most essential pressures. nected the panel by means flexible hoses, as
Illustrated I;g. 1. shown I;g. 2.
00
11
00
11
FlexIble hose
-=
00
11

Rubber etement
QQ Q Valves
QQ QQ
l Push button
On the engine is as standard Inounted an instrument

panet.
The following incorporating preSSlIre gauges the mosl Fig. 2. Cross section insIrument panel
essentIal pressures.
PIessure gauge :
The connecting pipes the manometers are equip-

1 L fresh water, l l 10 arr cooler
fresh waleI, inlet engine ped with valves which make possible replace
121/22 Lubricating l, lt/ll 10 l the manometers during operation.
l23 Lub. oil, ll 10 turbocharger
31 Charge , outlel from cooler
40 Fuel l, inlet 10 engine
Fig. . Lay-out insIrUInent
96.03 - ESQS
!/( Dieserl
509.05 Instruments and Automatics
DescrrpIioll
Page 2 (3)
Editron QIH
23/30
Instrumentation high press. drop across lub. l l lter

100 high - FW temperature - outlet engine
As standard the engine is supplied with the 10IIowing l starting air pressure - l engine
instrumentation mounted local the engine: high engine speed (overspeed)
herreter l air cooler

water The actual number and type the alarm- and shut-
hermeter 02 L waler - outlet from arr cooler down switches for the plant can be seen the list
Thermometer 03 L water - l from lub. 011 cooler Engine Automatic part list this section.
Thermometer 10 fresh water - rnle! 10 engine
Therrnometer 11 fresh water - outlet each cylinder

Thermmeter 20 LubrrcatIIlg l - ll 10 cooler Leakage Alarm ( 42)
Thermometer 22 LubricaIrng 011 - oUl Irom
ThermomeIer 30 Charge ll 10 cooter Waste and leak l from the comparemen t, for the
herffiomete r 31 Charge l - outlet from coler injection equipment. fuel valves, high-pressure pipes
Thermometer 140 Fuel l - ll 10 engine and engine feed pump ( mounted) is led a ll
Thermomeler 60 Exhaus! gas - outlel each cYIInder leakage alarm .
ThermomeIer 61 Exhausl gas - ull turbocharger
The actual number the instrumentation for the

plant can be seen the diagrams for the specific Normalleakage
plant the sections 512-513-514-515-5 16.
For code identification see 50.0..20. c
Pressostates and Thermostates

Leak alarm
rral ll
The engine is supplied with a number alarm- and
shut-down func tions. The alarms shall via the alarm
panel worn against an abnormal working condition,
which can lead break down and the shut-down
functions shall stop the engine belore a break down.
I.e. a shut-down is worse than an alarm because
a shut-down is given the engine could be severe
damage by running these conditions.
Hlgh level
As standard the engine is equipped with:
Shut-down Switches for

__ Leakoil
lw lubricating l pressure - inlet engine Alarm

high FW temperature - outlet engine Normal
high engine speed (over speed)
Alarm Switches for

, - ----"-'''{.- - - -
-
leaking fuel l
l w
lubri cating l pressure - l engine
lw prelubri cating l pressure (Ievel
Waste l outlet
alarm)
Fig. 4. Fuel / /eakage a/arm.
96.03 - ESOS
DescripIIon
Instruments and Automatics 509"05
Page 3 (3)
Edition 01
23/30
The alarm unit consists a b o wi th a Iloat switch Alarm 'or Prelubricating (LL 25)
lor l ee l monitoring, see {ig. 4.
Alarm lor missing prelubri cating, wh en the engine
The supply luel l the engine is led through the is stopped is given by means a leel swi tch (LL
unit in order keep heated , thereby ensuring 25) mounted the main lubricating l .
Iree drainage passage lor high-viscous wa-
ste/leak l.
Alarm and Shut-down 'or Overspeed
Under normal conditions there l l always be a smal-
ler amount waste/leak l Irom the comparement, When the mechanical overspeed is actIvated, see
this ill be led through the bore "" the 509.01 {ig. 2, a micro-switch ll release the alarm
" " as illustrated. lor overspeed (SAH 8 1) and activate the shut-down
solenoid the governor.
case a larger than normal leakage, the leel
the bo ll rise and the level switch "C" ll be The latter lncton is a back-up lr the mechanical
activated. The larger amount leak l l l be lead overspeed .
through the the "" .
96.03 ESOS
'$2, .f DieseII
Descri ption
Lambda ControIIer 509.10
Page 1 (2)
Edition 09
23/30
Purpose Thus the solenoid valve (4) opens. Th e jet system is

activated, the turbocharger accelerates and increases
The purose with the lambda controller is ( prevent the charge ai r pressure, thereby pressing the piston
injection more luel the combustion chamberthan (3) backwards the lambda cylinder (5). When the
can be burned during a momentary load in-crease. lambda ratio is satislactory, the jet system ll be
This is carried out by controlling the relation between de-activated.
the luel index and the charge air pressure.
At a 50% load change the system l l be activated
The Lambda controller is also used as stop cylin- lor about 3-8 seconds.
der.
1I the system is activated more than 1 seconds,
the solenoid valve ll be shut 011 and there l l be
Adantages a remote signal lor "jet system failure".
The lambda controller has the lollowing advan-

tages: Fuel oillimiting during start procedure
Reduction visible smoke case sud- During th e start procedure the lambda controller is
den momentary load increases. used as an index Iimiter.
Improved load ability. Hereby heavy smoke formation is prevented during

start procedure and fu rther the regulating device
Less louling the engine's exhaust gas cannot Qver-react.
ways.
Limitation luel l index during starting Air Consumption

procedure.
At 50% step load th e air consumpti on ll be as
fo llows:
Principles for functioning
Figure 1 illustrates the controller's operation mode. Cyl. no. 5 6 7 8

case a momentary load increase, the regulat-
ing device l l increase the index the injection Nm' 0.70 0.84 0.98 1.12
pumps and hereby the regulator arm (1) is turned,
the switch (2) l l touch the piston arm (3) and be
pushed downwards, whereby the electrical circuit
ll be closed.
04.15 - ESO-G
509.10 Lambda Controller Desc rptlon
Page 2 (2)
EdiIIon 09
23/30
1. Regulating arm
2. Switch (Pick-u)
3. Piston
4. Solenoid valve
5. Lambda controller
6. Overseed device
(mecanical activated 3/2 valve)
5 Charge air
receiver
3
2
1
"'=<
4 Engine's
compression
air system
Fig 1 Lambda controlfer inc/. 51aft Imitation
04.15 - ESO
Description 509,35
Page1(1) Starting
Edilion 01
23/30
Description Engine lTurbocharger
The starting box is mounted the engine's control activating the "Engine RPM/TC RPM ' button, the
side. Iront the box there are the lollowing indication is changed.
indications/pushbuttons:
Engine RPM indication is green light-emitting diodes
Indication engine turbocharger RPM and turbocharger RPM indication is red light-emit-
Indication electronic overspeed ting diodes.
Pushbutton ' Manual Start'
Pushbutton ' Manual Stop" ExIernal Indications
Pushbutton ' Remote'
Pushbutton lr "Local' There are signals engine RPM and tur-
Pushbutton lr ' Blocking' bocharger RPM.
Pushbutton lor change-over between engine Engine: 1200 RPM - 4-20 mA
and turbocharger RPM TC: - 60000 RPM - 4-20 mA
The luncton chosen is indicated the pushbut- The pushbuttons lor "Remote", "Local' and 'Block-
ton. See lig 1. ing' have potential Iree switches eternal indi-
cation.
Manual Start
components the starting box are wired the
Th e engine can be started by means the start built-on terminal bo.
button, but only l the button "Local' is ac tivated.
The manual. local start is an electrical, pneumati c

start, .. when activating the start button a sole-
noid valve opens air the air starter, thereby
engaging th e starter and starting the diesel engine.
r.OO\
(3
- ,-- --- -
~w
Throughout the star ting cycle the start button must

be activated.
,. ., .-
The air starter is automatically disengaged when the """-. '>00
diesel engine eceeds 140 RPM . the start button is ~
disengaged belore the diesel engine has ecee ded

140 RPM , further star ting cycles are blocked, l
5 sec. after the engine is at standstill.
( )( """ )rE!I~t!E_~.!.
START
TCRPM
( """ 0)( ;. 0)( :I<IGa)

Remote Start
Remote start can only take place l the pushbutton

'Remote' is activated.
Manual Stop
The 'Manual Stop" button is connected the stop

coil the governor.
Blocking
1I ' Blocking' is activated, is possible start

the diesel engine. Fig 1. Starfing box
94 .26 - ES2S-G
Description 509.40
Page 1 (1) Converter for Engine- and Turbocharger Signal
Edilion 01
L23/30
Engine signaI The ' engine ' signalswill be given through a relay.
One lor synchronizing and lor start!stop pre.
For measuring the engine's RPM, a pick-up mounted l b. l pump alarm blocking at start/stop.
the engine is used giving a Irequencydepending
the RPM. be able show the engine's RPM
an analogue tachometer, the Irequency signal Safe start
is sent through an f/I converter (Irequency/current
converter), where the signal is translormed a When the sale start signal is activated th e engine
proportional 4-20 mA - 0-1200 RPM signal. can start. When the engine reac h 140 RPM the air
starter ll be shut-oll.
Further, the converter has lollowing signals:
Further, the sale start signal is a blocking luncton
overspeed lor the air starter during rotatIon.
engine run
sale start
tacho lail Tacho faiI
The tacho lail signal ll be when everything

is 110rmal. 1I the pick-up the converter lals the
.-:------------- :------_._-_. ----_ .. __ . . _---_._----, signal l l be deactivated. E.g. l there is power
supply failure.
,: ,:,
..,...
LJ l eo-...Iot
<oo nP.l $lgnol
!::"":~ ~ ... 1~ The converter for engine RPM signal iS mounted

::::;- 1 : _______ -:::: ~ ,[----C;;: i the terminal bo the engine.
'------------------- ----------I;~~-~ J.
---::~----:---:-:?c~~~:::--- ~[' ~~:~-
!"
,, Turbocharger signaI
.I~% ------- ~ ,~-- ------
!@,-
For measuring the turbocharger RPM, a pick-up
mounted the engine is used giving a Irequency
depending the RPM. be able show the
ig 1. Corverter for engine RPM. turbocharger's RPM an analogue tachometer,
the frequency signal is sent through a f/ l converter
(Irequency/current converter), where the signal is
Overspeed translerred a proportional 4-20 mA - 0-60000
RPM.
When the engine speed reach the setpoint lor elec-
tronic overspeed the converter gives a shutdown The converter is mounted the term inal bo
signal and a alarm signal through a relay. engine.
Engine
When the engine speed reach 710 RPM 200

4-20mA
RPM + 1 seconds the converter gives a ' engine , 7' -24VOC
' signal. F Tachometor

T!C
Pick-p
The engine signal ll be deactivated when

.. 24VOC
the speed is 640 RPM. 1I the engine speed haven't
been 710 RPM the signal l l b e deactivated
at 200 RPM. Fig 2. COllverter for TC RPM.
96.30 - ES2S-G
Working Card Functional Test and Adjustment of Safety, 509-01.00
Page 1 (2)
Alarm and Monitoring Equipment Edilion 01
23/30
Safety precautions Special tools
Stopped engine Plate Item Note.

Shut-off cooling water See Related Procedure
Shut-off luel l
Shut-oll cooling l
Stopped lub. l circu l.
Description
Function test and adjustment salety, alarm and

monitoring equipment. Hand tools
See Related Procedure
Starting position
Related procedure
Overspeed trip 509-01.05

Pressostate 509-05.00
Therm ostate 509-05.01
Level switch (LL 25) 509-05.02
Analog pressure transmitter 509-05.03
Analog temperature transmitter 509-05.04
Man power Replacement and wearing parts
Working time hours Plate Item Qty./

Capacity man
Data

03.32 ESO
509-01.00 Functional Test and Adjustment Salety, Worki ng Card
Alarm and Monitoring Equipment
23/30
Maintenance monitoring and salety sy For check these lunctions use the working card s
stems mentioned under related procedure page 1.
One the most important parameters the pre

ventive work is that the alarm system as well as the Alarm System
shutdown and overspeed devices are lunctioning
100%. is important that all alarms lead prompt investi-
gation and remedy the error.
1I some these lunctions are operation, alarm is insignilicant. is therelore important
they have be repaired immediately. 1I this is th at all engine crew members are lam l a r with and
possible because the present working siluation, well trained th e use and importance the alarm
th e engine has be under constant observation system.
l can be stopped. The most serious alarms are equipped with slowdown
and/or shutdown lunctions.
It is recommended that all luncti ons are tested every
three months according the mentioned working
cards.
The extent the alarm and salety lunctions is

vari- able Irom plant plant.
03.32 ESO
DieseII

Page 1 (2) FunctionaI Test and Adjustment of Overspeed Edition 01
23/30
D Stopped engine Plate no lIem no Note

D Shut-ofl cooling water 52009 016
D Shut-off fuel l
D Shut-off cooling il
Descriplion:
Functional test and adjustment ! overspeed

trip. Hand lools:
key, 4 mm.
Allen key, 2 mm.
Slarling posilion:
Functional test and adjustment ! safety

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

Capacity man
Dala:

96 .03 - ESOS-G
}%,"l DieseII
509-01,05 WorkIng Card

Edi!Ion 01 FunctionaI Test and Adjustment of Overspeed Page 2 (2)
L23/30
1) The engine is run manually, (on governor the engine l the adjusting screw is opposite
'synchronizer') and at load, while watching the the opening the side ! the housing. w loosen
tachometer. the lock screw and turn the adjusting screw, using
the tubular spanner supplied, see fig 2.
On reaching the revolution number indicated
page 500.30 'Test Report" the overspeed
ping device must function, thus actu ating the stop
cylinders. The fuel injection pump control rods are
now moved zero index, and the engine stops.
2) If the overspeed device at a l

number different from tha t stated page 500.30
the 'Test Report' the overspeed device must
be adjusted.
FIg2.
the adjusting screwoutwards (slacken flyweight

spring) reduce the number. Be careful
screw the adjusting screw so far that
may touch the release arm. Tighten the lock screw
and test the overspeed device again.
4) Refit the covers when the overspeed device

functions at correct revolution number.
5) Th e overspeed device can be tested manually

Fig 1. by depressing the button af the housing, see
fig 1. This wll activate the flyweight and the arm for
release ! the air valve for the stop cylinders and
Adjustment Overspeed , the engine should thus stop. (This test must also be
carri ed without load).
3) Remove both covers the housing ! the
overspeed tripping device, see fig 1. 6) It is recommended and then, while the
engine is at a standstill, move the flyweight by
means ! the push button ensure that the flyweight
can always move with sufficient ease.
96.03 - ESOS-G
.:,,' DieseII
Page 1 (2) Adjustment and Test of On/Off Pressostate Edilion 01
L23/30
Safely precaulions : Speciallools:
Stopped engine
Plate Item Note

Shut-off l l
Shut-off cooling l
Descriplion:
Adjustment and test on/oH pressostate. (Iub.

oil,fuel l , water etc.). Hand lools:
Screw driver.
Testing pump.
Slarling posilion:
Functional test and adjustment saIety

Relaled procedure:
Worki ng time 1/2 hour Plate Item Qty/

Capacity 1 man
Dala:

Data torq ue moment (Page 500.40)
Decl aration weight (Page 500.45)
91.45 - ESOSG
' '( DieseII
509-05.00 Adjustment and Test of On/Off Pressostate
WorkIng Card
EdilIon 01 Page 2 (2)
23/30
Adjustment:
1) When the pressostate cover is removed and

locking screw pos. 5, fig 1 is loosened, the range e e
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read.
1. TrIal flange.
2. Drain screw.
3. Valve.
1. Range spindle.
2. Range scale.
3. Differenlial spindle.
4. DifIerentIal scale. FIg2.
5. Locking screw.
4) Remove the screw pos. 2.

Fig 1.
5) the testing pump the trial flange pos.
1.
2) pressostates having an adjustable differen-
tial, the spindle pos. 3 must be used to make the
adjusmen!. The differential obtained can be read Alarm for Falling Pressu re:
directly the scale pos. 4.
6) Pump the pressure l the switch has
Set points, see page 500.30. changed. The pressure ll slowly be relieved and
must be checked that the swi tch change back
the pressure stated as the alarm !.
Test:
It is possible make a functional test of the pres- Alarm for Rising Pressure:
su re switch. This is be carried according
th e following procedure. 7) Pump th e pressure l the switch chang-
es, and check that happens at the stated alarr
3) Shut off system pressure with the valve pos 3, !.
fig 2.
8) After the final check and adjustment, remove
the testing pump, mount the screw pos 2 and
the valve pos 3.
91.45 - ESOSG
Working Card
Adjustment and Test of On/Off Thermostate
509-05.01
23/30
Safety precaulions: Special lools:
11 Stopped engine Plate Item Note

Shut-off fuel l
Shut-off cooling l
Descriplion:
Adjustment and test on/off thermostate. (Iub.

l,
fuel l, water etc.). Hand lools:
Screw driver.
Special testing devices.
Slarling posilion:
Functional test and adjustment safety

Relaled procedure:

Capacity 1 man
Dala:

Data for torqu e moment (Page 500.40)
96.26 - ESOS-G
, DieseI/

EditIon 01 Adjustment and Test of On/Off Thermostate Page2 (2)
23/30
Adjustment: Test:
1) When the thermostate cover iS removed and 3) The funcional test of the thermostate is be
locking screw pos. 5, fig 1 is loosened, the range carried according the following procedure.
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read. 4) Take the sensor of the pocket.
5) Test the sensor a water bath, where the

temperaUre can be controlled.
Alarm for Falling Temperature:
6) Raise the temperaUre l the switch has

changed.
Then the tempera Ure must slowly be re duce d , and

check that the switch changes back at the tempera-
Ure stated the list page 50.0.30.
Alarm for Rising Temperature:

1. Range spindle.
2. Range scale.
7) Raise the temperaUre l the switch chang-
3. Differential spIndle. es and check that is happens at the stated alarm
4. DiIferential scale. points.
5. Locking screw.
8) Adjust if necessary.
9) The sensor is mounted again.

Fig 1,
2) Thermostates having an adjustable differential,

the spindle pos. 3 can be used while the scale pos.
4 is read.
Set points, see page 500.30.
96.26 - ESOS-G
Page 1 (2) Function and Test of Level Switch (LL 25) Edition 0'1
L23/30

Stopped engine
Plate no. Itemno. Note
Shut-off luel l
Shut-off cooling l
Descriplion:
Function and test level switch, LL 25,

lubricating l system. Hand lools:
Slarling posilion:
Functional test and adjustment salety

alarm and monitori ng equi pment, 509-01.00
Relaled procedure:
Working time 1/2 hour Plate lIem Qty/

Capacity 1 man
Dala:
Data lor pressure and tol erance (Page 500.35)

Data lor torqu e moment (Page 500.40)
91 .03 - ESOS-G
Edition 01 Function and Test Level Switch ( 25) Page 2 (2)
23/30
The level switch LL 25, which is mounted on the

main lubricating l the engine, gives alarm
lor missing prelubricating l.
13/
Function.
1) starting the prelubricating l pump the main

lubricating l ll be llled with lubricating l,
which means that the level switch is llted and the
alarm is disconnected.
Level swIlch
2) When the prelubricating is interrupted, the l b.
Main lubricalIng l
il ill , the system through the bearings,
which means that level switch is lowered and the
alarm starts.
Figl.
Test:
The test is carried out when the engine is stop-

ped.
3) Start the lubricating l pump, and let the pump

run about 5 min.
4) Stop the prelubricating l pump. The alarm

must be released alter - 5 min., depending the
l viscosity.
91.03 - ESOS-G
Page 1 (2) Adjustment and Test of Analogous Pressure Transmitter Edition 01
L23/30
Stopped engine
Plate Item Note

Shut-off cool ing water
Shut-ofl luel l
Shut-off cooling l
Stopped lub. l c ircul.
Descriplion:
Adjustment and test analogous pressure

transmitter. Hand lools:
Ring and open end sp anner, 1 mm.

Testing pump.
Slarling posilion:
Functional test and adju stment salety

alarm and monitoring equipment, 509-01 .00
Relaled procedure:

Capacity 1 man
Dala:

Decl aration weight (Page 500.45)
91.45 - ESOS-G
509-05.03 Wrking Card
Editin Q1H Adjustment and Test of Analogous Pressure Transmitter Page 2 (2)
23/30
The pressure transmitter registers the actual pres Adjuslmenl:

sure and marks the change ( an electrical signal,
which adjusts the pressure. 1) The pressure transmitter shall not be adjust-
ed, but the alarm limit must be set the alarm
plant. Kindly see the instruction book for the alarm
plant.
Set points, see page 500.30.

e e
Tesl:
2) It is possible ( make a functional test ! the

pressure transmitter. This is carried out according
to the following procedure:
3) Shut system pressure with the valve pos.

3.
4) Remove the screw pos. 2.
5) Mount the testing apparatus the trial flange

pos. 1. and pump a pressure within the working
area ! the transmitter.
1.
2.
TrIalllange.
Drain screw.
_ j If the alarm plan t has an instrument unit, the pres-
sure can be read this. Other wise the test can
be carried out by watching ! the alarm plan t gives
,--_
3. v_aIve. _ _
any alarm, when the alarm lm t which is stated
an page 500.30 is exceeded (! the alarm plant is
adjusted).
Fig 1.
6) The screw pos. 2 is mounted, and the valve

pos. 3. is opened after the test is finished.
9 t .45 - ESQS-G
Working Card Adjustment and Test of 509-05.04
Page 1 (2) Edition Q1H
Analogous Temperature Transmitter
23/30

Shut-off fuel '
Shut-off cooling '
Stopped lub. ' circul.
Descriplion:
Adjustment and test analogous temperature

transmitler, ( 100 sensor). Hand lools:
Special testing devices.
Slarling posilion:
Functional test and adjustment safety

Relaled procedure:
Mampower: Replacemenl and wearing parls:

Capacity 1 man
Dala:

Data torque moment (Page 500.40)
96.26 - ESOS-G
509-05.04 Adjustment and Test of WorkJng Card
EditIon 01 Page 2 (2)
Analogous Temperature Transmitter
L23/30
The 100 sensor consists a resistance wire Otherwi se the test can be carried by watching
which changes resistance depend ing the tem- l the alarm plant gives any alarm , when Ihe alarm
peratre. limit which is stated an page 500.30 is eceeded
(l the alarm plant is adjusted).
Look and design varily depending the place
measurement and manulactre. 5) The sensor is mounted again.
Adjustment:
1) The 100 sensor cannot be adjusted , but

the alarm lmt must be set the alarm plant.
Set , see page 500.30.
Test:
2) Th e lnct on a l tri al the 100 sensor can be

carried ! according to the lollowing procedure.
3) Take the sensor the pocket.
4) Test the sensor by diving the sensor the

water. Compare the signal Irom the sensor with the
water temperat re.
1I the alarm plan t has an instrument , the tempe- Fig 1.

ratre can be read this.
96.26 - ESOS-G
i,,@'.if Desel
Workiflg Card 509-10,00
Page 1 (3) Lambda ControIIer Edition 13
23/30

D Shut starting air
D Shut off cooling water
D Shut off l l
D Shut cooling l
Description Hand tools
Adjustment lambda controller. Adjustable spanner 10'-12'
Starting position
Related procedure
Manpower Replacement and wearing parts
Working time hour Plate Item Qty

Capacity man
Data

03.13 - ESO
+' DieseII
Edition 1 3
Lambda Controller Page 2 (3)
23/30
Adjustment of the Lambda Controller
adjustments are made when th e engine is

standslill posilion.
1) Check that the free space between the pick-

and th e band steel Ihe regulaling arm
is min. 1 mm, see lig 1.
~--~-- 3
4
1. Band stee!
2. Pick-up
3. RegulaIing arm
1. Lambda cylinder 3. Adj ustment screw
2. Piston of the 4. RegulaIing arm

lambda cylinder
i -------- ---------~I'--- - -r-j'l- ---

Fig 3 Latnbda Controlfer
a.
::>
'-.
,
--.-- ')
.::: ~
.2 1.. . . . . - - . -',
-.
:;;
c e
~ ~ 3
2) Turn the lever (Iig 2) the governor a few
2 times to lull load with an adjustable spanner
(spring between governor and luel rack fu ll
com-pressed). Check thal the luel index is 17
Fig 1 Check of free sace at Ihe fue l pump.
3) In case large deviation Irom index 17 ad-

justment is done by turning the regu laling arm
(4 ), lig 3. Finally adjuslmenl is done at the
adjustment screw (3) , lig 3.
~::i:~~I ~l
Stop screw
4) Adjustmenl compleled.
R ' Adjustment of the Stop Screw
5) Remove lor charge air pressure.
6) Supply air pressure l the piston rod reaches

ils upper posilion.

7) Turn Ihe lever (Iig 2) the governor lullload
with an adjustable spanner. Adjust the slop
screw (Iig 2) 10 110% load (slalionary 100%)
Fig2 Adjustment Qf the stop screw according 10 Ihe test bed, plus 1.5 index.
03.13 - ESO
WorkIng Card
Lambda Controller
509-10.00
23/30
Use the index arm on th e luel injection pump Note : In case start lailure due to wear the luel
nearest to th e lambda con troller as the control pump, the start index must be raised to a higher level
lor the index. by turning the self-Iocking nut anticlockwise.
8) Adj ustment completed.
Adjustment of Start Index, only if mounted
After adjustment the lambda index the start index

must be adjusted. -+1;:0=='=-=;~~~
t> - , 0
Self-Iocklng
......fc::--
l
~-~~:::~~ Force
Force the piston by the screw on the back, see fig 4.
Check th at the index is 18 mm. Adjustment is made
on the sell-Iocking nut on the back the lambda
controller, see fig 4.
Fig 4 Adjustment of start index
03.13 - ESO
+:( DieseI!
Plale
Page 1 (2) Governor and Governor Drive 50901-21
23/30
393
427 For goernor,

see special
instru ction book
~ 415
403
439
f~ 141
~ 153
~ 165
189 ~~-- 177
100 ro3
200 _________ 'Q' __
____ ~ 045

o~ 224
212 + ~- _____
057 ~
i-"':::::::::':') ~ 236
[:261 248
273
~ 285
m.YM-.l.. 297
:-""'--'J _ /L--- 307
332
320
06.44 ~ ESO
Plate
50901-21 Governor and Governor Drive Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Benaevnelse . Qty. Designatlon Benrevnelse
033 1 / Plug screw Propskrue 415 4/ Screw Skrue
045 1 / Gasket Pakning 427 1 / Shutdown solenoid Shutdown spole
057 4/ Nut Molrik 439 1 / Governor, Europa AegulaIor, Europa

(900 rpm) (900 rpm)
069 2/ Stud Tap
070 1 / O-rlng 0- 9
+ Item . 212 requlre + Item nr. 212 krrever
082 1 / Castle Kronernatrik an Indlvldual m atc h ~ en individual Iilpasn ing
Ing (by shIms) before (med shims) for monte-
094 1 / Spllt l Splil mountlng , contact, ring, kontakt B&W,
B&W, Holeby Holeby.
141 1 / Shlm (set 0,1 - Mellemlceg (se I 0,1 -
0,3 0.51,0 mm) 0,30,5 - 1,0 mm)
153 1 / Disc Skive
165 1 / 8all bearing Kugleleje
177 1 / Bevel gear wheel Konisk Iandhjul
189 1 / Feder
190 1/ Castle Kronern0Irik
200 1 / Spllt l Split
212+ 1 / Housing Hus
224 2/ SIud Tap
236 2/ Pln 8 1ift
248 1 / Plug
261 1 / Plug Prop
273 1 / Axle journal AkseJIap
285 1 / Bush 8esning
297 1 / Beve l gear wheel Konisk tandhju l
320 1 / Wear disc Slidskive
332 1 / feder
393 1/ Synchronizing motor Synkromiseringsmo!or
403 1 / Governor, Europa AegulaIor, Europa

( 72050 rpm) (72050 rpm)
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs~ side 500.50.
= Only aal l ab l e as part of a spare parts klt. tilgrengelig som en del af et reseredelssrel.
QtyJE = QtyJEnglne AnIal/E = Anlal/Molor
06.44 - ESO
Plale
23/30
021 -~ l - - - - 104
For governor, , _-- 116

see special 439
instruction book
!!!/-\...--- 153
@ - - 165
189 f
190
177
033
200 ~
045

o~ 224
212+ - ___
057 ~
~~~~ 236
~ 273
r:t:-- 248
261
~ 285
flm,1WJ:;(, 297
" ,,-,, "Sh _ - 307
332
320
06.32 - ESO
Plate
23/30
Item Item
. Designation Benrevnelse . Designation Benre vnel se
021 1 / Synchronnlzlng Synchroniserings- 320 1 / Wear di sc Slidskive

motor motor
332 1 / " Feder
033 1/ Plug sc rew Propskrue
439 1/ Governor Regulator
045 1/ Gasket Pakning 900 rpm 900 rm
057 4/ NuI Motrik

+ Item . 212 requIre + Ilem nr. 212 krrever
069 21 Stud Tap Indlvldu al match- individual tilpasning
Ing (by sh Ims) before (med shims) for monte-
070 1 / O-rl"g 0-"9 mountlng, co ntact, ring, konlakt B&W,
B&W. Hol" by Holeby.
082 1 / Castle nut Kronem01rik
094 1 / Spllt l Splil
104 1 / Shutdown Shut-down

solenoid spole
116 1 / Governor Regulator

72050 rpm 72050 rpm
128 4/ Screw Skrue
141 1 / Shlm (set 0,1 - Mellemlreg (scet 0,1 -

0,3 - 0,5 -1,0 mm) 0.30,51,0 mm)
153 1 / Dlsc Skive
165 1 / BaII bearlng Kugleleje
177 l Bevel gesr wheel Konisk tandhjul
189 1 / " Feder
190 1 / Castle KronemoIrik
200 1 / S l Split
212+ l Hou slng Hus

224 2/ Stud Tap
236 21 l 8Iift
248 1 / Plug Prop
261 1/ Plug Prop
273 l Axle journal Akseltap
285 1/ Bush Bosning
297 l Bevel gear wheel Konisk tandhjul
307 1 / Gear whee! Tandhjul
When ordering spare parts, see a/5o page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
Only aval lable as part of a spare parts klt. tilgrengelig som del af et reservedels$Get.
OtyJE = OtyJEngine Antal/E = Antal/Motor
06.32 ESO
DieseII
Plate
23/30
For actuator,
see speciaI
instruction book
116
141
~>---- 153
~ 165
189 ~ 177
190
033
200 ~
045
o~ 224
212+
057 ~
069 ~ .. -r-~""1 ~ 236
070 ~
082
1
~
1:261 248
273
285
f!{J!:;; 297
~- 307
332
320
06.45 - ESO
"J,I,tHiI MAN DieseI[
Plale
23/30
Item Item
. Deslgnatlon Benatvnelse . Deslgnation B e B
033 1 / P/ug screw Prop skr e 320 1/ Wear disc Slidskive
045 1 / Gasket Pakning 332 1 / Key Feder
057 4/ Motrik
+ Item .212 requlre + Ilem nr. 2 12 krcever
069 2 Stud Tap an individual match- individual Iilpasning
ing (by shims) before (med shims) for rnon-
070 1 / 0-rln9 0-rln9 mounting, con tac t, tering, kontakt
Diesel /5 . D S l A/S.
082 1 / Castle nut Kronemolrik
094 1 / Spllt l SpliI
116 1 / Actuator Akluator
128 4/ Screw Skrue
141 1 / Shim (set 0,1 - Mellemlc:eg (s;:eI 0, 1 -

0,3 -0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)
153 1 / Disc Skive
165 1 / Batl bearing Kugleleje
171 1 / Bevel gear wheel Konisk landhjul
189 1 / Key Feder
190 1 / Cast/e nut Kronemolrik
200 1 / Spllt l Split
212+ 1 / Housing Hus
224 21 Stud Tap
236 21 l Stifl
248 1 / Plug Prop
261 1 / Plug Prop
273 1 / Ax le Journal Akseltap
285 1 / Bush B05ning
297 1 / Bevel gear wheel Konisk Iandhjul
When ordering spare parIs, see also page 600.50. Ved bestiJling af reservedele, se ogsf side 600. 50.
= Only ava llable as part of a spare parts klt. tilgrengeHg som del af et reservedel sseI.
QtyJE = QtyJEngl ne AnlaVE = Antal/Molor
06.45 ESO
l~H!'lMAN DieseI!
Plate
Page 1 (2) ReguIating Deice 50902-06
23/30
015 ~ / Goernor a t e 50901
027 ----- ~~ 064
-------
::: --~~~
.
052 ?t~:
088 --.// .
111 ~ /
123 - /
076
135 ---.-/
147
159
160 /
11 R
~ 243
064
172 -
184 - / ;,.
' ...._~_
11
196 ---// / / , 255
206 ~'! . .!~~ 267
218 -
231 /1- " ~ 027
279
08:52 ~ ~ 280
040 / ~ 292
- -~.
302
363 ~
375 ~~, '-- _____ 326
, ""-- 351
~see
am 10
bda controller
plate 509
387
i - / 338 745
314
~~::
. ~ 422
399 /' 757
409 769
410 , 434
/ '-- 446
~
o . ~ 458
483 ~ '" 471
495
530
U 542
<!:r--'---.. 554
L-j::;;;J~ --- 566

578
06.45 - ESO
f,J,J,@II'fMANDieseII
Plate
50902-06 Regulating Device Page 2 (2)
23/30
Item Item
. Qty. Deslgnatlon Benrevnelse . Qty. Deslgnatlon Benmvnelse
015 1/ Screw Skrue 338 1/ Stop ring SIopring
027 2/ Locklng plate LlIseblik 351 1/ Screw Skrue
039 1 / Governor arm RegulaIorarm 363 1/C Linkage Le n ke led
040 21 Spllt l Split 375 1/C Spllt l Slil
052 21 5elf locking ! Se lvlfse nde moIrik 387 1/C n 51 "
064 21 Screw for ball head Skrue for kuglehoved 399 1/C Pln 51
076 1/ Sprlng loaded ll Fjederbelastet t rek - 409 1/C Sprlng arm Fjederarm
rod, complete stang, komplet
410 1/C Spring Fjeder
088 21 ll rod head Trcekslangshoved
422 3/C Spring n Fjederstift
111 1/ Splt SpliI
434 1/C Armholder Armhotder
123 1/ Pull rod end Trcekslangsende
446 1/C Screw Skrue
135 1/ Cylindr/cal ln Cylind risk 51ift
458 1/C Bushing Bosning
147 1/ Spring housing Fjederhu5
471 1/C Bearing bracket Lejebfik
159 1/ Po/nted screw PinoJskrue
483 21C Spring Fjederstift
160 1/ Spring Fjeder
495 21C Screw Skrue
172 1/ Cylindrical Cylindrisk sllft
530 21 Screw Skrue
184 1/ Gulde rlng Styrering
542 21 Screw Skrue
196 1/ Guide ring Styrering
554 21 Washer Skive
206 1/ rod Traakslang
566 21 Nut Molrik
218 1/ ! Molrik
578 1/ Bracket Konsol
231 1/ Locking plate Lfseb lik
745 1/ Regulating shaft, Reguleringsa ksel,
243 1/ Arm Arm 6 cyl. engine 6 cyl. motor
255 1/ Spri ng FjedersIifI 757 1/ RegulatIng shaft, Reguieringsaksel,

7 cyl. englne 7 cyl. motor
267 1/ Screw Skrue
769 1/ Regulatlng shaft, ReguleringsakseJ,
279 1/ GuIde l SIyrestift 8 cyl. engJne 8 cyl. molor
280 1/ Screw Skrue
292 1/ Bearing Leje
302 1/ Bu shIng 80sning
314 1/ Regulating shaft, Reguleringsaksel,

5 cyl. engJne 5 cyl. moIor
When ordering spare parts, see a/so page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
Only avallab/e as part of a spa re part klt. tilgaangelig som en del af et reservedelssaat.
QtyJE Qty./Engine =
l/ Antal/Motor
QtyJC QtyJCyllnder AntaVC = Antal/CyIinder
QtyJR = QtyJRegulating device AntaVR = Antal/ Reguleringsmekanisme
06.45 - ESO
, ~'H:'!IIIMAN DieseII
Plale
Page 1 (2) ReguIating Device 50902-07
23/30
015 ~ / Governor PIate 50901
027 - - - - -'tlJ/ , 064

y~~
039 - - - - -
040 --~"I?'
052 ! ~\
088 - /
111 /
.
123 ~
076
135 ----./ ~
147 - -'
159 - ~
160 / '
172 ~ 064
184 ~//,- 243
20;18 196~~ ' ~

~ ~:;
231
088 ~~ /~~' . l~~ 279
052 -
040 J
~ 280
292
363 ~~
302
375 ~/ ~ 326
Lambda controIIer
see pIate 5091
387 ~ / 351
/~A
~''> ~ "--- 422
338 314
399
409 ~ 745
757
410 ' ~"'-- 434 769
446
483 --~
,-- - '" " 458
471
495 ---------
530
U
@r--'~ 554
542
566
'---'- - 578
06.45 - ESO
I,,l$'MAN DieseI[
Plate
50902-07 ReguIating Device Page 2 (2)
23/30
Item Item
. aly. Deslgnatlon Bencevnelse . aly. Deslgnatlon Benmvnelse
015 l Screw Skrue 338 l Stop ring Stopring
027 21 Locklng pIate L~sebJik 351 l Screw Skrue
039 1/ Governor arm Regulatorarm 363 1/C Linkage Lcenkeled
040 2/ Splll pln Splil 375 1/C Splll pln Split
052 21 5elf locking Selvlasende melrik 387 1/C Stifl
064 21 Screw for ball head Skrue for kuglehoved 399 1/C Pln Stjfl
076 1 / Sp rlng loaded l FjederbelasleI trrek 409 1/C Spring arm Fjederarm
rod, complete 51an9, komplet
410 lIC Sprlng Fjeder
088 21 U rod head Trreksrangshoved
422 3/C Spring Fjederstift
111 1/ Split Split
434 1/C Armholder Armholder
123 1 / U rod e nd Trrekslangsende
446 1/C Screw Skrue
135 l Cyllndrica l Cylindrisk stif!
458 1/C Bushing Besning
147 1 / Sprlng houslng Fjederhus
471 1/C Bearing bracket Lejeblik
159 1/ Polnted screw Pinolskrue
483 21C Sprlng l Fjederstift
160 1 / Spring Fjeder
495 21C Screw Skrue
172 1 / Cyllndrlcal l Cylindrisk slift
530 21 Screw Skrue
184 1/ Guide ring SIyrering
542 21 Screw Skrue
196 1/ Gulde ring Styrering
554 2/ Washer Skive
206 1 / ll rod Trcekstang
566 21 l r k
218 1/ Nul Motrik
578 1/ Bracket Konsol
231 1/ Locking plate LAseblik
745 1/ Regulating shaft, Aeguleringsaksel,
243 1 / Arm Arm 6 cyl. englne 6 cyl. motor
255 1/ Sprlng Fjederslifl 757 1/ RegUating shaft, Aeguleringsaksel ,

267 1/ Screw Skrue
769 1 / RegulatIng shaft, Reguleringsaksel,
279 1/ Gulde Styrestift 8 cyJ. engine 8 cyl . motor
280 1 / Screw Skrue
292 1/ Bearlng Leje
302 1/ Bushl ng 80sning
314 1/ Regulating shaft, Reguleringsaksel,

When orderlng spare parts, see also page 500.50. Ved beslilling af reservedeJe, se ogs:' side 500.50.
= Only avail able as part of a spare part klt. ti lgengelig som en del af et reservedelsset.
aly./E OtyJEnglne AntaIIE = AntaVMotor
alyJC OtyJCylinder Antal/C = AntaVCylinder
alyJR OtyJRegulating device AntaVR = AntaVReguleringsmekanisme
06.45 ESO
Plale
Page 1 (2) Overspeed Device 50903-02
23/30
D ______ ~~~
~_ _ _ 034
s-_ - - - - 046
~ ~ 058
~~ 071
~ ?fj- ~~~
095 ---11 ?; 117
-i3~ 1 29
r 130
142
178J~ ~)~
' 154
191 -:../ 166,524
ID-- 201
500 -~ ~, ______ 213
237
~ ~ 225
249 . 262 ~
250 274 >-~

y_~;;:;;;;;;;~
286
512 489
~ 490
[-mt
06.45 - ESO
f,II@lIiMANDieseII
Plate
50903-02 Overspeed Device Page 2 (2)
23/30
Item Item
. Oly. Deslgnation Benrevnelse . Oly. Deslgnation Benrevnelse
010 1/ Socket Muffe 345 l Spring Fjeder
022 l Button Knap 357 l Button Knap
034 l Spring / FjedersIift 369 l Nipple l
046 1/ Sprlng Fjeder 370 l Spindle Spindel
058 4/ Screw Skrue 382 1/ Sprlng (Iefl) Fjeder (vensIre)
071 1/ Screw Skrue 394 l Splnd le Spindel
083 1/ Cover Dreksel 404 21 Washer Skive
095 l Spindle SpindeI 416 21 Screw Skrue
105 1/ Spring n Fjederstift 428 1/ 8all bearing Kugteleje
117 l Cyllndrlcal Cylindrisk 51jft 441 l Elastic coupling Elastisk kobling
129 l Arm 453 1/ Spring (rlght) Fjeder ( hjre )
130 1/ Screw Skrue 465 1 / l attachment Ventlhold e r
142 l Flywelght houslng Hus for svingvcegt 477 4/ Screw Skrue
154 1/ Adjustlng screw Justeringsskrue 489 1/ Pneumatic l Pneumatisk ll
166 1/ Sprlng Fjeder 490 l Silencer Lyddremper

72050 rpm 720 50 rpm
500 1/ Overspeed device, Overs e ed anordning,
178 1 / Clrclip Sikringsring complete koml eI
191 1 / Flywelght Svingvregl 512 1/ Spare parts kit for Reservedelskit for
item 489 item 489
201 1/ Key
213 1/ 8all bearing Kugleleje 900 rpm 900 rpm
225 1/ Housing Hus
237 1/ Cover O e k se l
249 4/ Washer Skive
250 4/ Screw 8 krue
262 l l 81
274 1/ Lever Arm
286 l Nul Motrik
333 1/ Spindle Spindel
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
= Only ava il able as part of a spare parts klt. tilge ngeli g som en del af l res erve d e l ssel.
Oty./E = OtyJEngine Antal/E = Antal/Motor
06.45 ESO
'i( DieseII
Plale
Page 1 (2) Instrument PaneI 50905-07
23/30
417 202 202
143
322
310
192 .---- 214
765
00
o
309
202 192
299
180 753
179
263 226
167
226 ---:9,'t;i ~:Jt::::;- 287
238
251 287 334

346
275 704
- 358
716
238 334
358 ---- 155
371
F)r 728
()
" "
/ 741
11'-; -'
L fresh water, inlet 10 air cooler

1 0 fresh waler, l engine
1 2 1 /22 Lubricating l , inletloullel 10 fjller
23 Lub. l , l 10 turbocharger
31 Charge air, outlet from cooter
40 Fuel l , inlet 10 engine
96.29 . ESOS-G
',I,l.f DieseI!
Plate
5090 5-07 Instrument PaneI Page 2 (2)
L23/3 0
Ite m Item
Qty. Deslgnatlon Bencevnelse Qty. Designation Benrevnelse
143 1/ Hou slng for Hus for 704 4/ Sc rew Skrue

In strument panel insIrumenIpanel
716 4/ Serrated lock washer SIjernefjederskive
155 1/ Bracket for Konsol for
in strument l instrument-panel 728 21 Screw Skrue
167 4/ Rubber clutch Gummikobling 741 2 Serrated Jock washer Sljernefjederskive
179 8/ ! Motrik 753 8/ Screw Skrue
180 8 Spring Jock Fjederskive 765 1 / Side ptate Sideplade
192 21 Pressure gauge Manomeler 417 1 / In strument panel, Jnslrument paneJ,

0-3 bar 0-3 bar complete komptel
( 31 and Pt 23) ( 31 og 23)
602 ) 31 Pressure gauge Manometer

0-6 bar 0-3 bar
( 01 , 1 10 , ( 01, 1 10,
21-22) I 2 1 -22)
--
~- 1i E Press ure gauge Manometer

0-10 bar ( I 40) 0- 10 bar ( 40)
226 6/ NeedIe valve Naleventil
238 1 / 3-way valve for 3-vejsvenlil for

1 21 -2 2 12 1 -22
251 1 / Was he r Skive
263 1 / Plpe
275 1 / Angle l Vinkelforskruning
287 21 Stralght Ligeforskruning
299 21 Pressure gauge ho se Manometer slange

140 mm 195mm
309 21 Pressure gauge hose Manomeler slange

195 mm 140 mm
310 21 Pressure gauge hose Manometer slange

340mm 300mm
322 61 Packlng rIng Pakningsring
334 21 Reduction Aeduklion
346 1 / Damper (fuel ) Dremper (fuel !)
358 21 Coupling for Kobting for

manometer manometer
371 1 / Damper Dremper

(chargJng alr) (ladeJufl)
When orderlng spare paris , see aJso page 500.50. Ved bestilling af reservedete, se ogsa side 600.50.
On ly avalJable as part of a spare parts klt. litgrengelig som del at el reservedelssret.

QtyJE Qty./Englne Antal/E = Antal/Motor
96.29 - ESOS-G
!+l$M MAN DieseI!
Plate
23/30
417 202
310
143
192 214
309
202 192
299
179-180
167 155
287
226
QQ Q
238
251
QQ QQ
334 334
263 371 346
275
287 358 358
98.35 - ESOS-L
I,I,HM'fMAN DieseI!
PlaIe
50905-11 Instrument PaneI Page 2 (2)
23/30
Designation Benmvnelse Designation Ben re vnelse
143 / Hou slng for HU5 for 395 4/ Lock was her LCses kive
instrument panel inslrument pa nel
417 / Instrument panel, Inslrument paneJ,
155 / Bracketforinstrument Konsol 'or instrument complete, 23/30 komplet, L23130
panel 23/30 panel, L23130
167 4/ Rubber clutch Gummikobling
179 M0trik
180 8/ Sprin g locks Fjedrende skive
192 2/ Pressure gauge 03 Manometer 0-3 bar

bar ( 31 and 23) ( 31 09 23)
202 31 Pressure gauge 0-6 Manom el er 0-3 bar,

bar, 01 , 10, 01 , , 1 2 1 -22
21-22
214 / Pressure gauge 0 10 Manometer 01 bar

ba r (I40) (I40)
226 6/ Needle valve l l l
238 / 3-way valve for 3-vejsvenIil for

121 -22 1 2 -22
251 / Washer Skive
263 / Steel plpe SI{tlro(
275 / Screwed connection Forskruning
287 2 Unlon Forskruning
299 2/ Pressure gauge hose ManomeIer slange

140 mm 140mm
309 2/ Pressu re gauge hose ManomeIer slange

195 mm 195 mm
310 2/ Pressure gauge hose Manometer slange

340mm 340mm
334 2/ Reduction ad apter RedukIionsforskruning
346 1 Damper (fue l 01 1) De mper (fuel l)
358 2/ Coupling for m ano Kobling for manomeIer

meter
371 1 / Damper De m per

(charglng al r) (Iadeluft)
383 4/ Screw Skrue
When ordering s pare parts, see also page 500.50. Ved beslilling af reservedele, se ogs:' side 500 .50
Only ava IIa ble as part a s pare parts ki IilgrengeHg som en del af re se rved e l ssel.
QtyJE QtyJEnglne. Qly./E AntalJMoIor
98.35 - ESOS-L
:,!II DieseII
Plate
23/30
49 07 06 07

19
17
18 07 08
L),. 48
16
07 06
15
05 47
04
03 12 09
09 14
10 l
11
/ 14 20
13
~ 43
21

22
44

'' 10 20
22 02
------ 23 -'
fi
:>
45 -' -'
46
~ , -'
00
q
~
~ L fresh water, inlet cooler

'"
,
10 fresh water, l engine
; 12 1 /22 Lubricating l, ll 10 filIer
~
23 Lub. l , inlet 10 turbocharger

iii 31 Charge . outlet from cooler
40 Fuel l , inlet 10 engine

5 0 .cool. l, l t 10 fuel valves
00021 ,ESO
Plate
50905- 1 2 Instrument Panel Page 2 (2)
23/30
Itern Item
aty. Design atIon Be nrevnelse Qty. Des lgnation Benrevnelse
1 / Housln g 10r Hus 23 t /E Damper (charging alr) O;:emper (ladelufI)

Instru ment pa nel inslrument pal1el
43 4/ Screw Skrue
02 1/ Bracket fo r l for
instrument panel inslrumenl panel 44 4/ Serrated lock washer Stjernefjederskive
03 4/ Ru bber clutch Gummikobling 45 21 Screw Skrue
04 8/ Molrik 46 21 Serrated iock washer Stjernefjederskive
05 81 Sprlng lock Fjederskive 47 81 Screw Skrue
06 2/ Pressure gauge ManomeIer 48 1 / Side plate Sideplade

03 ba r 0-3 bar
( 31 and 23) ( 3 1 og 23) 49 1/ Instrument panel, InsIrurnenl panel,
complete kompleI
07 4/ Pressure gauge Manomeler
06 bar 0-3 bar
( 01 , 110 , 50, ( 0 1, 110 , 50,
21-22) I21-22)
06 1/ Pressure gauge Manometer

0-1 0 bar ( 40) 0-10 bar ( 40)
09 7/ Needle l Nflll
10 1/ 3-way l for 3-vejsventil for

21-22 21-22
11 1 / Washer Skive
12 1/ Pipe
13 1/ Ang le / Vinkelforskruning
14 2/ Straight l Ligeforskruning
15 21 Pressure gauge hose Manometer slange

195 mm 195 mm
16 21 Press ure ga uge hose Manomeler slange

140mm 140mm
17 21 Pressure gauge hose Manomeler slange

300 mm 300mm
1 1/ Pressure gauge hose Manometer slange

340 mm 340mm
19 7/ Packlng ring Pakn ingsring
20 21 Reductlon Aeduklion
21 1 / Damper (fuel 011) Dremper (fuel )
22 21 Coupting fo r mano- Kobfing

meter manomeler
When orderin g spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
= On ly avallable as part of a spare parts klt. tilgrengelig som en del af et reseredelssret.

QtyJ E = Qty.lEngIne AnlallE = Antat/Molor
00.2 1 - ESO
Plate
Page 1 (2)
Instruments 50907-17
23/30
Fig. and Description Range Code Item .
0-8 bar PSL 22 012

L 10
L22
6-18 bar L 70 024
Pressostate

L 10 2m 061
5m 073
2m 085
5m 097
8m 107
12 2m 119
TSH 12 5m 120
22 8m 132
TSH 22
Thermostate
0.2-2.5 bar 21-22 144
[ ]
43-40
~
~
.;
"
~
~
~
~ gJ
i
9

'"
"'"
" Difference Pressostate
07.45 - ESO
150907 -17 Instruments Plate
Page 2 (2)
L23/30
Fig. and Description Range Code Item .
0-4 bar 31 156

r
r- - 0-6 bar 10 168

0-10bar 22 181
40

'-- -
0- 16 bar 70 203

~
U~
Pressure Transmitter
~
Need)e Valve with 3/8' thread 239
r
r-
Needle valve with 1/2' thread 240
~ ~(I~
\J ~
Needle Valve
10
-

-

1-10 bar L 40 048
11
I.U.nJ
LJ
Pressostate
07.45 - ESO
Plate
Page , (3) Thermometer IS0907-09H
L23/30
Scale Length Item

Fig. Code
F C L1 .
40-240 0-120 110 100 252
02
31
40-240 0-120 11 0 63 22 264

20
R
1J
~
40-600 0-300 150 100 30 276
. L1
.1
40-400 0-200 110 40 40 288
51
r-- 40-220 0-120 110 100 03 311
i
10
11

'- LH

e L1
.-----'

L.. ~
04.11 - ESO
150907 -09 Thermometer
Plate
Page 2 (3)
L23/30
Scale Length Item

Fig. Code
F C L1 .
~ 100-
@
1300 50-650 100 115 60 323
r--T'------.
\- 1
1
'--
,..., -
335~ Pocket 115 335
100-
1300 50-650 65 215 61 347
~
@ =
ru
-
359-
@
Pocket 215 359
04.11-ESO
',N@,'''iMANDieseII
Plate
Page 3 (3) Thermometer 1 50907-09
23/30
Scale Lenglh Ilem

Fig. Code
1 .
120-1200 50-650 140 215 61 360

372~,---
62
r----
F,II" =-
L-,"H'=---'l~J--')
1 Thermo-
meler 372
384 Feeler
396- t L1 ~ NiCr- Ni 384
Pockel 100 396
120-1200 50-650 165 115 60 406

43 1~
120-1200 50-650 190 115 60 418
J)1 r ~
-
(~ ~>~
Q=\
11 ....J
')43
'-
- J 1=
L-L JI
....J
Feeler
NiCr-Ni 431
'"
v
i';
~
-
The rmo-
~
meler 443
i
:1
""
455- 1 L1
~ Pockel 200 455
04.11 - ESO
Plate
Page 1 (1) Pick-up 1 50908-02
23/30
Length Item
Fig. Range Code
Lmm no
J: 1 81 Working temp. SE 90 018
1 F==='
-25"C - 70"C
]
r
<>
'"
[[
Cabel length: 3
~ .
r
"---.J
1==
f=
0 - 1 kH z 55 SE 89 031
Pick-up
101 SE 90-3 043
,J

: ~
0748 - ESO
Mi'.{MAN DieseII
Plate
Page 1 (2) Lambda ControIIer 50910-02
23/30
__________________ _ _ _ J
_
D'
, ,
019

020

032

~
<
a"
v
~
:!;
"
"
97.14 - ESQS
Plate
50910-02 Lambda Controller Page 2 (2)
23/30
Item Ilem
. Qty. DesJgnation B e n a: vn e l se . Qty. Deslgnatlon Benrevnelse
019 1 / RegulaIing arrn, Reguleringsarm,

complete komplel
020 1 / Pick-up, Pick-up.

Incl. sleeve incl. afstandsrrng
032 1 / Lambda cylinder, Lambdacylinder,

complete komplet
When ordering spare parts, see also page 500.50. Ved bestilling af r8servedele, se ogs~ srde 500.50.
On ly availabIe as part a spare parts kit. u tilgrengelig sr en del af el reservedelssret.

QtyJE = Qty.JEngine Antal/E = Antal!Motor
97.14 - ESOS
',ll$%. MAN DieseII
Plate
Page 1 (2) PreIubricating AIarm ( 25) 50919-01
23/30
r
J 018
031
1 r
043
(,
- -~ - ~
, Switch t
~!
' -
,,~ 055
-.J
07.11 - ESO
l
50919-01 Prelubricating l Alarm ( 25) Page 2 (2)
23/30
Item Item
. Qy. Deslgnation Benm vnelse . Qty. DesIgnatlon Bencevnelse
018 1/ Plug screw Propskrue
031 / Packing ring Pakningsring
043 1/ Loctite 577 LocIile 577
055 1 / L l switch Niveauafbryder
When orderlng spare parts, al50 page 500.50. Ved bestilJing af reservedele, se ogsf side 500.50.
= Only available part of a spare parts klt. Iilgc:engelig som en del af reseredelssa3t.
QtyJE = aIyJEngine AnIaVE = Anlal/Motor
07. 11 -ESO
Plale
Page 1 (2) LeveI Switch Sump (LAULAH 28) 50920-13D
L23/30H-7201750RPM
694
~~ ----
,..!.i
574
rf'Tl ..'- ----
l---- 562
586 r:: ;: ~ 669
621 ~ 670
~ ~_ 580
550 812
PIate
50920-13D LeveI Switch Sump (L 28) Page 2 (2)
L23/30H-7201750RPM
Item Ilem
. Qty. Designation Benaavnelse . Qty. Designation Benrevnelse
550 t/E for l ee l alarm Gehause,

Alarmeinheit
562 2/ Aange Ransch
574 8/ ! Mutter
580 2/ Red. adaptor Re d uz i e rs Uc k
586 2/ ! Mutler
598 2/ Gasket Dichtung
608 1 / Pipe Leilung
621 t/E Plpe Leitung
633 1/ Leve! switch Niveaualarm
645 2/ PIug screw Stopfen
657 2/ Gasket Dichtung
669 2/ Gasket Dichlung
670 81 Screw Schraube
682 1/ LeveI alarm, complete Alarmeinheit

kompletI
694 2/ Connector conneclore
812 1/ Level switch Niveauaiarm
When ordering spa re parts, see al50 page 500.50. Ved beslilling af reservedele, se ogsA side 500.50
Only avallable as part a spare parts kit. u tilgcengelig som en det af el res ered e l ssaa I.
Qty.lE QtyJEnglne aty./E Antal/Motor
QtyJI QtyJlndlvJdual aty.ll AntaVIndividuel
llJ Dieserl
PlaIe
Page 1 (2) LeveI Switch n Sump ( 28) 50920-13
L23/30H-900RPM
454
501 --t:"
07.18 - ESO
"lJ,MAN DieseII
Plate
50920-13 LeveI Switch Sump ( 28) Page 2 (2)
L23/30H-900RPM
Item Item
. Qy. Designatlon Ben ce n e l se . Qy. Designation Benaevnelse
430 4/ Nul MGIrik
442 1/ l 10r level R0r for niveau-

swltch alarm
454 1/ for l ee l for

alarm l eel alarm
491 2/ Red. adaptor Red. adapter
501 4/ Screw Skrue
513 1/ Plate Plade
525 1 / Gasket Pakning
549 2/ L l swltch Nieaualarm
579 1 / 10 level Aor for niveau-

swltch alarm
560 2/ Red. adaptor Red. adapIor
777 l Dipstick, complete PejlesIok, komplet
769 n Loctite 577 Loctile 577
966 1/ ! swltch, Level switch,

complete komplel
961 1 / 0 -rl"9 0- 9
When orderlng spare parts, see al50 page 500.50. Ved bestilllng af reservedele, 5 ogsA side 500.50
Only available part a spa re parts klt. lilgrengelig som en det af el reservedelsscet.
Qly./E Qty./Englne Qly.lE Anlat/Molor
QlyJI = QtyJlndividual Oly./1 Anlal/tndividuel
07. 16 - ESO
'l Dieserl
Plate
Page 1 (2) LeveI Switch n Sump (LL 28) 50920-14
L23/30
454
501
07. 18 ESO
f,J'i DieseI!
Plale
50920-14 LeveI Switch Sump ( 28) Page 2 (2)
23/30
Item Item
. Qy. Deslgnation Benre vnelse . Qy. Designation Benrevnelse
430 21 l M0trik
442 Plpe for level R0r for niveau -

swltch alarm
454 for l l for

alarm l l ala rm
466 1 / PUg s crew Propskrue
478 1/ Packing ring Pakningsring
491 Red. ad aptor Red. adapler
501 4/ Screw Skrue
513 1/ Plate Plade
525 Gasket Pakning
549 1/ Level switch Niveaualarm
580 1/ Red . adaptor Red . adaptor
777 1 / Dipstlck, compl ete Pejlestok, kompleI
789 n Loctite 577 Loctite 577
968 1/ l switch, Level swiIch,

complete ko mplet
981 1 / 0-rln9 0- 9
When orderlng spare parts. see al50 page 500.50. Ved besIilling af reservedele, se ogsf side 500.50
On ly ava ilable as part of a spare parts kit. Kun tilgrengelig som del aI el reserede l $sre l.
Qly./E QtyJEnglne QIy.lE Antal/Motor
QlyJI QtyJIndJvldual Q Antal/lndividuel
07.18 - ESO
Plale
Page 1 (2) LeveI Switch Sump (Dipstick ) 50920-15
23/30
454
501
@
07 .18 - ESO
Plate
50920-15 Level Switch n l Sump (Dipstick only) Page 2 (2)
23/30
Item Item
. Designatlon Benrevnelse . Oeslgnation Benrevnelse
454 1/ for l l '

alarm level alarrn
466 21 Plug screw Propskrue
478 21 Packlng ring Pakningsring
501 4/ Screw Skrue
513 1/ Plate Plade
777 1/ Dlpstlck, complete Pejlestok, komplet
968 1/ Level swltch, Level switch,

comp/ete kompleI
981 1/ 0- "9 0 -rln9
When orderlng spare parts, see also page 500.50. Ved beSlilling af reservedele, se ogsa side 500.50
Only aai l ab l e as part a spare parts kit. u IIgreng e lig som del af ! reseredelssre l.
QtyJE QtyJEnglne Q'y./E Antal/ Molo r
QtyJI QtyJlnd ividuaI Q,y.1I AnIal/ lndividuel
07.18 - ESO
, Dieserl
Plate
Page 1 (2) FueI Leakage AIarm ( 42) 50925-08
23/30
035 023
059
047
1_-- 060
072

084
096 106
07.18 ESO
Plate
50925-08 Fuel l Leakage Alarm ( 42) Page 2 (2)
23/30
Item Item
. Oty. Designation Benrevnelse . Oty. Deslgnatlon Benrevnelse
035 1/ Packlng ring Te lnin gsring
047 1! l evel switch Niveaukontakl
059 l Plug screw Propskrue
060 l Packlng rlng e lnin gsri ng
072 1/ Fuel oll leakagealarm, Bre ndolie Iekage

complete () alarm, kompIet (D)
084 1/ Fueloil leakagealarm, Brcendolie lcekage

compIete (JIS) aIarm, kompIet (JIS)
096 l Instruction pIate Instruklionsplade
106 2JE Screw Skrue
When ordering spare parts , see al$O page 500.50. Ved beslilHng af reservedele, se ogsl side 500.50
OnJy ava llable as part of a spare parts kIt. lilgcengelig som del af et reservedeIssreI.
Oty./E = QtyJEngine. Qty./E = AntallMolor
07. 18 - ESO
l iJ Dieserl
Ptate
Page 1 (2) LocaI Starting - 1 50935-11
23/30

~
OVE'SPEO
O~OO~
"'"
B&W
#20000
300 '
~oooo
0"900 029
~"ooo
I~O~ TC
-8
8
V
ENG.
' """"'cP,,., :/
",
/"
( START STOP Jt.tJ~Ir:!.3.:~)

CAPM
( REMOTE
O
)( OCAL BOCKIN<tJ
~ 017
./
V
07.45 ESO
DieseI!
Plate
50935-11 LocaI Starting - 1 Page 2 (2)
23/30
Item Ite m
. . Designation Bencevnelse . . Oesignation Benmvnelse
017 1 / Pane l Panel
029 1 / Sta rtlng box Starlboks
When orderln g spare parts, see al50 page 500.50. Ved bestill ing af reservedele, se ogsA side 500.50.
= Only availabl e as part of a spare parts kit. tilgcengeHg som del af et rese redelsscet.
QtyJE = QtyJEnigne. Q ty./E = QIy./Motor
07.45 - ESO
Plate
Page 1 (2) Local Starting - 2 50935-12
23/30

~
oYRSPEED

A~
0&- """" CiJ
L(JNLUU,
I PRESS. 300 - 0- 900 029

HQIt HIESII
I.

~"'"
I~O\ C
-~
/
G:NCV
STQP
ENG.
' "'" 08
"'.,
/
/'
~"
( START )( STOP Jt-E.I'J~t:!.~R!:~J

TCRPM
( REMOTE
O
)( OCAL BOCKIN%)
~ 017
/
./
07.45 - ESO
lll$'MAN DieseII
Plale
50935-12 LocaI Starting - 2 Page 2 (2)
23/30
Item Item
. Q. Designation 8encevnelse . Qty. Designation Benrevnelse
017 1/ Panel Panel
029 1/ Starting bo Startboks
When orderin g spare parts, see al50 page 500.50. Ved bestilling af reservedele, se ogsfl side 500.50.
= Only avaJlable as part of a spare parts kit. tilgcengelig som del af l reservedelssret.
QtyJE = Qty./En igne. Qty./E = Qly./Motor
07.45 - ESO
lIlg..'MAN Dieserl
PIate
Page 1 (2) LocaI Starting - 2 (incl. high Iub. temp.) 50935-13
23/30
~
O\IRSPEED ~~~
w R. ooQ20000 30000 40000 ~
IL POSS. 300 - 0-900
HIGH fRESt Q 5<.

010000
WATERTEMP.

EMERGF'NCV
STQP
,40.0
q."
'-b
TC
50000
60000
J
ENG. 1200
fllGH .
QLTEMP.
017
//
07.45 ESO
III'l$'IMAN DieseII
Plale
50935-13 LocaI Starting - 2 (incl. high Iub. il temp.) Page 2 (2)
23/30
Item Item
. Qty. Designatlon Ben;:evnelse . . Deslg nation Bencevnelse
017 1 / Panel Panel
029 1 / sta ng box SlarIboks
When ordering spare parts, see atso page 500.50. Ved bes liring af reservedele, se ogsA side 500.50.
= Only aa ll ab l e as part of a spare parts kit. Kun lilgcengelig $om en del af re servede lss ce
QtyJE = QtyJEn lgne. Qly. /E = Qty./Motor
07.45 ESO
Plate
Page 1 (2) Engine Control 50936-13
23/30
11 _____ 536
345
=
095 u .z 585
573 333
656 644
,,;
404 274
'"
v
~
~ 394 561
142 548
'"
07.45 - ESO
" Dieserl
Plale
50936-13 Engine ControI Page 2 (2)
23/30
Item Ile m
Deslgnation Benrevnelse " Designation Ben cevnelse
095 1 / Safety system, Si kkerhedssyslern,

8ase l Base !
142 1 / Terml nal, earth Jordklemme
274 3/ End stop Endestop
333 1 / Analog Analog

module oulutmodul
345 21 Olgllal Digilal

ou tput mod U e oUpulmodul
394 2JE Fuse terminal Sikringsklemme
404 1 / End plate Endeplade
536 1 / Panel Panel
548 50/ e rmin a l double Klemme, dobbell
561 1 / End plate Endeplade
573 ' / Processor (CPU) Processor l (CPU)
585 '/ ErId cap Endestykke
644 '/ Analog Analog

modu le inputmodul
656 ' / C n vee r Konverter
668 l Cable Kabel
When orderin g spare parts, see also page 500.50. Ved bestilling af reservedele, ogs<\ side 500.50.
Onl y avallable as part of a spare parts klr. tilgcengelig som en del af eI reseredelsscet.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.45 ESO
,,'( Dieserl
Plate
Page 1 (2) TerminaI / S0936-20H /
23/30
619
607 620 250
tY .- ~
!.)'
597 ;;;;;;",
--
'" :2
632 w ..
wwo
703 ~ ~~~~g ~ ~ ~ ~ ~ ;
:

--------~ 274
644
225 668

394 : 1
416 ----- ~
JV
68 1 ~ ~ T~~ ~ 490 477 453 274

536
693
500 489 465 656
07.45 - ESO
PIate
Poge 1 (2) Motor Control 50948-01
General

--;:======::;----,
@ WOODWABD @
h---@-- ---I1=~~ __~

,
--------------------------------------------
98_13 -
f,zlM!:II MAN DieseII
l
50948-01 Motor Controi Page 2 (2)
Generai
Item Item
aty Designation Bencevnelse aty Design ation Bencevnelse
016 1 / motor control motor conlrol
When ordering spare parts, see also page 500.50. Ved beslll ing af rese rvedele, se ogsA side 500.50.
= Only avail able as part of a spare parts kit. litgrengelig som del af l reservedelssceI.
Qty/E = Qty/Engine Qly/E = I/
96.13
PJate
Page 1 (2) Converter 50956-01
General
021
(ftS ... 1 ~
:]
' . ~lSm ~
~~ ~~~ 5

033
045
07.37 - ESO
@" DieseII
Plale
50956-01 Converter Page 2 (2)
GeneraI
Item Item
no Qy Deslgnation Benmvnelse aly Deslgnatlon Benrevnelse
021 11 Coverter Converler
033 1 / Cable, length 1.8 m Kabel, lrengde 1.8 m
045 1/ Cable, length 1 m Kabel , lrengde 10 m
When orderlng spare parts, see al50 page 500.50. Ved bestilling at reservedele, se ogs~ side 500.50.
Only ava ll able as part a spare parts klt. tilgrengelig 5Qm del af el reservedelssret.
Qly/E = Qly/Englne Qly/E = Qty/Motor
07.37 - ESO
Section 510
Crankshaft and Main eags
Description
Crankshaft and Main Bearings 510.01
Working card
Checking Main BearingsAlignment (Dell ection)(Hydraulic Tightened Connecting Rodj 510-01.00

Checking of Main Bearings Alignment (Autolog) 510-01.00
lnspection of Main Bearing Shells 510-01.05
lnspection of Guide Bearing Shells 510-01.10
Vibration Damper 510-04.00
Plates
Crankshaft 51001-04
Coupling for Central Drien Lub. l Pump 51002-01
Resilent Gear Wheel 51002-02
Flywheel with Flexible Coupling and Gear Rim 51002-01
Flywheel with Gear Rim 51002-02
Torsional Vibration Damper 51 004-01
Torsional Vibration Damper 51004-26
Plates
Torsional Vibration Damper 5100433

Tuning Wheel 5100402
f,J+fM1fMAN DieseII
Description
Crankshaft and Main Bearings 510.01
Page 1 (1)
Edition 01
23/30
Crankshaft Vibration Damper
The crankshaft, which is a one-piece forging with l special cases a vibration damper is mounted
ground main bearing and crankpin journals, is sus- the crankshaft ( lmt torsional vibrations. The damper
pended inderslung bearings. The main bearings consists essentially ! a heavy flywheel totally
are equipped with insertion-type shells, which are closed a light casing. small clearance is allowed
coated with a wearing surface. attain a suitable between the casing and the flywheel, and this space
bearing pressure the crankshaft is provided with is fi lled with a highlyviscous fluid. The casing is rigidly
counterweights, which are attached ( the crankshaft connected ( the Iront end the engine crankshaft
by means (w screws. and the l connection between the crankshaft
and the damper flywheel is through the Iluid. Under
At the flywheel end the crankshaft is fitted with a gear conditions ! vibration, the casing and damper
wheel which through an intermediate wheel drives flywheel tend ( rotate as unit, since the force
the camshaft. Also fitted here is the flywheel and a required ( shear the viscous fi lm is consi-derable.
coupling flange for connection ! a reduction gear or As the torsional vibration amplitudes increase, the
an alternator. At the opposite end there is a claw-type casing lollows the movement the crankshaft but
coupling for the lb. l pump or a f l e i ble gear wheel the flywheel tends ( rotate unilormly by virtue !
connection for lb. l and water pumps. its inertia, and relative moti on occurs between the
flywheel and the casing. The viscous fluid film there-
fore undergoes a shearing action, and vibration
energy is absorbed and appears as heat.
96.03 ESOU
Working Card Checking of Main Bearings Alignment (Deflection) 510-01.00
(Hvdraulic Tghtened Connectin~ Rod)
23/30

Stopped engine
Shut-ofl cooling water
Plate no.
520
Item no.
011
Note
Shut-off fuel l 52010 059

Checking ! main bearin gs alignment (autolog).
Slarling posilion:
Turning gear engagement. (11 mounted).

Cover for crankshalt has been removed from
frame.
Relaled procedure:
Working time 1 1/2 hours Plate Item Qty

Capacity 2 men
Dala:

Data lor torqu e moment (Page 500.40)
00.27 - ESO
44' Dieserl
510-01.00 Checking of Main Bearings AIignment (DefIection) Working Card
(Hydraulic Tightened Connecting Rod)
23/30
AIignmen\ Main Bearings. As the crankshafts medium speed engines arevery

stiff, any great deviation s th e aIignment result
he main bearing sheIIs shouId be positioned cIearance at the bottom sheIi th e bearings.
so that they keep the main bearing journaIs the
crankshalt centered a straight (ashore horizon he cause incorrect main bearing position may
taI) . Deviations Irom this centre cause the be wear the bearings misaIignmnet the
crankshaft bend and increase the ioad some engine.
main bearings.
adjacent main beari ngs are pIaced . th e Elfecting he Deflection Measuremen\.

crankshalt centre thi s pIace be iowered
lorm an arc, causing the intermediate crank throw h e delIection measurement is effected by pIacing a
bend such a way that "cIoses" when turned springI oaded diai gauge the centre punch marks
bottom position and ''opens'' position. provided lor this purpose, see l ig. 1.
As the magnitude such axiai Iengthening and "CIosing" the throw dead centre is regard ed
shortening during the turning the throw increases as negative, (compression the gauge).
the difference the height th e
beari ng, is measured as a check th e aIignment the exampIe, page 3, the delIecti on reading is
and condition the bearing. th erelore negative.
'"

for measuring (autolog)
Exisling cenlre punch marks for

measuring (aulolog)
Fg. 1 P/acing da/ gauge
00.27 ESO
23/30
As during the turning the throw, the gauge and the The total dellection (''opening-closing'') the throw
connecting rod ill meet near the bottom position during the turning Irom bottom to top position is
the throw, the measurement lor the bottom position entered lig. 4.
is to be replaced by the average the two near by
positions either side. These ligures are due to vertical misalignment
the main bearings.
The dial gauge is set to , when the crank throw
is the near-bottom ( lig. 8) and during the Similarly, horizontal misalignment procedures the
turning the throw is stopped the position horizon- ligures the table lig. 5.
tal-top-horizontal-near bottom (P-T-S-Y lig. 8) lor
reading the gauge. Besides misalignment the bearings, the readings
can be inlluenced by ovality eccentricity the
journals.
Checking The Deflection Measurement.
The reading is entered the table page 6, see Engines Equipped with Turning Gear.
example lig. 2 - 6.
When taking these dellection readings lor the three
As "bottom" reading is used the mean value the aftmost cylinders, the turning gear should at each
two "near bottom" readings and , lig. 3. stoppage be turned a l ttle backwards to ease 011
the tangential pressure the teeth the turning
wheel as this pressure may otherwise lalsily the
readings.
00.27 ESO
510-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 04
"(Hvdraulic Ti~htened Connectin~ Rod) Page 4 (7)
23/30
Deflection of crankshaft in 1/100 mm. (0.01 mm).

DefJeclion from vertical
misalignment
Cyl. .
l - bottom
Crank position 1 2 3 4 5 6
' = V 2 -1.5 4 4.5 -2 2
BoIIom 51art
Fig.4.
Left side 2 2 -1 2
3 -2 4 5 -2 3
DefJeclion trom hori-
Right side S 3 -2 2 1 zontal misalignment
BoIIom stop 2 -1 1 2 Right side - left side

orpS= -1 2 -1
Fig.2. Fig.5.
1 80IIom (0,5 ) = -0.5 -0.5 Check + = C 4 -2.5 4 5.5 -2 4

gauge
readings + S= 5 -2 4 -1 3
Fig.3.
Fig.6.
C and D should be nearly the same, reading for cylinder 4 to be repeated.
Front end .
Closing" the crankthrow is considered 81art position .
negaIive. Turn anli clockwise
Fig.7. Fig.8.
00.27 - ESO
lHvdraulic Tiahtened Connectina Rod\
23/30
Measurement ! Crank Throw Deflections by Means l Indicator (Autolog)
Crank throw deflection ; Difference dial indicator readings diametrically

opposile crank throw posilions, .. position s dis-
placed 180".
Vertical deflection ; Difference top-bottom readings.
l deflection ; Difference side-side readings.
Vertica f Horizontal Dellections CrankThrows
Unless otherwise stated the values refer cold engine.
For new realigned aggregate Aim for + - 3/100 mm

Acceptable + - 5/100 mm
For aggregate service realignment

is recommended deflections exceed + - 9/100 mm
Vertical Dellection Cran k Throw ! Flywheel
Unless otherwise stated Ihe values refer cold engine.
Rigid coupling between Flexible coupling between

diesel engine and driven machine diesel engine and driven machine
For new realigned For new real igned

aggregate + 3/ 100 mm aggregate Aim for - 9/100 mm
Acceptable - 11/100 mm
For aggregate service realignment is For aggregate service

recommended deflection measured realignment recomme ndable
warm engine exceeds - 9/100 mm deflection exceeds -1 6/100mm
00.27 - ESO
510-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
23/30
Process/Proces 1. 0. .
PlanVAnlceg Page of/Side af
Engine / Engineer/Oeralor DalelDaIo
Instruction/lnstruktion
,
/;J '.,. \
.' ' : 1,
'\
\,
" \
r
, {
~
r t \ !
~ \~\,,i' (~
\ {
\~
\
~ ~ ~ ~
jY
Righl side Left side
\(,i
1/100 mm
(g )
Boltom end/ Bottom starV
Bund slut Bund 51art
Right side Aight side
CyI. 2 3 Cyl. 2 3
Left side Cyl. 2 3
Left side
Aemarks/Bemcerkninger
00.27 ESO
"l DieseII
Working Card Checking of Main Bearings AIignment (Deflection) 510-01.00
23/30
ComponenVKomponent Type 1. 0. .
ProcessIProces Page of/Side af
Tesl place/ Tesl bed/proehal Cold/Kold

Condition
board/Om bord WarmNarm
Testsledl
Tilsland PlantlMaskinhal
Engine .:
Motornr.:
Cyl . . 1 2 3 4 5 6 7 8 9
8oltom
Left side
Righl side S
Botlom V
Botlom
(0.5)=
Deflection from
vertical misalign-
menl.
- bottom
orT - = V
Deflection from
horizontal mis-
alignment.
Left side - Right
~ sideorP-S = H
~
~~
'-

~ readIngs.
~ += C
~
+ S=
00.27 - ESO
Page 1 (6) Checking of Main Bearings Alignment (Autolog) Edition 05
L23/30
SafeIy precautions: Special lools:

11

Stopped engine
Shutoff starting air
Shutoff cooling water
Plate no.
52010
Item no.
011
Note
Shut-olf luel l 52010 059

Shut-off cooling l
Descriplion:
Checking main bearings alignment (autolog).

Hand lools:
Slarting posilion:
Turning gear engagement. (11 mounted).

Cover lr crankshalt has been removed Irom
Irame.
Relaled procedure:
Working time 1 1/2 hours Plate Item Oty

Capacity 2 men
DaIa:

01.46 ESO
$%'" Dieserl
Edilion 05 Checking of Main Bearings AIignment (AutoIog) Page 2 (6)
L23/30
AlignmenI Main Bearings.
The lower main bearing shells should be positioned

so that they keep the main bearing journals the
crankshaft centered a straight (ashore horizon-
tal) l. Deviations from this centre l ne cause the
crankshaft bend and increase the load some
main bearings.
If w adjacent main bearings are placed low, the

crankshaft centre l ne w ll this place be lowered
lorm an arc, causing the intermediate crank throw
bend such a way that "closes" when turned
bottom position and ''opens'' position.
Fig 1. PIacing { dial gatIge.
As the magnitude such axial lengthening and
shortening during the turning the throw increases
the difference th e height th e Checking The DeffecIion Measuremenl.
bearing, is measured as a check th e alignment
and condition the bearing. The readi ng is entered the table page 6, see
example fig. 2 - 6.
As the crankshaitsof medium speed engines are
stiff, any great deviations the alignment w ll result As "bottom" reading is used the mean value th e
clearance at the bottom shell the bearing s. w "near bottom" readings and , fig. 3.
Th e cause incorrect main bearing position may The total deflection (''opening-closing'') the throw
be wear the bearings misalignmnet the during the turning from bottom position is
engine. entered fig. 4.
These figures are due vertical misalignment

EffecIing The DeflecIion Measuremenl. the mai n bearings.
Th e deflection measurement is effected by placing a Similarly, horizontal misalignment procedures the

springloaded dial gauge th e centre punch marks fi gures the table fig. 5.
provided this purpose, see fig. 1.
Besides misalignment the bearings, the readings
"Closing" the throw dead centre is regarded can be influenced by ovality eccentricity th e
as negative, (compression the gauge). journals.
the example, page 3, the deflecti on reading is

th erefore negative. Engines Equipped wiIh Turning Gear.
As during the turning the throw, the gauge and the When taking these deflection readings the three
connecting rod wll meet near the bottom position aftmost cylinders, the turning gear should at each
the throw, the measurement the bottom position stoppage be turned a l ttl e backwards ease off
is be replaced by the average the w near by the tangential pressure the teeth the turning
positions either side. wheel as thi s pressure may otherwise falsi fy th e
readings.
The dial gauge is set , when the crank throw
is the near-bottom ( fig. 8) and during the
turning the throw is stopped the position horizon-
tal-top-horizon tal-near bottom (- T-S- fig. 8) lor
reading th e gauge.
01.46 - ESO
Page 3 (6) Checking of Main Bearings A/ignment (Aut%g) Edilion 05
23/30
Deflection crankshalt in 1/100 mm. (0.01 mm).

OefIection from verlicaII
misalignmenl
Cyl.No.
Crank posilion 1 2 3 4 5 6
- bottom
-= V 2 -1.5 4 4.5 -2 2
8ollom slarl
Fig4.
Left side 2 2 -1 2
3 -2 4 5 -2 3
Oeflection Irom hori
Righl side S 3 -2 2 1 zonlal misalignment
Bollom stop 2 -1 1 2 Left side - right side

orP-S= -1 2 -1
Fig2. Fig5.
BoIlom (0,5 ) = 8 -0.5 0.5 Check + 8= C 4 -2.5 4 5.5 -2 4

gauge
readings + S= 5 -2 4 -1 3
Fig3.
Fig6.
C and D should be nearly Ihe same, reading lor crank throw 4 10 be repeated.
~
S(Lo~p

(g;
)
Front end view.
Closing the crankthrow is considered Slart in position .
negalive. Turn anti clockwise
Fig 7. Fig8.
01.46 - ESO
Edilion 05 Checking of Main Bearings Alignment (Autolog) Page 4 (6)
23/30
MeasuremenI crank Ihrow deflections by means dial indicaIor (AuIolog)
Crank throw deflection = Difference in dial indicator readings in w diametrically

Opposite crank throw positions, . . w positions dis-
placed 180 .
Vertical deflection = Difference in top-bottom readings.
l deflection = Difference side-side readings.
VerIical and horizonIal deflecIions crank Ihrows
Unless otherwise stated the values refer to cold engine.
For new realigned aggregate Aim for + - 3/ 100 mm

Acceptable + - 5/ 100 mm
For aggregate service realignment

is recommended f deflections eceed + - 8/100 mm
Vertical deflecIion crank Ihrow aI flywheel
Unless otherwise stated the values refer cold engine.
Rigid coupling between Fleible coupling between

diesel engine and driven machine diesel engine and driven machine
For new realigned For new realigned

aggregate + 3/ 100 mm aggregate Aim for - 8/100 mm
Acceptable - 10/100 mm
For aggregate service realignmenI is For aggregate service

recommended deflecti on measured realignment is recommended
warm engine eceeds - 8/100 mm deflection eceeds - 14/100mm
01.46 - ESO
"I,I,'. DieseII
Page 5 (6) Checking of Main Bearings AIignment (AutoIog) Edition 05
23/30
Process/Proces !., .
PlanVAnlceg Page of/Side af
Engine Type/Motorlype Engineer/Operator Oate/Dalo
InsIructIoll/lnsIruklion
1
l----
- ----
-------
-~
~l Rightside

~ ~ leffside
--0- (Q )
1/100 mm
Boltom end/ Boltom startJ
Bund slut Bund slart
-
Righl side Righl side
Cyl. 1 2 3 Cyl.no 1 2 3
I~O~O~O~~ ~o ~~
Left side Cyl. 110 1 2 3
Left side
RemarksJBemcerkninger
01.46 - ESO
' DieseII
Edition 05 Checking of Main Bearings AIignment (AutoIog) Page 6 (6)
23/30
Componenl/Komponent Type 1.0. .
Process/Proces Page ol/Side af
Test place/ Test bedlr0Vehal D ColdlKold

Condilion
D boardlOm bord D Warm/Varm
Teslsledl
i I sIa nd D PlanVMaskinhal
Engine . :
Molornr.:
Cyl. . 1 2 3 4 5 6 7 8 9
Botlom
side
Right side S
Boltom V
BoIIom
(0.5xV)=B
DeIlection from
verlica l misalign-
ment.
botlom
or T =
Defleclion from
horizonIal mis-
alignmenI.
Left s ide RighI
sideor p S= H
"-
readIngs.
+ = C
01 .46 - ESO
Working Card
Inspection of Main Bearing Shells
510-01.05
23/30

11 Shut-off starting air
Shut-off cooling water 52010 106 2 pieces
Shut-ofl luel l 52010 202
Stopped lub. l circul. 52010

52021
52021
155
405
501
2 pieces
Hydraulic tools
2 pieces
52021 513
Description: 52021 202
Dismantling, inspection and!or replacement and

mounting main bearing shells. Hand lools:
Allen key, 12 mm.

Lead hammer.
Slarting posilion: Silastene.
Copaslip.
Relaled procedure:
Inspection guide beari ng shell , 510-01. 1

Criteri a lr replaceme nt bearings, 506-01. 16

Capacity 2 men
Dala:
Data lr pressure and tolerance (Page 500.35)

Data l r torque moment (Page 500.40)
96.30 - ESOS-G
Edilion 01 Inspection of Main Bearing Shells Page 2 (3)
23/30
Make Ready lor Dismantling the Main Bear-

ing
1) Dismount crankcase covers in Iront and

si te the bearing concerned.
2) Turn the engine until the crank is in a conveni-

ent position lor carrying the work.
3) Dismount the bracing screw (side screw).
4) Mount the hydraulic tools and loosen the main

bearing stud nuts. Foroperation ofthe hydraulic tools,
see working card 520-01.05.
Fig 2. Mounting , Wire Straps.
8) Lift the main bearing cap a l l and unscrew

th e bearing stud nut.
9) Fi t guide tubes on the threads the bearing

studs and lower the bearing cap make rest on
the collar the guide tubes.
Dismantling the Main Bearing Shells
1 ) Remove the locking piece Irom the bearing

cap and take the bearing shell.
11) Fit the l main bearing, fordis-mant-

ling main bearing shell, the lubricating
Fig 1. MoulJting of Hydraulic /5.
hole in the crankshaft and turn out the bearing
shell by turning th e crankshaft , see fig 3.
5) Dismount the hydraulic tools and slacken the

nuts somewhat.
Dismantling the Main Bearing Cap
6) Fit the eye screws, diagonally, in the threaded

holes the main bearing cap, see fig 2.
Pass th e supplied through the eye screw and at-

tach as shown, so as to keep the bearing cap in place
l for upper main bearing
when the main bearing stud nuts are removed.
7) Work th e main bearing cap loose from the

engine frame with a lead hammer similar. Fig 3. Mounting of (00/ for upper main bearing.
96.30 - ESOS-G
Working Card 510.01-05
Page 3 (3) lnspection of Main Bearing Shells Edition 01
L23/30
Cleaning 16) Lubricate the end the bearing shells wi th

molycote pasta similar.
12) Clean all machined surfaces, frame, bearing
cap, stud, nuts and bearing shells. 17) Insert the lower bearing shell the bearing
cap and mount the locking piece.
Inspection Main Bearing Shells Lubricate the bearing shell and journal with clean
lubricating l.
13) Inspect the main bearing shells according 10
working card 50.6-0.1.16.
Mounting the Main Bearing Cap
Note: he bearing is marked according 10 size and
when rep/aced l musl be by a new bearing of Ihe 18) Raise the bearing cap position, dismount
same size. the guide tubes, coat the beari ng studs with molycote
pasta similar and the bearing stud nuts.
Mounting the Main Bearing Shells Make sure that the bearing cap and bearing shell
are their correct position.
14) Push the bearing shell as far position
as possible. 19) Dismantle the straps.
15) Fit the l main bearing the l b 20) the hydraulic tools, see working card
ricating hole the crankshaft and turn the 520.-0.1.0.5, and tighten the nuts as prescribed
bearing shell by turning the crankshaft . page 50.0.-40..
Make sure that the shell enters its correct position 21) Coat the back side the bracing screws' (side
then remove the l main bearing. screws') hexagonal head with a thin coat silastene
or similar.
22) the screws and tighten with a torque

spanner as indicaled page 50.0..40.
96.30 - ESOSG
Page 1 (3) Inspection of Guide Bearing Shells Edition 01
23/30
Safely precauIion5: Special 10015:
Stopped engine Plate Item

Shut-off 5tarting air
Shut-off cooling water 52006 273 80 - 360 Nm
Shut-off ul l 52010 106 2 pieces
Shut-ofl cooling l 52010 202
Stopped lub. l circul. 52010 011
52010 155 2 pieces
52021 405 Hydraulic tools
52021 501 2 pieces
De5cripIion: 52021 513
52021 202
Dismantling, inspecIion and!or replacement
and mounting guide bearing shells and thrust
washer.
Hand 10015:
SlarIing 05: Allen key, 12 mm.

Lead hammer.
Silastene.
Copa5lip.
Relaled procedure:
Inspection main bearing shells. 510-01.05

Criteria ' replacement bearing
shells. 506-01.16
Manpower: Replacemenl and wearing part5:

Capacity 2 men
DaIa:

96.20 - ESOS
',l'I@',,,(MANDieseII
Edition 01 Inspection of Guide Bearing SheIIs Page 2 (3)
23/30
Make Ready lor Dismantling the Guide Bea-

ring
1) Dismount the crankcase covers opposite the

bearing concerned.
2) Turntheengine untilthecrank is aconvenient

position for carrying ! Ihe work.
3) Dismount the bracing screw (side screw).
4) Mountlhe hydraulic tools. see fig 1, and loosen

Ihe guide bearing stud nuts. For operation ! the
hydraulic tools, see working card 520-01.05.
Fig 2. Mounting of Wire Straps.
9) Fit guide tubes the threads ! the bearing

studs and lower Ihe bearing cap 10 make l resl
Ihe coIIar ! Ihe guide tubes.
Dismantlng the Guide Bearing SheIIs
10) Remove Ihe locking piece from Ihe bearing

cap and lake th e bearing sheIi.
The thrusl washer ! Ihe gUde bearing is parlially

countersunk l Ihe engine frame and attached by
means ! four screwed-on clamps which are visible
after lowering the bearing cap, see fig 3.
Fig 1. Mounting Hydraulc Tools.
5) Dismount the hydraulic tools and slacken the

nuts somewhat. ThrusI washer
Dismantlng the Guide Bearing Cap
6) Fit Ihe eye screws, diagonally, the threaded

holes th e guide bearing cap, see fig 2.
Pass the w supplied through Ihe eye screw and

attach as shown, so as keep the bearing cap
place when the guide bearing stud nuts are
removed. Fig 3. Guide Bearing with ThrIst Washer.
7) Work the guide bearing cap loose from the

engine frame wi th a lead hammer similar. 11) Unscrew the clamps and push the thru st
washers.
8) Lift the guide bearing cap a lttle and unscrew
the bearing stud .
96.20 - ESOS
Page 3 (3) Inspection of Guide Bearing Shells Edition 01
23/30
---
---1

i
~
1/,
'1
1:/,1
~'
~ Guide for mountirlg of upper SllelI.
Fig 5. Mounling of Upper Shell Guide Bearing.

Fig 4. Dismounling of Upper ShelJ.
Note: Clearance guide bearing axially, see page

12) The upper bearing shell is dismounted by 50.0.35.
means special l see lig 4.
17) Lubricate Ihe end the bearing shells with
molycote pasta similar.
Cleaning Components
18) Insert the lower bearing shell the bearing
13) Clean all machined surfaces, Irame, bearing cap, and mount the locking piece.
cap, stud , nuts and bearing shells.
Mounting Guide Bearing Cap

Inspection Guide Bearing Shells
Lubricale the bearing shell and journal with clean
14) Inspecl the guide bearing shells according 10 lubricating l.
warking card 50.60.1.16.
19) Raise the bearing cap position, dismount
th e guide tubes, coat the bearing stud with molycote
Mounting the Guide Bearing Shells pasta similar and l the bearing stud nuts.
The bearing shells Ihe guide bearing , which are Make sure thal the Ihrusl washers, bearing shell and
identical those the main bearings, are narrower bearing cap are their correcl position .
than the bore lor the guide bearing and is therelore
essen ti al that the shells are positi oned perfectly cor- 20) Dismanlle Ihe straps.
recl the bore.
21) the hydraulic lools, see workng card
For this purpose a guide l is supplied lor posilio- 520.-0.1.0.5, and tighten Ihe nuts as prescrbed
ning the engine Irame when the upper bearing page 50.0.-40..
shell is be litted, see lg 5.
22) Coat the back side the bracing screws' (side
15) Push Ihe bearing shell correct position screws') hexagonal head with a thin coat silastene
thraugh this guide tool, by using l item 202, l similar.
necessary use a plastic hammer.
23) the screws and tighten with a torqu e
16) Fil th e thrust washers and clamps. spanner as ndcated page 500.40..
96.20 - ESOS
Page 1 (3) Vibration Damper Edition 01
23/30

Stopped engine Plate lIem Note
D Shut-off l l
Descriplion:
Taking a silicone l sample

Hand lools:
Slang posilion:
Relaled procedure:
Working time 2-4 hours Plate lIem Qty/

Capacity 1 man
See plate 51004
Dala:
Data ' pressure and tolerance (Page 500.35)

Data ' torque moment (Page 500.40)
96.03 - ESOS-G
510-04.00 Vibration Damper
Working Card
23/30
The vibration damper is equipped with extraction 3) Rotate the engine in orderto bring the extraction
plugs which provide the opportunity testing th e plugs (6) the damper in optimal positi on, see fig
viscosity the silicone l inside the damper without 2.
having dismantle .
Corresponding the condition the silicone l an

approximate assessment the damper efficiency
is possible.
si ticone l sample should be extracted as follows

by means a special tube that can be required from
& W Holeby, see p/ate 51004.
1) After the engine is stopped let damper cool

down nearly 40' C.
2) For access the damper remove the blank

fl ange () on the Iront end cover () see fig 1. VL-- - 6
In some cases is necessary to dismount the lub.

lpump the cooling water pump, lr access
the damper. --.,,-1-- 5
-!J--- 6
=r.J-J-- 7
. 81ank ffange cooJing waler pump.

. Front end cover.
C. Damper.
D. Geawheel (if mounIed) Fig 2. Vibration Damper
. Main bearing (Frame)
F. Crankshaft.
4) Prepare the samplecontainer (1 ) by removing

one its caps (11) , see fig 2 C.
Fig 1. Mounting of Vibra.tion Damper.
96.03 - ESOS-G
' DieseII
Working Card
Vibration Damper
510-04.00
23/30
5) Unscrew and remove one Ihe exlraclion 8) Tighlen bolh exlraclion plugs wilh Ihumb and
plugs (6) and replace l wilh Ihe sample conlainer fo refinger Ihen turn Ihem furlher 450 (aboul 20 Nm) .
(1 ). Seal bolh plugs by caulking Iheir grooves.
meeling Ihe inerlia ring (3) unscrew Ihe conlainer 9) Send Ihe sample conlainer 10 &
one revolulion . Holeby, a l: Service Deparlmenl , logelher wilh Ihe
label filled in wilh:
6) Remove Ihe second cap from Ihe sample
conlainer and wail unlil silicone flui d (5) begins 10 Name ship.
l oulfrom Ihe free end. Depending on Ihe silicone Engine Iype.
viscosily Ihe process needs a cerlain amounl lime. Engine no.
possible l, can be speeded by means : Running hours.
Dala for vibralion damper.
Turning Ihe damper unlil Ihe sample conlai -
ner is undernealh Ihe crankshaft. 1) For hours belween laking new samples, see
Temporarily removing Ihe second exlraclion page 500.25.
plug 100.
The quanlily s il cone l removed l so small th al
7) As soon as Ihe silicone fluid begins 10 l , 10 1 such samples can be laken wilhout risk.
shul Ihe sample conlainer by Ihe cap. Remove Ihe
conlainer from Ihe damper casing, wipe off Ihe sea-
ling jace round Ihe exlraclion hole and screw in Ihe
plugs logelher wilh new sealing washers (7).
close Ihe second side Ihe conlainer.
96.03 - ESOS-G
PIale
Page 1 (2) Crankshaft I S1001-04H
23/30
128
177 -----
094
070
189
069 190
021+ 200
153
~
.;
:;"
q
9
>
>
082
98.34 - ESOS
f,!,J,MI,,(MAN DieseII
IS1001-04H Crankshaft PlaIe
Page 2 (2)
23/30
Item Item
. Designation Benaavnelse . Qty. Deslgnatlon Benaavnelse
021+ 2/G Counterweight Kontravcegt
069 2IW Screw 10r Skrue for

counterwelght kontravcegt
070 lIG Plug screw Propskrue
062 / Plug screw Propskrue
094 100 Screw Skrue
104 101 5elf locking nut SelvlAsende rn0Irik
116 101 Washer Skive
126 1/ 011 throw ring Olieafslyngningsring
153 1 / Cyllndrical Cylindrisk 51ift
165 1/ Crankshaft, Krumtapaksel

5 cyl. engine 5 cyI. moIor

(crankshaft) (krurnla)
169 / Crankshaft Krurnlapaksel

6 cyl. engine 6 cyl. moIor
190 1 / Crankshaft Krumtapaksel

7 cyl. engi ne 7 cyl. motor
200 1/ Crankshaft KrumIaaksel ,

8 cyl. engine cyl. motor
+ Item . 021 require + Ilem "r. 021 krGever

Indivldual match individuellilpasning
ing before mountlng for monlering, kontakt
contact Dlesel Diesel
When ordering spare parts, see also page 500.50. Ved bestilIing af reservedele, se ogsA side 500.50.
Only aval lable as part of a spare parts kit. n lilgcengeHg som en del af et reseredelssret.
QtyJE = QtyJEnglne Antal/E = AntaI/MoIor
QtyJW = QtyJCounterweight IW= AntaJIKontravcegt
QtyJC = QtyJCyllnder AntaIIC = AntalICyJinder
96.34 - ESOS
,,:, DieseI[
PlaIe
Page 1 (2) Couplng for Centrai Drien Lub. Pump 51002-01
L23/30
\
'\ \
\
~crankShaft
(Plate 51001)
~ 279
015
027
' - - - 038
06.43 ESO

51002-01 Couplng for Central Driven Lub. l Pump Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Deslgnation Bencevnelse
015 1 / Coupling flange Koblingsflange
027 3/ LockIng plate Lfsep l ade
038 6 Screw Skrue
279 1 / Flyweight Svingvregl

5 cyl. engine 5 cyl. molor
When orderi ng spare parts, see al50 page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
Only available as part of a spa re parts kit. tilgengelig som del af re se re d e l ssre l.
QtyJE = QtyJEngine Anlal! E = Antal/Motor
06. 43 ESO
'' / DieseII
Plale
Page 1 (2) ResiIient Gear WheeI 51002-02
23/30
/~
Crankshaft
(Plate 51001)
123 ~
111
206
088 \
267
052 - \ \
160
196 - \
)fp~
\ ~_x ~~
218 "< "-- 147
172 '--- , 0/ ~~ 111
111 --- 159
231 ----
\\~:t::..~\ ~ 172
L 184
040
064
'---- 076
06.41 - ESO
Plale
51002-02 Resilent Gear Wheel Page 2 (2)
23/30
Ilem Item
. aty. Deslgnation Benrevnelse . Qy. Designation Benrevnelse
040 3/ Distance piece Afstandsstykke
052 3/ Dfstance plece Afstandsstykke
064 61 Spring Fjeder
076 6/ Sprlng guide Fjederstyr
088 61 sllde shoe Glidesko
111 1 21 l M0trik
123 / l Journal Akseltap
135 21 Screw Skrue
147 4/ 5el' locking t Selvlasende m01rik
159 2 Hexagon soc. screw Scetteskrue

with cup
160 21 Cylin drica l Cylindrisk 511ft
172 1 81 Locklng washer Laseskive
184 61 Screw Skrue
196 / Gear wheeI andhjul
206 / Hub Nav
218 / Side plate Sideplade
231 4/ Cyllndrical l Cylindrisk slift
243 / Resillent gear wheel, Fjederende landtljul ,

complete komplet
267 21 ll ll
When ordering spare parts, see also page 500.50. Ved beslillng af reservedele, se 095a side 500. 50.
= Oniy ava iIabIe as part of a spare parts kit. Kun tilgrengelig som en dei af et reservedelssrel.
QtyJE = Qty./Englne Anlal/E = Anlal/Molor
06.41 - ESO
MiM'.MAN DieseI!
Plale
Page 1 (2) FIywheeI with FIexibIe CoupIing and Gear Rim 51003-01
23/30
071+
083
\/
105 ~
/
\
/./'' \/
\
~ /
o ~,
o .~,
0' ."
.

117 ~
0 095
d \ - 046+
- - 058
/
/
~
'--.. 022
96.03 - ESOS
,, .J DieseII
PlaIe
51003-01 FIywheeI with FIexibIe Coupling and Gear Rim Page 2 (2)
23/30
Item Item
. Qty. Desigation 8encevnelse . Qty. Designation Bencevnelse
1 / Gear rlm Tandkrans
022 14/ Screw Skrue
034 1 2/ 5elf locking nut, 10r S ellase nde moIrik for

Item . 046 Ilem nr. 046
046+ 1 21 Fitted bolt Pasbolt
058 1 / Flywheel Svinghjul
071+ 12JE Fitted bolt Pasboll
083 1/ Flexlble coupllng, Fleksibel kobling,

complete kompleI
095 24/ Rubber element Gummielemenl
105 21 Screw Skrue
117 1 2/ 5elf locking nut, for SelvlAsende moIrik

Item . 071 ilem nr. 071
+ Item 046 and 071 + Ilem nr. 046 and 071

require an indivldu- krrever individu el
al matching, before lilpasning, for monte
mounting. ring
When orderlng spare parts, see also page 500.50. Ved beslilling af reservedele, se ogsA side 500.50.
l ava ll able as part of a spare parts kit. tilgC'e ngelig som en del af el rese rve delsset.
OtyJE = OtyJEnglne Qly. /E = Antal/ Motor
96.03 ESOS
Plate
Page 1 (2) Flywheel with Gear Rim 51003-02
23/30
105
\
\
\
\ ,
\

046+
058
Crankshaft
(PlaIe 51001)
- - - - - - 010
/'
~ 022
96.03 ESOS
Plate
51003-02 Flywheel w ith Gear Rim Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Benrevnelse . Qty. Des lgnatl on Benrevnelse
010 1 / Gear rlm Tandkrans
022 14/ Screw Skrue
034 1 2/ 5elf locki ng , for Selvlasende rn0trik for

Ilem . 046 item nr. 046
046+ 1 21 Fltted bolt Pasbolt
058 l Flywheel Svinghjul
105 2 Screw Skrue
+ Ilem 046 require an + Ilem nr. 046 k reveren

Indlvldual mat chIn g individuel Iilpasning for
before mounting. montering.
When orderin g s pa re pa rls, see al$o page 500.50. Ved besIilling af reservedele, se ogsa side 500.50.
Only available as part of a spare parts kit. tilgcengelig som en del af el reservedelssaeI.
QtyJE = Qty./Eng ine Qty./E = I!
96.03 - ESOS
PIaIe
23/30
105 -'.
\ '.
046+
-----~ 010
~ 022
96.03 - ESOS
I,, !: DieseII
Plate
51003-03 FIywheeI with Gear Rim Page 2 (2)
23/30
Item Item
. . Designatlon Benrevnelse . . Designatlon Benmvnelse
l Gear rim Tandkrans
022 14/ Sc rew Skrue
034 1 2/ Self locking , for Selvlasende meIrik for

tem . 046 item nr. 046
046+ 1 21 Fitted bolt Pasboll
058 1/ Flywheel Svinghjul
105 21 Screw Skrue
+ Item 046 requlre an + Item nr. 046 krreveren

indlvidual matching individuel tilpasning for
before mountlng. monrering.
When ordering spa re arts , see also page 500.50. Ved bestilling al reservedele, se 0953. side 500.50.
Only availabie as part of a spare as kit. lilgcengeiig som del af el reservedelssret.

QtyJE = QtyJEngine Qty./E = Anlal/Motor
96.03 " ESOS

PlaIe
23/30
105 -,
\
\,
\
\
/
:(\
\ 046+
- - 058
'-----------
/'
~ 022
07,14 ESO
Plale
51003-22 Flywheel with Gear Rim Page 2 (2)
23/30
Item Item
. Qty. Deslgnatlon Bencevnelse . Qty. Designatlon Benrevne lse
1/ Gear rim Tandkrans
022 14/ Screw Skrue
034 121 Self locking , for Se lvl~se nd e motr k for

iIem . 046 item nr. 046
046+ 1 21 Fltted bolt Pasbolt
058 1/ Flywheel Svinghjul
105 21 Screw Skrue
+ Item 046 require + lIem nr. 046 krreveren

IndlvIdual matchlng individuel tilpasning for
before mounting. montering.
When ordering spare pa rts, see al50 page 500.50. Ved bestilling af reservedele, S ogs:' side 500.50.
= Only ava il able part of a spa re kit. tilgcengelig som del af el reservedelsscet.
./ = QtyJEngine Qty.lE = Antal/Motor
07.14 - ESO
Plate
23/30
105 \
\
,,
046+
- - - - - - 058
./
~ 022
07. 14 - ESO
Plale
51003-23 Flywheel with Gear Rim Page 2 (2)
L23/30
Item Item
. Qty. Deslgnation Benrevnelse . Qty. Deslgnatlon Bencevnelse
010 1/ Gear rlm Tandkrans
022 1 4/ Screw Skrue
034 12/ Self Iocklng , for Selvlfksende rne l ri k for

item . 046 ilem nr. 046
046+ 1 21 Fitted bolt Pasbolt
105 21 Screw Skrue
+ Item 046 requlre an + Item nr. 046 krceveren

indl v ldu al matc hlng individuel tilpasning for
before mount lng. montering.
When ordering spare p arts, see al50 page 500.50. Ved bestilling af reservedele, se ogsc\ side 500.50.
On ly available as a spare p arts kit. Kun tilgcengelig som del af l reseredefssret.

Qty./E = QtyJEn gine Oty./E = Antal/Motor
07. 14- ESO

PlaIe
23/30
105 ,
\
\
,
"
O
o~ /
0/ '------- 058
/' ,
/ / \
, \
\ "LCrankshaft
\
\ (Plate 51001)
'- 034
---------
~ 022
~
~
,n
08.21 , ESO
''" DieseII
Plate
51003-24 FIywheeI with Gear Rim Page 2 (2)
23/30
Ilem Ile m
. . Designation Benrevnelse . Qty. Des ignatlon Ben cene l se
010 1/ Gearrlm Tandkrans
022 14! Sc rew Skrue
034 12JE 5elf locking n , fo r SelvlAsende m0trik for

Item . 046 Ilem nr. 046
046+ 121 Fitted boIt Pasbolt
105 21 Screw Skrue
+ Ilem 046 requlre an + Ilem nr.046kraeveren

Indivldual matchlng individuellilpasning for
before mountlng. monIering.
When ordering spare parts, see a/5o page 500.50. Ved besIilling af reservedele, se ogsA side 500.50 .
Only availabIe as part of a spare parts kit. tilgrengelig som en del af l reservedelssoo t.
QtyJE = QtyJEngine Qty.lE = AntaVMotor
08.21 ESO
,+, , DieseII
Plate
Page 1 (2) TorsionaI Vibration Damper 51004-01
23/30
____- 016
~ 02'
053
r 041
'
, 0
94.23 ESOS
+ DieseI[
Plale
51004-01 TorsionaI Vibration Damper Page 2 (2)
23/30
Item Item
. . Designation Benrevnelse . aty. Deslgnatlon Benrevnelse
016 1/ Torsional vibration Svingningsdremper

damper, with 25 mm med 25 mm monle
mountlng flange ringsflange
028* 21 Seallng washer Tcetningsskive
041 - 1/ Sample container Pr0Veudtagings-

beholder
063+ 1 / Sampllng klt tor tor- Prevesret for sving-

sional vibration dam- ningsdremper
per
+ See al50 working + Se ogsC arbejdskorI

card 510-04.00 510-04_00
When ordering spare parIs, see al50 page 500.50. Ved bestilling at reseredele , se ogsC side 500.50.
= Only aval lable as part of a spare parts kit. Iilgrengelig som en del af l reservedelssret.
QtyJE = QtyJEnglne AntalIE = Anlal/Motor
94.23 - ESOS
Plate
Page 1 (2) Torsional Vibration Damper 51004-26
23/30
~- 016
~028*
053
r 041
*
, 0(1
07.14 - ESO
'}2,.lf DieseII
PIale
51004-26 Torsional Vibration Damper Page 2 (2)
23/30
Item Item
. Designation Bencevnelse . Qty. Designation Bencevnelse
016 1/ Torsional vibration Svingningsdcemper

damper, with 25 mrn med 25 mm monle-
mountlng flange ringsflange
020' 21 Sea ling washer Tretningsskive
041' 1 / Sample contalner Pr0Veudtagings-

beholder
053+ 1 / Sampllng kit for tor w

rveset for sving-
sional vlbration dam- n i ng sde mper
-'
+ See al50 worklng + Se ogs(\ arbejdskort

card 510-04.00 510-04.00
When order/ng spare parts, see also page 500.50. Ved besliJling af reservedele, se ogS3. side 500.50.
Only aval lable as part of a spare parts kit. tilgenge l ig som del af et reseredelssret.
QtyJE = QtyJEngin_ Antal/E = ll/
07 .14 - ESO
PlaIe
23/30
~- 016
~028*
053
r 041
*

07.14-ESO
PlaIe
51004-27 Torsional Vibration Damper Pag" 2 (2)
L23/30
Ile m Ilem
. aty. Deslgnation B e n ;;ene l se . . Deslgnatlon Bencevnelse
016 1 / Torsiona l vibratlon Svingningsdremper

damper, with 25 mm med 25 mm monIe-
mounIlng Ila"ge ringsflange
028" 21 Sea llng washer Te lnin gssk ive
041- 1 / Sample container Pr0veudtagings-

beholder
053+ 1 / Sampling klt for 10- Prevesret for sving-

"'
+ See al50 working + 5e 09S8. arbejdskorI

card 510-04 .00 510-04.00
When ordering spare parts, see al50 page 500.50. Ved besIilling af reservedele, se 095<\ side 500.50.
On ly aval lable as part a spare parts kit. lI939 " 9 l9 som del al re s eredelsse t.
QtyJE = QtyJEnglne Anlal/E = Antal/Motor
07.14 - ESO
Plate
23/30
~- 016
~028*
053
r 041
*

07.14 - ESO
Plate
L23/30
Ile m Ilem
. aty. Deslgnatlon B e n cenel se . . Deslgnation Bencevnelse
016 1 / Torslonal vibration Svingningsdcemper

damer, with 25 mm med 25 mm monle-
mounting 1la"ge rings fl ange
028" 21 Sealing washer Tetn i ngsskive
041" 1 / Sample conta lner Pr0Veudtagings-

beholder
053+ 1 / Sampllng kit for lor- Provesml for sving-

per
+ See al50 worklng + Se ogsA arbejdskort

card 510-04.00 510-04.00
When ordering spare parts, see also page 500.50. Ved bestilling af reservedeJe, se ogsa side 500.50.
On ly avallable as part of a spare parts klt. tilgcengelig som del af l reserede l sseI.
QtyJE = QtyJEnglne Antal/E = Anlal/Motor
07.14 - ESO
Plate
23/30
~- 016
~028*
053
r 041
*

07 .14 - ESO
'' 'l Dieserl
Plate
5 1004-29 TorsionaI Vibration Damper Page 2 (2)
23/30
Item Item
. Qty. Designation B e n ev n e l se . Qty. Deslgnation Benrevnelse
01 6 1 / Torslona l vibration Svingningsdcemper

dam per, w it h 25 m rn med 25 mm rnonIe-
mounting f lan ge ringsflange
028* 21 Sea llng washer Telni n gsskive
041 * 1 / Sample contalner Pr0veudtagings-

beholder
053+ 1 / Sampli ng kit for tor- Provesret for sving-

siona l vibrat ion dam- ningsdremper
,
+ See al50 working + Se ogsa. arbejdskort

card 510-04.00 51004.00
When orderlng spare parts, see a/5o page 500 .50. Ved bestHling af reservedele, se 0958 side 500.50.
= Only avallable as part of a spare parts klt. tilgrengelig som del af l res e redel ssret.
QtyJE = QtyJEn glne Antal/E = Antal/Motor
07. 14 ESO
Plate
23/30
___- 01 6
~028*
053
r 041
*

07.1 4 - ESO
,$1,I DieseI!
Plate
23/30
Item Item
. Qty. Designation Benrevnelse . Qty. OesI9"atlo" Bencevnelse
016 1 / ors i onal

vlbratlon Svingningsdremper
damper, with 25 mm med 25 mm monIe-
mountlng 1la"ge ringsflange
028" 2/ Sealing washer Tcetningsskive
041 1 / Sample container Pr0vedtagings-

beholder
053+ 1/ Sampling klt for tor- Provesrel for sving-

sionaI vibration dam- ningsdremper
pe'
+ See al50 \vorklng + 5e ogsA arbejdskorl

card 510-04.00 510-04.00
When orderlng spare parts, S also page 500.50. Ved besIilHng af reservedele, se ogsA side 500.50.
On ly aval lable as part a spare pans klt. Kun Iilgrengelig som del af reservedelsscet.
QlyJE = QlyJEngine Antal/E = Antal/Motor
07.14 - ESO
PlaIe
23/30
~- 016
~028*
053
r 041
*

07.14 - ESO
I DieseII
Plate
23/30
Item Ilem
. aty. Oeslgnation Bencevnelse . aty. Designation Bencevnelse
016 1 1 Torslonal vibration Svingningsdcemper

mountlng fla"ge ringsflange
028' 2/ Seallng washer c:etningsskive
041' l Sampie container Prveudtagings-

beholder
053+ l Sampllng kit for lor- Provescet for sving-

sional vibraIion dam- ningsd<:emper
per
+ See also worklng + Se ogse\ arbejdskorl

card 510-04.00 510-04.00
When orderlng spare parts, see al50 page 500.50. Ved bestilling at reservedele, 5 095'" s ide 500.50.
= On ly avaiIable as part a spare parIs kit. tiJgrengeIig som en del af el reseredel sscet.
QtyJE = QtyJEngine Anlal/ E = Anlal/Motor
07.14 - ESO
+'. DieseII
PlaIe
23/30
~- 016
~028*
053
r 041
*

07.14 - ESO
Plate
23/30
Item Item
. aty. Oesignation Bencevnelse . Qty. Designation Bencevnelse
016 1 / Torsional vibration Svingningsdcemper

damper, wlth 25 mm med 25 mm mon1e-
mountlng flange rings flange
028" 2/ Sealing washer Tetni ngsskive
041 " 1 / Sample contalner Pr0veudlagings-

beholder
053+ l Sampllng kit for - Provesret for sving-

slo"al vibraIion dam- ningsdcemper
per
+ See al50 worklng + Se ogsa arbejdskort

card 510-04.00 510-04.00
When ordering spare parts, see al50 page 500.50. Ved bestilling af reservedele, 095<\ side 500.50.
Only ava iIable as part a spare as kit. Kun titg.engelig $om en del af el re serede l ssre I.
QIyJE = QIyJEnglne AnIal/E = AntallMolor
07. 14 - ESO
PlaIe
23/30
____- 016
~028*
053
r 041
*
, 0
07.14 ESO
PIale
23/30
Item Ilem
. Qty. Designation Benrevnelse . Qty. Deslgn ation Bencevnelse
016 1 / orslonal vibration Svingningsdc.emper

damper, with 25 rnm med 25 mm monIe-
mounting I1ange ringsftange
028" 21 Sealing washer Tretningsskive
041 " l Sample contal ner Pr0veudtagings-

beholder
053+ 1 / Sampllng klt 10 tor- Prvesret for sving-

510nal vibration dam- ningsdremper
,

card 510-04.00 51004.00
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
Only avallable as part of a spare parts kit. tilgc.engeJig som en del af el reseredelssret.
atyJE = QlyJEnglne Antal/E = l/
07.14 ESO
Plale
23/30
___- 016
~028*
053
r 041
*

07 .14 - ESO
Plate
23/30
Item Item
. aty. Des ignatlon Bencevnelse . Qty. Designation B enre nel se
016 1 / Torsional vibration Svingningsd<Emper

damper, with 25 mm med 25 mm monle-
mounting 11a"ge ringsfl ange
028" 21 Sealing washer .:etningsskive
041 " 1 / Sample contai ner Pr0veudtagings-

beholder
053+ 1 / Sampllng kit 10r tor- Provescet for sving-

"'
+ See also worklng + Se ogsA arbejdskort

card 510-04.00 510-04.00
When ordering spare parts, see a l50 page 500.50. Ved beSlilling af reservedele, 5 ogsa side 500.50.
On ly ava llable as part a spare parts klt. Kun Iilgrengelig som del af el reseredeJssret.
Qly.lE = QlyJEngin" l/ = Antal! Motor
07 .14 - ESO
+'I DieseII
Plate
23/30
~- 016
~028*
053
r 041
*

07. 14 - ESO
Plate
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Des ignatio n Be ncevne lse
01 6 1 / Torslonal vi bratlon Svingningsd<emper

dam per, w ith 25 m m med 25 mm monte-
mounting tlange ringsIlange
028 21 Seallng washer et n ingss kive
041- 11 Sampte container Pr0veudtagings-

beholder
053+ 1 / SamplJng kit for tor- Provesaal for sving-

sio nal vibrati on dam- ningsdremper
por
+ See also worklng + Se ogsf arbejdskort

ca rd 510-04.00 510-04.00
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
On ly avallable as part of a spare part s kit. tilgcengelig som del af l re sere delssc I.
aty./E = QtyJEnglne Anta l/E = l
07 .14 - ESO
Plate
23/30
~- 01 6
~028*
053
r 041
*

07. 14 - ESO
Plate
L23/30
Item Item
. Qty. Deslgnation Bencenelse . Qty. Designation Bencevnelse
016 1 / ors ional vibration Svingningsdcemper

mounting I lange ringsflange
028 21 Sealing washer Trelni ngsskive
041 " 1 / Sample container Pr0veudtagings-

beholder
053+ 1 / Sampllng kit 10r tor- Provesret sving-

sional vibratlon dam- ningsdremper
pe'
+ See al50 worklng + Se ogsA arbejdskor!

card 510-04.00 510-04.00
When orderlng spare parts, see al50 page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
Only avallable as part a spare parts kit. u tilge ngetig 50m en del af el re se re d e l sset.
aly./E = alyJEnglne Antal/E = Antal/ Motor
07.14 ESO
Plale
L23/30
~- 016
~ 028*
053
r 041
*

07. 14 ESO
DieseII
Plale
23/30
Item Item
. Qty. Deslgnation Bencevnelse . Qty. Designation Bencevne lse
016 1 / Tors/onal vibration Svi ngningsdremper

damper, with 25 mm med 25 mm monte
mountlng tlange ringsIlange
028" 21 Sealing washer ret n ingsskive
041 " 1 / Sample container Pr0Veudtagings-

beholder
053+ 1 / Sampl1ng klt 10r tor- Provesret tor sving-

sional vibration dam- ningsdcemper
per

card 510-04.00 510-04.00
When ordering spare parts, see also page 500.50. Ved beslilling al reservedele, se ogsA side 500.50.
On ly avallable as part a spare parts k lt. tilgcengelig som del af et reservedelsscet.

Qty.lE = QtyJEnglne AnIallE = Antal/Motor
07.14 - ESO
PlaIe
23/30
~- 016
~028*
053
L 041
*

07 .14 - ESO
,, DieseII
Plale
23/30
Item Item
. Deslgnation Bencevnelse . Qty. Designation Benrevnelse
016 1/ Torsional ibrat i on Svingningsdremper

damper, with 25 mm med 25 mm monte-
mountlng flange ringsIlange
028" 21 Sealfng washer Tcetningsskive
041 " 1 / Sample container Pr0veudtagings-

beholder
053+ 1/ Sampling kit for - Provesrel sving-

sio nal vibration dam- ningsdremper
p_r
+ See al50 worklng + Se ogsfl arbejdskort

ca rd 510-04.00 510-04.00
When ordering spa re parts, see al50 page 500.50. Ved besIilling reservedele, se 09s:' side 500.50.
l avaiIable as a spare parts kit. IiIgrengelig som en del af el reservedelssc:et.

./ = QtyJEngln_ Antal/E = Antal/ Motor
07.14 - ESO
'+,' DieseII
Plale
Page 1 (2) Tuning WheeI IS1004-02H
23/30
065
94.23 - ESQS
,,' DieseII
IS1004-02H Tuning WheeI Pla le

Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Bencevnelse . aty. Designation Bencevnelse
065 1 / uning wheel with, Afstemningshjul med

25 mm mounting 25 mm monIerings-
flange flange
When ordering spare parts, see also page 500.50. Ved bestilling af reseredele , se ogsfl side 500.50.
Only avallable as part a spa re parts kit. Iilgcengelig som del af l reseredelssret.
Qty,/E = QtyJEngfne Antal/E = Antal/ Motor
94,23 - ESOS
"l'l, DieseII
Plate
Page 1 (2) Tuning WheeI 151 04-39
23/30
065
07. 18 ESO
IS1004-39H Tuning Wheel Plale
Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Designation Bencevnel se
065 1 / Tuning wheel with, Afslemningshjul med

25 mm mounting 25 mm monlerings-
flange fiange
When ordering spare parts, see a l50 page 500.50. Ved bestilling af reservedele, se ogsf side 500.50.
= Only avallable as part a spa re parts kit. tilgrengelig $om del af l reserede l sscet.
Qty./E = QtyJEngine AnlalfE = Antal/Motor
07.18 ESO
"'' DieseII
Plate
Page 1 (2) Tuning WheeI 51004-40
23/30
065
07.18 - ESO
"+!:( DieseII
PlaIe
51004-40 Tuning WheeI Page 2 (2)
23/30
Item Item
. Qty. Oeslgnation 8 enrevnelse . Qty. Des ignatlon 8enrevnelse
065 1 / Tu ni ng wheel with, Afstemningshjul med

25 mm mounting 25 mm monterings-
flange flange
When ordering spa re p a rs , see al50 page 500 .50. Ved bestifling af reservedele, se 095 side 500.50.
Only availabte as part of a spare parts kit. Kun tlgre n ge l i g som del af reservedelssrel.
Qly./E = QlyJEnglne Antal/E = Antal/Motor
07.18 ESO
I':'l$H MAN DieseII
Plate
Page 1 (2) Tuning WheeI !S1004-41H !
23/30
065
07.18 - ESO
" DieseI!
S1004-41 Tuning WheeI Plate

Page 2 (2)
23/30
Item Item
. . Deslgnation Bencevnelse . aty. Deslgnation Bencevnelse
065 1 Tuning wheel with, AfstemningshjuJ med

25 mm mounting 25 mm monterings-
flange flange
When orderlng spare parts, $ee also page 500.50. Ved bestiJling al reservedele, 5 ogs~ side 500.50.
= Only avallable as of a spare parts klt. tilgrengelig som del af reservedelssoot.

atyJE = QtyJEnglne Antal/E = Antal/Motor
07.18 - ESO
Section 511
Engine Frame and Base Frame
Description
Engine Frame and Base Frame 511 .01
Working card
FunctionaI Test of Crankcase Safety ReIief VaIes 511 -01.00
Plates
Frame with Main Bearings 51101-10
Mounting of Pumps 51102-05
Front Coer for Lubricating Pump 51102-10
Mounting of Pumps 51102-11
Coers Frame 51106-17

Description
Engine Frame and Base Frame 511.01
Page 1 (1)
Edition 01
23/30
Frame the sides the Irame there are covers for acces
10 the camshaft, Ihe charge air receiver and crank-
The engine Irame iS made cast , and iS at- case. Some of the covers are ltted with relief valves
tached the the base Irame by means which ll act, should l vapours the crankcase be
bolts. The cross girders the Irame are provided ignited, for instance the event of a hol bearing.
with bores lor the main bearings which the crank-
shalt iS underslung, .. iS carried by the main The charge air cooler housing iS a integrated part
bearing caps. of the frame.
The main bearing caps are attached by means

studs and nuts, which are loosened and tightened Base Frame
with the aid hydraulic tools. After mounting, the
main bearing caps are lrther secured by means Engine and alternalor (gear, pump) are mounted
bracing screws, which are screwed horizontally a common base Irame which iS welded design.
the sides the caps and tightened against the
sides the engine Irame. The main bearings are The base Irame iS used as lubricating l reservoir
equipped with replaceable shells which are litted 'wet sump'.
without scraping.
The crankshalt guide bearing iS located at the

wheel end th e engine.
94.26 ESOU
Working Card
Functional Test of Crankcase Safety Relief Vales
511-01.00
23/30
Safely precaulion5: SpeciallOOl5:
liI Stopped engine Plate Item Note.

Shut- off starting air
Shut-off luel l
Shut-oll cooling l
De5criplion:
Functional test crankcase salety reliel val-

ves. Hand 10015:
Slarling 05 :
Relaled procedure:

~
!
Capacity 1 man
511 06 058 1/cyl.
Dala: 511 06 071 1/reliel valve
51106 740 12/reliel valve
06.46 - ESO
511-01.00 Functional Test of Crankcase Safety Relief Valves
Working Card
23/30
FunctionaI Testing
Functi onal testing th e crankcase salety l l

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

the salety l l valves with paint.
Check Opening Pressure
check the opening pressure, proceed as

10ows:
1) Remove the l l valve cover Irom the engi-

ne.
2) Place the cover on the Iloor with the pressure Fig 1 Cover with reIief va/ve
area upwards.
3) l a weight at 5 kg on the pressure area.
The ll valve must open under this pres-

sure.
4) Remount the l l valve cover the engine.
1I the salety relief valves are actuated , the

engine must be stopped immediately, and
must not be restarted until the cause is detected
and the lault is detected, see also description
503.04, Ignition in Crankcase.
06.46 - ESO
, ,,,' Dieserl
Plate
Page 1 (2)
Frame "th Main Bearings 51101-10 J
L23/30
050
049
062
lf
324 Bearings,
see plate 507
05
086
397
098
Coolerbox see 312
plate 51203
Guide screw,
see plate 50705
- - 157
. " "
- - 253
" "
216 300+
157
121 -f"\-\---fI-l,c, 241 265 ---..

336 290 ~
133
+-- ___ 169
145 169 Bearings, 0705 324
see plate 5
324 170
336
108+
170
336
00.09 - ESO
I+l$z."IMAN DieseII
Plate
51101-10 Frame with Main Bearings Page2 (2)
23/30
Item Item
. Qty. Deslgnatlon Ben:evnelse . Qty. Deslgnation Benoovnelse
013 1/ Frame Stativ 336 11 Molykote paste Mlykote
025 5/ Braclng bolt Sideskrue 397 1/ Frame complete, inci. Stativ komplet. inkl.
item 049, 062, 108, 133, item049,062, 108, 133,
049 4/C Nut for cylinder M0trik cYIInder 145, 169,170,216,241 , 145,169,170,216,241,
head stud drekseltap 290,300,324,348,361 , 290,300, 324,348,361,
plate 50701 item 048, plate 50701 Item 048,
050 4/C Protective cap Beskytlelseshrelte 061 , 073, 276, plate 061 , 073, 276, pIate
50705 Ilem 350, 362 50705 iIem 350, 362
062 4!C Stud for cyllnder lap for cylinderdcek-
head sel
074 1/ Plug Prop + Item 108. 300 + Itemnr. t08,300krre

require an individual ver en IndivIdueJ
086 1/ Coupllng KoblIng matchlng before tilpasl i ng f0r [
mounting, contact tering, kntakt
098 2/ Plug B&W, Ho leby B&W,
Holeby
108+ 1/C Matn bearl ng cap Hovedlejedceksel
121 1 / Screw Skre
133 1/ Securing piece Sikringstykke
145 1/8 Sprlng Fjederslift
157 1/C Maln bearlng she ll Hovedlejeskafler 2/'2

212
169 2/8 Main bearing stud Hovedlejela
170 2/8 Nut for main M0Irik for

bearing stud hovedlejelap
216 2/ Cylindrical Cylindrisk slift
228 1/ lug Prop
241 2/ Bracing bolt Sideskrue
253 2/ Thru$t washer Trykskive
265 4/ Locking piece Lasestykke
290 4/ Screw Skrue
300+ 1/ Gulde bearing cap StyreJejedreksel
312 11 Loctite 542 Loctite 542
324 11 Loctite 243 LocIiIe 243
When orderlng spare parts, see also page 500.50. Ved bestIIing af reservedele. se ogS8. side 500.50.
Only available as part of a spare parts kt. u tilgrengelig som en del af et reservedelssret.
QlyJE = Oty./Englne Aotal/E = Antal/Motor
QlyJC Oty./Cylinder Antal/C = AnIal/Cyl inder
QlyJB Qty./Bearlng Antal/B = AnIal/Leje
QlyJJ = QtyJIndividual Antal/I = AntaJ/lndivIduelt
00.09 - ESO
PlaIe
Page 1 (2) Mounting of Pumps 51102-05
23/30
093

High temperature
fresh water pump,
see Plate 5161
164
temperature
fresh water pump,
see Plate 5161
247
06.50 - ESO
Plale
51102-05 Mounting of Pumps Page 2 (2)
23/30
Item Item
. Qy. Designation Bencevnelse . Qy. Designatlon Ben:evnelse
093 l Guard end, 10re Endedreksel, for
103 1 / Cover Dreksel
140 24/ Screw Skrue
152 1 21 Screw Skrue
164 2 Guide Styreslft
176 31 Spray plpe SprGjter0r
188 6/ Locking plate L~ seplade
211 6/ Screw Skrue
235 1 / Sealing ring TeIningsring
247 21 l MoIrik
451 1/ Screw Skrue
When orderlng spare parts, see al50 page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
= l ava ll able as part of a spa re parts klt. Kun Ilgrengelig som del af rese redelsscel.
QlyJE = QlyJEnglne Antal/E = Antal/Motor
06.50 ESO
Plate
Page 1 (2) Front Cover for Lubricating l Pump 51102-10
23/30
081
Q Q
Q
Q Q
For Iubricating
pump, see
Plate 51501 Q
Q
Q Q
020
019
032
06.50 ESO
Plate
51102-10 Front Coer for Lubricating l Pump Page 2 (2)
23/30
Item Item
. Qy. Designatlon Benrevnelse . Qly. Deslgnation Bencevnelse
019 1/ Cover DEksel
032 6/ Screw Skrue
081 1/ Guard end, fore Endedreksel, for
140 24/ Screw Skrue
164 21 Guide l SIyrestift
247 21 l Motrik
451 1/ Screw Skrue
When ordering spare parts, see also page 500.50. Ved beslilling af reseredel e, se ogsA side 500.50.
Only aval lable as part of a spare parts kit. tilgcengelig som del af l reservedelsscet.
QlyJE = Qly./Englne Antal/E = Antal/Motor
06.50 ESO
Plate
Page 1 (2) Mounting of Pumps 51102-11
23/30
093

235 \ "-

223 ",
164
247
152
451

For fresh water pump,

see Plate 5161
~
<
152
~
~
~ For lubricating l pump,

;j; see Plate 51501
06.50 - ESO
Plate
51102-11 Mounting of Pumps Page 2(2)
23/30
Ite m Item
. a l y. Designatlon Benmvnelse . a l y. Des ignatlon Benm vnelse
093 1 / Guard end, fore Endedreksel, 'or
103 1 / Cover Dceksel
115 2/ Cover Dceksel
140 24/ Screw Skrue
152 18JE Screw Skrue
164 21 G ulde l Styrestitt
176 2/ S pray l Sprojler0r
188 4/ Locking plate Laseplade
211 4/ Sc rew Skrue
235 21 SeaIlng rln9 TceIningsring
247 2 l trk
451 101 Screw Skrue
When orderlng spa re parts, see al50 page 500.50. Ved bestilling af reservedele, 5 0950:\ side 500.50.
Only avail able BS part a spare pa rts klt. li lgrengelig som del reservedelssrel.
Qty./E = QtyJEn gine Antal/E = Antal/Motor
06.50 - ESO
PlaIe
Page 1 (3) Covers Frame 51106-17
23/30
490
")"\ffi12!-t - - 058
-'----- 071
071 083
764
752 ~t-
~
ro 715
~ 058
416
""
2> 703
5 cyl. OOOOrllOOOO
~
394
~
693 6 cyl . OOrllOOOOrllOO
~ 489
~
7 cyI.
OOrllOOrllOOrllOO
"
8cyl.
OOrlllJrllOOOOrlllJ
"
Cover see When ordering cover fo r
plaIe 51102 crankshaft with re lief valve,
please see diagram with covers.
07.09 - ESO
l:+~Z' !I'[MAN DieseII
Plate
51106-17 Covers Frame Page 2 (3)
2330
Item Item
Qty. Desi " atlo" Benrevnelse Qty. Desi " atlo" Bencevnelse
010 6/0 Screw Skrue 296 Han d le Handlag

22/ 5 cyl. eng ine 5 cyl. motor
056 2/C 0-rl"9 O-ri"g 26/ 6 cyl. eng ine 6 cyl. motor
071 12/0 Washer Skive 34/ 8 cyl. engl ne 8cyl. molor
063 6/0 5elf locking Selvlasende m0Irik 306 Washer Skive

24/ 5 cyI. engine 5cyl. molor
129 6/C Screw Skrue 26/ 6 cyl. eng lne 6cyl. molor
32/ 7 cyl. eng ine 7cyl. molor
130 Cover Dceksel 36/ a cyl. eng lne 8 cyl. motor
2/ 5 cyl. e ngine 5 cy. motor
3/ 6 cyl. engine 6 cyl. motor 321 Guard intermediate Mellemskc:erm
3/ 7 cyl. engine 7 cyl. molor 4/ 5 cyl. engine 5 cyl. motor
4/ cyl. engine 8 cyl. motor 5/ 6 cyl. englne 6 cyl. motor
142 Gasket Pakning 7/ 8 cyl. engine 8 cyl. motor
3/ 6 cyl. engine 6 cyl. molor 333 2/C Stud Tap
4/ 8 cyl. engi ne 8 cyl. molor 345 1/ Guard end fore Skrerm, for
154 Screw Skrue 357 1/ Guard end fore Skrerm, for

56/ 5 cyI. engine 5 cyl. motor
66/ 6 cyl. englne 6 cyl. molor 369 1/ Guard Skrerm
601 7 cyl. engine 7 cyl. molor
681 8 cyl. englne 8 cyl. molor 370 14/ Screw Skrue
166 1/ Cover Dreksel 362 1/ Guard end fore Skrerm, for
176 1/ Gasket Pakning 394 6/C Screw Skrue

only for 900 rpm kun for 900 omdr.
191 2/C Stud
404 2/ Screw Skrue
201 2/ Stud Tap
416 Cover for Dreksel for
213 4/C Screw Skrue crankcase . krumtaphus
6/ 5 cyl. engine 5 cyI. motor
225 1/C Cover for camshaft Dreksel for kamaksel- 6/ 6 cyl. englne 6 cyl. motor
houslng hus 1 / 7 cyl. engine 7 cyl. motor
11/ 8 cyl. eng ine 8 cyl. motor
237 1/C O-rlng O-ring
426 4/ Screw, 72050 rpm Skrue. 72050 rpm
249 5/ Screw Skrue
441 2/ Tapered dowel Slyreslift
250 5/ Washer Skive
453 2/ Washer Skie
262 1/ Guard end aft Skrerm, agter
465 2/ ! Metrik
274 1/ Guard end aft Skrerm, agIer
477 6/C ! MeIrik
286 Spring Fjederstift only for 72050 rpm kun for 72050 omdr. ~
22/ 5 cyl. engine 5 cyl. molor ro

26/ 6 cyl. engine 6 cyl. molor 469 6/C Screw Skrue ~
30/ 7 cyl. engine 7 cyl. motor on ly for 72050 r pm kun for 72050 omdr. :
~
34/ 8 cy/. engine 8 cyI. motor
~

9
ro

ro
When ordering spare parts, see also page 500.50. Ved besli lling af reservedele, se ogS8. side 500.50.
Only avaiiabIe as part of a spare parts kit. tlgrengeIig som del af reseredeIS$a31.
Qty./E QtyJEngine Antal/E = Antal/Molor
QtyJC QtyJCyllnder AnIal/C = Anlal/CyHnder
Qty./D QtyJSafety cover Antal!D = AnIal!sikkerhedsdreksel
07.09 - ESO
',:,,"MAN DieseI!
Plale
23/30
Item Item
Qty. Designation BencevneIse Qty. Designatlon Bencevnelse
490 Cover with safety D.;eksel med sikker-hed-

va lve, complete svenIiI, komplel
4/ 6 cyI. engine 6 cyl. moIor
4/ 7 cyl. engine 7 cy molor
5/ 8 cyl. englne 8 cyl. moIor
500 Guard intermediate Me ll emska:rm, kompleI

complete, incl. Item inkl. Ilem 191,286,298,
191, 286, 298, 308, 308,321,333
321,333
4/ 5 cyl. englne 5 cyl. molor
5/ 6 cy/. engIne 6 cyl. motor
6/ 7 cyl. englne 7 cyI. moIor
7/ 8 cyl. engine 8 cyl. moto
693 /1 Packlng Silicone

siHcone paste
703 1 / Cover D~kse l
715 6/ Screw Skre
740 1/0 0-rl"9 O-ri"g

752 Safety valve, Sikkerhedsvenlil,
complete komplet
4/ 5 cy l. eng lne 5 cyl. moIor
4/ 6 cy . engine 6 cyt. motor
4/ 7 cyl. englne 7 cyl. molor
5/ 8 cyl. englne 8 cyl. motor
764 1/0 Flange Fiange
788 4/ Screw, 900 rpm Skrue, 900 rpm
When ordering spare parts, 8ee al80 page 500.50. Ved bestilling af reservedele, se ogS8. side 500.50.
Only avai lable as part of a spare parts kit. Kun lilgoong elg som del af et reseredelsscel.
Qly./E Qty.lEngine Antal/E = AntallMoIor
Qty./C OtyJCyIinder Antal/C = AnlallCylinder
QtyJD = OtyJSafety cover AnlallO = AnlaI/sikkerhedsdceksei
07.09 ESO
Plale
Page 1 (2) Covers Frame 51106 -30
23/30
644
07.09 ESO
,,' DieseI!
Plate
23/30
Item Item
. aly. Deslgnation Benrevnelse . aly. Deslgnatlon Benrevnelse
512 1 / Cover 212 Dceksel 2J2
524 221 Screw Skrue
536 4/ Gulde l Slyrestift
548 4/ Nul Metrik
561 1! PUg screw Propskrue
573 4/ Screw Skrue
585 1/ Sea ling ri ng 2/2 Tcetningsring 2/2
597 16/ Screw Skrue
607 21 Gulde SIyreslift
619 21 M0trik
620 21 Cyllndrical Cyli ndrisk sllft
632 1 / Cover Dceksel
644 8/ Screw Skre
668 21 Screw, 72050 rpm Skrue, 72050 rpm
681 4/ Screw, 72050 rpm Skrue, 72050 rm
693 11 Packlng Silicone

sillcone paste
776 21 Screw Skrue
811 21 Screw, 900 rpm Skrue. 900 rpm
823 4/ Screw, 900 rpm Skrue, 900 rpm
When ordering spa re parts, see also page 500.50. Ved bestilling af reservedele, 5 ogs:' side 500.50.
= Only avallable as part of a spa re parts klt. tilgrengelig som en del af el reseredelssret.
aly./E = QtyJEngine Anlal/E = Antal/Motor
QtyJIndlvlduaI Anlalll = AntalIIndividuelt
07.09 ESO
,,.' DieseII
Plate
23/30
490
:~~- 058
010 J.-j---- 071
071 083
764
752 ~tl1
428
~
416
058
703 394
693
489
Cover see
plate 51102
06.49 - ESO
Plate
23/30
Ilem Ile m
. Designatlon Bencevnelse . Deslgnation 8encevnelse
010 610 Coach bolt Breddeboll 321 Guard intermedlate Mellemskrerm

058 21C 0 -ri"9 O -ring 5/ 6 cyl. engine 6 cyl. motor
071 1210 Washer Skive 7/ cyl. engine 8 cyl. motor
083 6/0 5elf locking Selvlflsende ffi0trik 333 21C S Iud Tap
129 8/C Screw Skrue 345 1/ Guard end fore Skcerm, for
154 28/ Screw Skrue 357 1/ Guard end fore Skerm, for
166 2 Cover Deksel 369 1/ Guard Skerm
178 21 Gasket Pakning 370 6/ Screw Skre
191 21C Stud Tap 382 1/ Guard end fore Skcerm, for
201 2/ Stud Tap 394 6/C Screw Skrue

only for 900 rpm kun for 900 omdr.
213 4/C Screw Skrue
404 21 Screw Skrue
225 11C Cover for camshaft Oreksel for kamakseJ-
houslng hus 416 Coer for Dreksel for
crankcase krumlaphus
237 lIC O-ri"g 0- 9 6 5 cy. engine 5 cyI. motor
7/ 6 cyl. englne 6 cyI. moIor
249 5/ Screw Skrue 9/ 7 cyl. engIne 7 cyl. motor
1 / cyl. engine 8 cyI. moIor
250 5iE Was her Skive
428 4/ Screw Skrue
262 l Guard end aft Skcerm, agIer
441 21 Tapered dowel Styrestitt
274 l Guard end aft Skcerm, agter
453 21 Was her Skive
286 Spring Fjederstifl
221 5 cyl. engine 5 cyl. motor 465 2/ MoIrik
30i 7 cy/. e ngine 7 cyJ. motor 477 6IC Metrik
34/ cyl. englne cyI. motor only for 72050 rpm kun 72050 omdr.
298 HandIe HCndtag 489 6/C Screw Skrue

221 5 cyl. engine 5 cyl. motor l for 7205 0 rpm kun for 72050 omdr.
261 6 cyl. engine 6 cyI. motor
30/ 7 cyl. englne 7 cyI. motor 490 Cove r with safety Dceksel med sikker-
34/ 8 cyl. englne cyl. motor valve. complete incl. hedsventil, komplet inkl.
item , 022 , 034 , ilem , 022 , 034,
308 Washer Skive 046 , 071 , 083 , 095 , 046, 071, 083, 095,
24/ 5 cyl. engIne 5 cyI. motor 105, 117 105, 117
28/ 6 cyl. engine 6 cyl. motor 3/ 5 cyl. englne 5 cyl. motor
321 7 cyl. engine 7 cyl. molor 4/ 6 cyl. engine 6 cyl. motor
361 8 cyl. englne cyt. motor 4/ 7 cyi. engine 7 cyl. motor ~
.;
5/ cyl. engine cyJ. molor
"
~
~

~
<:
Q
:.\
~
ro
Wh en orderlng spare parts, see aIso page 500.50. Ved bestilling af reservedele, se ogs<.\ side 500.50.
"
Only avaIlable as part a spare parIs klt. tilgcengelig som del af reseredelssce t.
atyJE QtyJEngine Antal/E = Antal/Motor
atyJ C QtyJCy/inder AntaIIC = Antal/Cylinder
atyJD = QtyJSafety cover Antal/D = Antal/sikkerhedsdc:ekseJ
06.49 - ESO
',liM MAN DieseII
Plale
23/30
Item Item
. Oty. Deslgnatlon Benrevnelse . Oty. Design ation Ben mvnelse
500 Guard Intermedlate Mellemskrerm, kompleI

compIete, incl. item inkl. item 191,286,298,
191, 286, 298, 308, 308,321,333
321,333
4/ 5 cyI. eng ine 5 cyl. molor
51 6 cyl. englne 6 cyl. motor
6/ 7 cyl. englne 7 cyl. moto
7/ cyl. engine 8 cyl. motor
693 11 Packlng Silicone

srIlcone paste
715 6/ Screw Skrue
740 1/0 0-rl"9 O-rlng
752 Safety va lve, SikkerhedsvenIil ,

complete komplet
4/ 5 cyl. engine 5 cyl. moIor
4/ 6 cyl. engine 6cyl. motor
5/ 8 cyl. engine cyl. motor
764 1/0 Fl ange Flange
When ordering spare parts, see al50 page 500.50. Ved besIilling af reseredele , se ogsf side 500.50.
Only avai lab/e as part of a spare parts klt. tilgc:engelig som en del af et reservedelssc:el.
Oty./E Qty./Englne AnIa l!E = Antal! MoIor
Oty./C Qty./Cylinder AnIal/C = AnIal!Cylinder
OtyJD Qty./Safety cover AntaVD = AnIal/sikkerhedsdc:eksel
06.49 ESO
Section 512
Turbocharger System
Description
Turbocharger System 512.01

Cleaning the Turbocharger 512.05
SericeWater Washing of Compressor
Cleaning the Turbocharger 512.15
SericeWater Washing - Turbine Side
Working card
Overhaul of charging air cooler 512-01.00

Water Washing of Compressor Side 512-01.05
Water Washing of Compressor Side - 512-05.00
Turbocharger Type NR15/R
Water Washing of Compressor Side - 512-10.00
Turbocharger Type NR20/R
Water Washing of Turbine Side 512-15.00
Plates
Charging Cooler - Freshwater 51201-04

Charging Cooler - Freshwater 51201-05
Exhaust Pipe Arrangement 51202-01
Exhaust Pipe Arrangement 51202-02
Tubocharging Arrangement 51203-09
Tubocharging Arrangement 51203-10
Steam Trap 51208-01
Description
Turbocharger System
512.01
Page 1 (2)
Edilion 01
23/30
Water washing , turbine side, inlet 7 Exhaust gas, oullet 2 1 air, inlet
Waler washing,
compressor side wilh
quick coupling, inlet
Water washing
compressor side
Lambda CyHnder 6 Drain from turbocharger, outlet
Fig. 1. Diagram for Turbocharger System
Turbocharger System The charging air cooler iS a compact tube-type

cooler with a large cooling surface. The cooling
The turbocharger system the engine, which iS a wa-ter iS passed twice through the cooler, the end
constant pressure system, consists an ehaust covers being designed with partitions which cause
gas receiver, a turbocharger, a charging air cooler the cooling water to turn.
and a charging air receiver, the latter being integrated
the engine frame. The cooling water tubes are f i ed to the tube plates
byepan s ion.
The turbine wheel the turbocharger iS driven by the
engine ehaust ga5, and the turbine wheel dri-ves From the ehaust valves, the ehaust iS led through
the turbocharger compressor, which iS moun-ted a water cooled intermediate piece to the ehaust gas
the same shaft. The compressor sucks air from the receiver where the pulsatory pressure from the indi-
engine room, through the air filters. vidual ehaust valves iS equalized and passed to the
turbocharger as a constant pressure, and further to
Turbocharger, see separate manual. the eha u st outlet and silencer arrangement.
The turbocharger pumps the air through the char- The ehaust gas receiver iS made pipe sections,
ging air cooler to the charging air receiver. From the one each cylinder, connected to each other, by
charging air receiver, the air flows to each cylinder, means compensators, to prevent ecess i ve stress
through the inlet valves. the pipes due to heat epansion.
95.26 - ESOS
1,J,IIMi,,MAN DieseII
512.01 Turbocharger System Description
Page 2 (2)
EdiIion 01
23/30
the cooled intermediate piece a thermometer for avoid excessive thermal loss and ensure a
reading the exhaust gas temperature iS fitted and reasonably l w surface temperature the exhaust gas
there iS also possibility ! fitting a sensor for remote receiver is insulated.
reading.
95.26 - ESOS
',I,I,/( Diesell
Description Cleaning the Turbocharger Service 512.05

Page1(1)
Water Washinq of Compressor Edilion
General
Compressor Chemical cleaning ll not improve the cleaning

process as this primarily iS based on th e mechanical
Fouling of the airways depends primarily on the PU- effect Irom the impact the water droplets.
rity the inlet air and thus, in turn, on the general
maintenance condition the machinery, .. mainly Certain types fluid solvents can give lormation
the gas and il tightness of the engines and on the of deposits on the compressor wheel, and should
Iresh air ventilation system the engine room. under no circumstances be used.
Fouling airlilter, compressor charging air cooler The intervals between cleaning by injection water
may be observed as changes in performance para- should be adjusted alter assessing the degree and
meters: rate of louling in the particular plant, .. based on
observations and experience.
Decreasing charging air pressure.
Decreasing turbocharger rotor speed.
Increasing exhaust gas temperature.
Severe louling airways may even result in
compressor surge.
Regular cleaning during operation by injection

water before the compressor wheel l l reduce the
louling rate considerably, and consequently prolong
the intervals between dismantling necessary lr
mechanical cleaning.
94.26 . ESOU-G
',,, Dieserl
Description CIeaning the Turbocharger Service 512.15

Page 1 (1)
Water Washing - Turbine Side EdiIion 01
23/30
V28/32S
Description
The tendency louling the gas side turbo- Heavily contaminaled turbines, which where
chargers depends the combuslion condilions, cleaned periodically Irom the very beginning after
which are a resull ofthe load and the mainlenance an overhaul, cannol be cleaned by Ihis method.
condilion the engine as well as Ihe quality Ihe
le l l used. 1I vibration the turbocharger occur after waler-wa-
shing has been carried out, the washing should be
Fouling Ihe gas ways will cause higher exhaust repealed. 11unbalance slill exisls, this is presumably
gas temperatures and higher surlace temperatures due 10 heavy louling , and Ihe engine must be sl op-
the combusti on chamber components and will ped and the turbocharger dismanlled and manually
also lead 10 a lower performance. cleaned.
Tests and practical experience have shown thal The washing waler should be taken Irom Ihe Iresh
radiaHlow turbines can be successlully cleaned water syslem and Irom Ihe Iresh cooling waler
by injection water the inlet Ihe turbine. system sall water system. cleaning agenls and
The cleaning ellecl is based th e water solubility solvents need be added 10 Ihe water.
the deposils and the mechanical action th e
impinging water droplets and Ihe water Il rale. avoid corrosion during slandstill , the engine must,
compleling waler washing al least 1
The necessary waler Il is dependent the gas hour belore slop so Ihat all parts are dry.
Il and the gas temperature. Enough water musl be
injected per time l so Ihal, l the Il will
evaporale, but abou t 0.25 I/min. wi ll I l 011Ihrough Water Washing System
the drainage opening the gas outlet. Thus ensuring
Ihal sullicienl waler has been injected. The water washing sysl em consisl s a system
equipped with a regulaling valve, a manoeuvring
Service experience has shown thal Ihe above men- valve, a 3-way cock and a drain wi th a drain
tioned waler l gives the optimal cleaning ellect. 1I valve Irom the gas outlel, see illuslration working
the waler f is reduced the cleaning effect wi ll be card 512-15.00.
reduced disappear.lfthe recommended waterllow
is exceed, there is a cerlain risk a accumulalion The waler lr washing the turbine, is supplied Irom
water Ihe turbine casing , which can result Ihe extern al fresh water system through a Ilexible
damage Ihe lurbocharger. hose wilh couplings. The Ilexible hose musl be
disconnecled after waler washing.
The besl cleaning ellecl is obtained by cleaning at
lw engine load approx. 20% MCR. Cleaning al lw activaling the manoeuvring valve and Ihe regu-
load ll also reduce lemperature shocks. lating valve, water is led Ihrough the 3-way cock 10
Ihe exhausl inlermediate flange, equipped with
Experience has shown, Ihal washing al regularinler- a channel 10 lead Ihe waler 10 Ihe gas inlel Ihe
vals is essential 10 successfuI cleaning, as excessive turbocharg er.
louling is thus avoided. Washing al intervals 100
hours is Iherelore recommended. Depending the Th e wal er which is evaporated, is led l through
l qualily Ihese inlervals can be shorler longer. Ihe drain Ihe gas outlet.
However, the turbine musl be washed al Ihe lalesl
when Ihe exhaust gas lemperature upstream the
turbine has risen aboul 20 C above Ihe normal
lemperature.
96.39 - ESO
Page 1 (2) Oerhaul of Charging Air Cooler EdiIion 01
23/30
Slopped engine Plate Item Nole

Shul-off slarling air
Shul-off cooling water
Shul-off fuel l
Shul-off cooling l
Stopped l b. l circul.
Descriplion :
Overhaul charging air cooler.

Hand lools:

Slarling posilion: Allen key, 1 mm.
Wire rope.
Tackle.
Relaled procedure:

.;
q
~
Working time 3-4 hours Plale Ilem Qy!
:1;
Capacily 2 men
'"
~
51201 11 3 6!cooler
~ Dala: 51201 029 1!cooler
9w
~ 51201 066 1!cooler
w
" Dala pressure and lolerance (Page 500.35) 61203 035 1!cooler
Dala lorque momenl (Page 500.40)
Declaralion weight (Page 500.45)
96.20 ESOS
iJ DieseII

Edition 01 Overhaul of Charging CooIer Page 2 (2)
23/30
The charging air cooler is normally cleaned and 4) Clean the cooler elemenI the water and air
overhauled at the inIervals indicaIed the "Planned sides.
Maintenance Program", or l observations prove thaI
the cooler does work satislactory, see section After using cleaning agents the manulacting recom-
502. mendation must be lollowed.
The greatest care must be eercised when dismant-

Overhaul Charging Cooler. ling cleaning and mounting the cooler element, as
the thin lns the tubes cannot stand impacts and
1) Close the cooli ng water l and l valves pressure.
and disconnecI the pipes.
1I nevertheless, the metal is bended, should be
2) Remove the screw (1) , fig 1, which secure the carelully straightened, as benI lns ll increase the
end cover the cooler element the cooler hous- pressure drop across the cooler considerably.
ing, and l l the cooler element half-way !.
Should ore more cooler tubes become leaky
Place a wire rope round the cooler element and at- iVthey must immediately be made tight, either by
tach a tackle hook, after which the elements are lfted epend in g the tube ends the tube plates or by
and pulled th e cooler housing and landed blanking th e tube(s) concern ed with plugs.
a couple wooden planks the floor.
is important that the charging air cooler is leaky
as any sea water that leaks ll be carried along
with the air the cylinders where the salt contained
5 th e water l l damage valves, piston rings, and
cylinder liners.
5) Also clean end cover and coat the inside

with an anti-corrosion blocks agent. lnspect the anti-
corrosion (6) and renew necessary.
No!e: That paint or similar must not be applied
2 these blocks.
6) Fouling and deposite the pipescan be remo-

ved by using a hand or machine operated circular
steel brush. The inner diameter is 13 mm.
7) When mounti ng the air cooler, renew all gas-

kets.
3 ! Service Periods.
longer periods service the air cooler is

Fig 1. drained ilthe coolanI is sea waIerlollowed by flushing
with fresh water and left with drain and venting cocks
open.
3) Remove screws (2) and end cover (3) reversal
chamber (4) and side plates (5). Iresh water coolanI systems recommendations
lor the entire system is lollowed.
96.20 - ESOS
Page 1 (1) Water Washing of Compressor Side Edition
General
Safety precautions Special tOOl5

Shut-off l il
Shut-off cooling l
Stopped lub. l circul .
Press button (Blocking - Reset)
Water washing compresso r side.

Turbocharger cleaning with engine service.
Starting position
Related procedure
Workin g time 1/4 hour Plate Item Qty

Capaci ty 1 man
See the special instructions turbocharg er.
Data

02.20 - ESOS-G
Working Card Water Washing of Compressor Side 512-05.05
Page 1 (2)
TurbochargerType 15/ Edition 01
5,6L23/30H

Shutofl starting air
Shutoff cooling water Hand injector.
Shut-off fuel l
Shut-off cooling l
Descriplion:
Water washing compressor side.

Turbocharger cleaning with engine service. Hand lools:
Slarling posilion:
Relaled procedure:
Manpower:
Working time 1/4 hour
Capacily man Plate Item Qty/
Dala: See the special instructions lor turbocharger.

91.45 - ESQS
!'( DieseI!
512-05.05 Water Washing of Compressor side Working Card
Edition 01 Turbocharger Type 15/ Page 2 (2)
5,623/30
Clean ing Procedure. Compressor cleaning by inspection water with

a hand injector is sufficient l a normal degree
The cleaning process is only be carried out. when louling is present.
the engine is at operating temperature and when
is loaded as close as possible l u load. In case serve dirt being deposited in the compres-
sor. dismantling the compressor. is necessary.
The engine must not be shut immediately after
cleaning but should beallowed operatecontinuous- Components lor mechanical and manual cleaning
lor some time ensure drying out the charge are necessary.
air system.
For manual cleaning compressor, see specia/
instruction.
Sequence Operations.
For wate r washing compressor side. see a/so
1) Run the engine wi th as high a load as pos- description , water washing.
sible.
2) Unscrew the plug . see fig 1. together with the

seal ring Irom air l l' silencer.
3) Fill the hand injector with clean Iresh water

and insert through the screw plug opening.
4) Inject the complete content the hand injector

within a period 4 - 1 sec.
5) Run the engine lor about 1 minutes at unal-

tered high load.
6) Make comparative measurements the ope- Hand injector - - - - '

rating data. Thiscomparison ll indicatethe success
or lack same the washing procedure.
1I necessary. carry the washing once more. Fig 1.
7) Screw in the plug togeth er with the seal ring

the air ll ' silencer.
91.45 - ESOS
I+Hg.:MAN Dieserl
Working Card Water Washing of Compressor Side 512-05.05
Page 1 (2)
TurbochargerType 20/ Edilion 02
7,8L23/30H
Slopped englne Plate Item Note

Shut-off startlng alr
Shut-off coollng water
Shut-off fuel 011
Shut-off coollng 011
Stopped lub. 011clrcu!.
Descriplion:
Water washlng compressor slde.

Turboch arger cleanlng wlth englne servlce. Hand lools:
Slarling posilion:
Relaled procedure:
Working time 1/4 hour Plate Item Qty /

Capacity 1 man
See the special instructions turbocha rger.
Dala:

91.45 - ESOS
512-05.05 Water Washing of Compressor Side Working Card
Edition 02
rbocharaer Tvpe 20/ Page 2 (2)
7,823/30
Cleaning Procedure. 1I necessary, carry out Ihe washing once more, but
wilh 1 minutes interval from Ihe initial washi ng.
The cleaning process is only 10 be carried l, when
Ihe engine is al oeral in g lemperature and when l Compressorcleaning by injection olwater is sufficient
is loaded as close as possible 10 lull load . l a normal degree louling is present.
The engine musl l be shut immedialely after case severe dirt being deposited the compres-
cleaning but should be allowed 10 operale conlinuous- sor, dismantling the compressor components lor
lor some tim e ensure drying th e charge manual cleaning is necessary.
air system.
For manual cleaning compressor side , see spe-
cial instruction.
Sequence Operalions.
For water washing compressor side, see also
1) Run the engine with as high a load as pos- description for water washing.
sible.
2) Remove th e lilling plug (6) , see fig 1 the

dosage container (5) and lll the conlainer with water.
Screw the lilling plug.
7
3) Activate the push buttom the manoeuvring
valve (3) lor approx. 20 sec.
, Irom th e compressor outlet casing w ll w be

supplied via the pipe connecti on (2) the dosage
6
container, and ll lorce th e water through the hose
(7) the injection tube (8) .
The water l l enter the compressor atomized

condition, impinge the vanes the compressor
wheel with high velocity and thus wash the dirt
deposited. 5 3
4) Run th e engine lor aboul 1 minutes at unal- 1 Charge air line 2 Pipe
tered high load. 3 Manoeuvring l 4 Hose or pie
5 Dosage container 6 Filling plug

5) Make comparative measurement the opera- 7 Hose r 8 Injeclion tube
ting data.
This comparison w ll indicate the success or lack

same th e washing procedure. Fig 1. Arrangement (, water washing.
91.45 - ESOS
DieseII
Page 1 (2) Water Washing of Turbine Side Edition 01
23/30

Shut-off fuel l
Shut-off cooling l
Descriplion:
Water washing turbine side, cleaning with

engine service. Hand lools:
Slarling posilion:
Relaled procedure:
Working time 1/2 hour Plate no. Item no. Qty. 1

Capacity 1 man
See the special instruction turbocharger.
Dala:

91.04 - ESOS
Edition 01 Water Washing ofTurbine Side Page 2 (2)
23/30
Cleaning Procedure. 3) Turn the 3-way cock 10 position 2 ' " , see
lig . 2 and check lor Iree passage. 1I ok turn the
1) Adjusl Ihe engine load 10 approx. 20 % and lel water wash position 3 "Wash".
Ihe engine stabilize lor 1 min.
4) Connect the water supply the water wash
2) Open th e drain cock at the turbocharger outlet system.
and check lor Iree passage, see fig 1.
5) Activate the manoeuvring valve, see fig 1.
Then open the regulating valve and adjusl th e water

Il l
the drain Il is approx. 0,25 I/min .
3-way cock ==
6) Continue the water washing 5 - 1 min. l
the drain water is Iree particles.
Plale wilh clean-
ing instruction --. 7) Release the manoeuvring valve and disconnect
the water supply.
Manoeuvering
valve
th e 3-way cock 10 position 1 , "Closed" and check
Regulaling valve
Cleaning
-
... ... ."
that the water drain Il has stopped .
inlel - ... --
8) Continue at this load at least 5 min . belore
Drain cock increasing the load the normal condition.
9) After the water washing, the engine should

lor at least 1 hour belore stop.
Fig 1. Arrangement for water washing. Note: The regulaling valve has be opened
slowly.
The manoeuvring valve musl be locked open

position.
Pos ition 1 Position 2 Postion 3
The water injection tim e mentioned item 6 musl
' Closed' " ' Wash"
be exceeded.
w ~:C Wdj:C ~ For water washing turbine side, see also descrip-
lor water washing.
TC - Turbocharger
W Water
F - Freeair
Fig 2. 3-way cock.
91.04 - ESQS
Plate
Page 1 (2) Charging Cooler - Freshwater 51201 -04
523/30-72050
623/30 -72050
- 294
221
101
113
029
030
042
054 " ' -
066
078
091
-~ c
"-
233

030
- 208 017
97.06 ESOS
PlaIe
51201-04 Charging Cooler - Freshwater Page 2 (2)
523/30-72050
623/30-72050
Ilem Item
. Qty. Desig rl atiorl . Oty.
017 1/ Crossmember Travers
030 2/ I A.r
042 1 1 Cooler block K01erblok
054 1 / Gasket end cover Pakning endedreksel
066 4/ Plug sc rew Propskrue
078 4/ Cu-washer Cu-skive
091 11 End coer Endedreksel
1 4/ Nu' Motrik
11 3 8/ Screw Skrue
125 1/ plate Topplade

reversing cover vendekammer
149 11 Reversl ng cover Vendekammer
150 29/ Screw Skrue
174 31 Screw Skrue
198 5/ Screw Skrue
208 11 Bottom platB Bu ndtade
221 8/ Screw Skrue
233 1/ 0 -rl"9 0-rln9
257 1/ Gas ket Pakning
269 1 / Rlng Ring
270 1/ Draln pipe for WMC DrcenrGf for WMC
282 22/ Screw Skrue
294 1 / Water mi st catcher Vandudskiller
304 1 / Charging air cooler, LadeluftkGler, komplel,

comp/ete, Incl. Item inkl. Ilem 01 7, 029, 030,
017,029, 030,042, 054, 042,054,066,078,091,
066,078,091 , 101 ,113, 101 , 113, 125, 137, 149,
125,137,149,150,174, 150, ' 74, 186, 198,
186,198,208, 221 ,233, 208,221,233,269,270
269,270 and 294 09294
When ordering spare parts, see also page 500.50. Ved beSlilling af reservedele, se ogs<\ side 500.50.
On ly aa ll a bl e as part of a spare parts klt. tilgrengelig som en del af et reservedelssret.

OyJE = Oty./Englne. AnIal/E = Anlal/Motor
a.yJK = Cooler Anlal/K = ler
97.06 - ESOS
l,,' DieseI!
PIate
Page 1 (2) Charging CooIer - Freshwater 51201-05
6L23/30H-900
7-823/30-7205900
- 294
221
/
101
066
233
208 - 017
(j \ ...+
>'(1
~ \ \
\ - 304
282
97.06 - ESOS
Plale
51201-05 Charging Cooler - Freshwater Page 2 (2)
6L23/30H-900
7-823/30-72050/900
Ilem Item
. Oty. Oesignation Benrevnelse . Qty. Oesignatlorl 8erJrevneIse
029 11 Crossmember Travers
030 21 Plpe A.r
042 1 / Cooler block K01erblok
054 1 / Gas ket end cover Pakning endedmksel
091 1 / End cover Endedceksel
101 4/ Nut Metrik
113 Screw Skrue
125 1 / plate Toplade

reversing cover vendeka mmer
149 1/ Reverslng cover Vendekammer
150 29/ Screw Skrue
174 31 Screw Skrue
186 31 Cu-washer Cu-skive
198 5/ Screw Skrue
208 1 / Bottom plate Bundplade
221 8/ Screw Skrue
233 1/ 0-rl"9 0- 9
269 1/ Rlng Ring
270 11 Draln pipe for WMC Drc:enr0r for WMC
282 221 Screw Skrue
294 1 / Water mist catcher VandudskiHer
304 1 / Charglng l cooler, Ladeluftkoler, kom pleI,

complete. Incl. Item inkl . item 01 7,029, 030,
017,029,030,042,054, 042,054,066,078,091,
066, 078,091,101 ,1 13, 101,113, 125,137, 149,
125, 137,149,150, 174, 150, 174, 186, 198,
186,198,208,221,233, 208,221,233,269,270
269,270 and 294 og 294
When orderlng spare parts, see also page 500.50. Ved besIilling af reservedele, se ogsa side 500.50.
Only ava llable as part of a spare parts klt. Iilgrengelig som del af el reseredeI ssceI.
Oty./E Qty./Englne. = Anlal!Motor
atyJK = Cooler Antal! K = l
97.06 - ESOS
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-01
5L23/30
6L23/30-72050
132
073
132
061 085 107
097
r--~
] ~
000

~-~
fu
132

,~

168
144
156
239
~ 012-181
(240
024 024
_ ,
/ '
'Q
~~~;'
7:36
193
203 264
v-
~ 252
264
98.34 - ESOS
Plale
51202-01 Exhaust Pipe Arrangement Page 2 (2)
523/30
623/30-72050
Ite m Item
. Des lgn ation Be n ev n e l s e no. aly. Designation Benre vnelse
01 2 1IC Intermediate plece, Mellemstykke, kom-

comp lete, incl. item plet, inkl. item 18 1, 193,
181 , 193, 2 03 , 21 5 203,215 og 227
and 227
024 2IC Gasket Pakn ing
036 4IC Screw Skrue
061 1 Exhau st for Udstodsr0f for

cyl. 1 cyI. 1
073 1 Flange Ftange
085 Co lnpensator Kompensator

41 5 c yl. en gine 5 cyl. motor
5 6 cyl. engi ne 6 cyl. motor
097 1 Compensator Kompensalor
107 1 End cover, aft Endeplade. bag
144 Screw Skrue
156 1 6 Nul Molrik
168 8 Screw Skrue
181 1IC Intermediate piece MellemsIykke
193 3IC Plug screw Propskrue
203 3IC Gasket Pakning
215 1IC Plug sc rew Propskrue
227 1IC Sea llng ring Tretningsring
239 1IC Screw Skrue
240 4IC Screw Skrue
252 1IC Cooll ng wate r Kolevandsnippel

nlpple
264 2IC O-rlng O-rlng
276 Exhaust pi pe Udstzdsrzr

4 5 c yl. eng ine 5 cyl. motor
5 6 c yl. englne 6 cyl. motor
288 8 Screw Skrue
When orderlng spa re parts, see also page 500.50. Ved besIilling af reservedele, se ogsA side 500.50.
Only avallable as part of a spare p arts kIt. tilgrengelig som del af el reservedelsscet.
Qly.lE QtyJEn g/ne AnIal/E = Antal/ MoIor
Q y.C = QtyJCylInder Antal/C = AnIal/cyIinder
98.34 - ESOS
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-02
7-823/30-72050
6-7-8L23/30H-900
132
073
132
]
'--'~ ,
'" t. 2Jr;1~
144
156
=..J

239
012-181
240
024 ( 024
_
215
193
203 1-:
~ 252
264
227
264
98.34 ESOS
/ DieseI[
Plale
51202-02 Exhaust Pipe Arrangement Page 2 (2)
7-823/30-72050
6-7-8L23/30H-900
Item Item
, Qty. Deslgn atlon Benrevnelse no. aty. Deslgnation Benrevnelse
012 lIC IntermedIate piece, Mellemstykke, kom-

complete, Incl. item l l , inkl. Ilem 181, 193.
181, 193, 203, 215 203. 215 og 227
and 227
024 2fC Gasket Pakning
036 4/C Screw Skrue
061 l Exha ust pipe for Ud S Idsrr lor

cyl .1 cyl. 1
073 l Exhau st UdstodsrOf
085 Compensator Kompensalor

5/ 6 cy l. engine 6 cyl. molor
7/ 8 cy. engine 8 cyl. motor
097 l Co mpensator Kompensalor
107 l End cover, aft Endeplade, bag
144 / Screw Skrue
156 8/ l Molrik
168 1 61 Screw Skrue
181 lIC Intermediate p lece Mellemslykke
193 3/C Plu g screw Propskrue
203 31C Gasket Pakning
215 lIC Plug screw Propskrue
227 lIC Sea llng ring Tffitningsring
239 lIC Screw Skrue
240 4/C Screw Skrue
252 lIC Cooli ng water K01evandsnippel

nl pple
264 2fC rin g O-ring
276 Exhaust pl pe Udsl0dsror

7/ cyl. engine 8 cyl. molor
When orderl ng spa re pa rts, see also page 500.50. Ved beslilling af reservedele, se ogs~ side 500.50.
Only ava iIabIe as part of a spare parts klt. tilgrengelig som del af re serede lss ret.
Qly./E QtyJEnglne Antal/E = AnIal/Motor
QlyJC = QtyJCy ll nder Antal/C = Antal/cylinder
98.34 ESOS
"+ DieseI!
Plate
Page 1 (2) Turbocharging Arrangement 51203-09
523/30-72050 RPM
623/30 -72050 RPM
151
246 ---I;:o\'""",,~
018 See ins1ruction book

for turbocharger
234
209
210
449 ______
450 -_---.:::~
462
295 ---)
283 ? :>' ==:!;!i'-1 02 ~'.--- For charge alr cooler

378 see plate 51201
138
114

378
,,\ ~,
, ;'

----:::::::~~,;:::::= 295
"....- - 283
305
391~ 391 317
401 413
401 6 425
401
305
03.18 - ESOS
fN" , MAN Dieserl
Plate
51203-09 Turbocharging Arrangement Page 2 (2)
523/3072050 RPM
623/3072050 RPM
Ilem Item
. Qty. Designation Be nrevne lse . Qty. Designation Be n ~ v n eI se
018 1 / Gas outlet Gasudlob 449 1 / Gasket Pakning
031 1 2/ Screw Skrue 450 4/ Screw Skrue
043 1 / Bracket for Konsol 'or 462 1/ Diffu sor Ditfuser

tubocharger turbolader
055 61 Screw Skrue
067 6/ Spring lock Laseskive
079 61 Screw Skrue
114 1 / S hle ld Skmrm
138 1 / Cooler box ( Kolerboks for ladeluft

charge alr
151 1 / Compensator KompensaIor
209 1/C Inlet p/pe Indslromningsror
222 4/C Screw Skrue
234 1/C Sealing ring Trelningsring
283 21 PJug screw Propskrue
317 2/ Packlng ring Pakningsring
378 11 ac ki ng Si licone
sillcone paste
391 4/ Nut M0trik
401 8 Screw Skrue
413 21 Support Holder
425 2 Support Holder
437 4/ Sc rew Skrue
When ordering spare pa rts, see also page 500.50. Ved bestilJing af reservedele, se ogs~ side 500.50.
= On ly avaiIable as part of a spare parts klt. til gengelig som en del af et rese rve d e l sse l.
Qty.lE OtyJEnglne Antal/E = AnIal/Motor
Qty./C OtyJCylinder AntaVE = Antal/CyJinder
Qly./1 = OtyJlndi vidu al Antal!1 = Antal/lndividuell
03.18 ESOS
'}1',,, DieSeII
Plate
P_ge 1 (2) Turbocharging Arrangement 51203 - 10
6L23/30H-900
7-823/30-72050/900
151
354
246
271 ~~f(-- 031

-.....
366
330
018
329
092
See Instructlon book
for turbocharger
234
258
209
043 - --L./) 210
067
055
449
450 ---=:::::~
295
283 '""'~-- For charge cooler
see plate 51201
533
378
138
114

378
Ifl ",.,~..

....
~:::::::;J.~~~ 295
~I~
\ ....- - 283
305
391 ~ ~ 391 317
401 413 305
~425
401 401
97.06 ESOS
+ Dieserl
Plate
51203-10 Turbocharging Arrangement Page 2 (2)
623/30-900
7-823/30 -72050/900
Item Item
. Qty. Designation Bencevnelse . Qty. Designation Benrevnelse
018 1/ Gas o utlet Gasudl0b 366 1 6/ Screw Skrue
031 16/ Screw Skrue 378 /1 Packing Siticone

si llcone paste
043 1 / Bracket for Konsol for
tubocharger lurbolader 391 4/ Nut MeIrik
055 5 Screw Skrue 401 8/ Screw Skrue
067 5 Sprlng lock Laseskive 413 21 Support Holder
079 6/ Screw Skrue 425 21 Support Holder
092 1 / Gasket Pakning 437 4/ Screw Skrue
102 14/ Screw Skrue 449 1/ Gasket Pakning
114 1/ Shie ld Skrerm 450 4/ Screw Skrue
126 1 8/ Screw Skrue 462 1/ Diffuser
138 1/ Cooler box for K01erboks for ladeluft 533 1/ Flange Flange
charge
151 1 / Compensator KomensaIor
209 1/C ll e pipe IndstromningsrBf
222 4/C Screw Skrue
234 1/C Sealing ring Tretningsring
258 16/ Nut M0trik
295 2/ Packlng rlng Pakningsring
317 21 Packlng rlng Pakningsring
329 1 / Plug screw Propskrue
342 1 / Packing ring Pakningsring
354 1 6/ M0trik
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs~ side 500.50.
Only avai lable as a a spa re as kit. Kun tilgrengelig som en del af el reservedelsset.
Qty.lE = QtyJEngine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/E = Antal/Cylinder
QtyJI QtyJIndividual Antal/l = AnlaVlndividuelt
01.30 ESOS
PlaIe
Page 1 (2) SteamTrap / 51208-01 /
23/30
V28/32S
015
052
064
039
040
97.07 - ESOS
f,I,:,tH'fMAN DieseII
151208-01 SteamTrap ptaIe
Page 2 (2)
23/30
V28/32S
Item Item
. Deslgnatlon Bencevnelse . Qty. Designatio n Bencevnelse
015 1/ Stea m trap, Vandudlader,

complete komplel
027 l Packing Pakning
039 1 / Cli p Ktemme
040 / House, bottorn Hus, bund
052 / House, t op HU $,
064 / Swimmer Svommer
076 1/ Valve Venlil
When orderlng spare a s, see al50 page 600.50. Ved beSlilling af reseredele, ogSt' side 600.50.
On ly avallab/e as par t of a spare parts kit. Iilgcengelig 50m del af reservedelsscel.

QtyJE = Qty.lEnglne Qty./E = QIy.lMotor
97.07 - ESOS
5ection 513
Compressed System
Descrition
Compressed System 513.01
Working card
Filter 513-01.21
Oerhaul, Test and Inspection of Turbine Starter 513-01 .30
Main Starting Vale 513-01.40
Check of Compressed Piping System 513-01.90
Plates
Turbine starter 51309-01

Main Starting Vale 51310-01
Muffler 51312-01
Emergency Starting Vale 51313-01
Starting Vale 51314-01
Main Stop Vale 51315-03
Strainer 51316-01
Safety Vale 51319-01
ON-OFF Vale for Jet System 51320-01
Filter 51321-02
Pressure Reduction Vale 51322-02
, ,Ji@'MAN DieseII
Descriplion
Compressed Air System 513.01
23/30
On011 valve
for jel system
Reduclion
l
Charging . Max. Working pressure: 10 bar

air t Starting Reduction valve and salety
l l 10 be removed.
Emergency
valve
Standard
Optionals
Fig 1 DiagraIn for compressed air system.
General Control System
The compressed air system the engine contains The air starter is activated electrically with a pneu-
a starting system, starting control system and saIety matic 3/2 way solenoid valve. The valve can be acti-
system . Further, the system supplies air ( the jet vated manually from the starting bo the engine,
system. and ! can be arranged ' remote control, manual
or automatic.
The compressed air is supplied from the starting
air receivers (3 bar) through a reduction station, For remote activati on, the starting spool is connected
where from compressed air at 7-9 bar is supplied so that every starting signal ( the star ting spool goes
( the engine. through the safe start function, which is connected
( the converter ' engine RPM .
avoid dirt particles the internal system, a strainer
is mounted the l ! line ( the engine. Further, the system is equipped with an emergency
starting valve which makes ! possible to activate the
air starter manually case a power fai lure.
Starting System
The engine is started by means a built-on air

starter, which is a turbine motor with gear bo, saIety
clutch and drive shaft with . Further, there is a
main starting valve.
OO.1 1 -ESO
MlM,, MAN DieseII
513.01 Description
Edilion 05 Compressed System Page 2 (2)
L23/30
Safety System When the maximum permissible RPM iS exceeded,

the overspeed device wi ll activate a pneumatically
As standard the engine iS equipped with a pneuma- controlled lambda controller, which l l bring the luel
tically/mechanically overspeed device, which starts index and stop the engine.
operate l the maximum permissible RPM iS
ceeded. This device iS l itted the end cover the
engine driven lubricaling pump and iS driven Irom Emergency Starting Valve
the pump through a resilient coupling.
The emergency starting valve is activated by means
a screw-driver similar as illustrated l ig 2.
Pneumatic Start Sequence
When Ihe starting valve is opened, air wi ll be supplied

th e drive shalt housing the air starter.
Press down Emergency
start vaIve The air supply ll - by acti vating a piston - bring the
drive engagement with Ihe gear rim
the engine wheel.
When Ihe is lully engaged, the l air ll

Il to, and open the main starting valve, whereby
air ll be led 10 the air starter, which will start 10
turn the engine.
When the RPM exceeds approx. 140, at which l iring

has taken place, the starling valve is closed whereby
Fig 2 Emergency start alve.
the air sl arter is disengaged.
OO.11-ESO
Page 1 (2) Filter Edition
General
Stopped engine Plale no Ilem no Nole

Shut-off cooting water
Shut-off fuel l
Shut-off nozzle cooling l
Press Blocking - Reset
Cleaning and/o r maintenance air filter.
Starting position
Related procedure
~
.; Manpower Replacement and wearing parts
"
v
~
~
Working time hours Plale no Ilem no Qy/
~
Capacity man
"
~
Data
"
"
Data lor torque momenl (Page 500.40)
02.46 - 50
,,'.J DieseII
EdiIion FiIter Page 2 (2)
GeneraI
Cleaning Filter replace filter element
1) Depressurize !. 7) Depressurize !.
2) Remove bowl and bowl guard assembly by 8) Remove bowl and bowl assembly by turning
turning counter-clockwise. counter-clockwise.
3) Inspect bowl lor damage seals and replace, l 9) Unscrew ballle by turning counter-clockwise.
nessesary.
1) Remove lilter element and discard.
4) 1I bowl becomes dirty clean it by wiping the
bowl with a soft dry cloth mild detergen!. 11) Install new filter element and reassemble
reverse ord er.
5) Before returning to service, insure that aII seals
have been rein stalled replaced. 12) Belore returning to service, insure that all seals
have been reinstalled replaced.
6) ReinstaII bowl and bowl guard assembly and
rotate bowl guard clockwise to securely lock 13) Reinstall bowl and bowl guard assembly and
place. Align arrow bowl guard with arrow lilter rotate bowl guard clockwise to securely lock
body. place. Align arrow bowl guard with arrow lilter
body.
~ L
1f
Fig 1 Fi/ter
02.46 - ESO
WorkIng Card
Overhaul, Test and Inspection ofTurbine Starter
513-01.30
Page 1 (9) EditIon 01
23/30

ShU-off cooling water 52006 261 20 - 120 Nm.
Shut-off l l
Shut-off cooli ng l
Descriplion:
Disassembly, overhaul and assembly the air

starter. Hand lools:
Allen key, 4 mm.

Allen key (Iong), 8 mm.
Screwdriver.
Slarling posilion: Big screwdriver.
Chisel.

connections the ai r starter have been re- Retaining ring pliers.
moved, and air starter is removed. Plastic hammer.
Lubricating l.
Copaslip similar.
Sleeve.
Bearin g puller.
Relaled procedure: Impact Wrench
Bearing pressing tool.
Working time 4 hours Plate Item /

Capacity 1 man
See plate 51309.
Dala:

Declaration weight (Page 500 .45)
03.4 7 - ESO-G
III,,zN'fMAN DieseII
513-01.30 Worklng Card
Ed itlon 01 OverhauI, Test and Inspection ofTurbine Starter Page 2 (9)
23/30
General lformato
7 6
1) Always mark adjacent parts the housing
exhaust cover (1) , motor housing (8), intermediate
gear case (13), gear case (28) and drive housing
(40) so these members can be located the same
relative position when the starter is reassembled.
Note: disassemble the starter any lurtherthan

necessary replace damaged parts.
Never reuse old seals O-rings.
Never wash the inertia drive a solvent.
2) remove any part which is a press l

a subassembly unless the removal that part
is necessary lor replacement repairs.
3) Always have a complete set seals and 0-

rings hand belore starting any overhaul the Fig 1.
turbine starter.
4) When grasping a part a vice, always use 5) Remove the dellector retaining screw (5) , de-
copper-covered vice jaws protect the su rface the Ilector retaining spring (4) and the splash dellector
part and help distortion. This is particularly (3) Irom the housing exhaust cover (1), See fig 2.
threaded members.
Housing Exhaust Cover, Motor Assembly, and

Motor Housing
5
1) 1I replacing the motor assembly (12) , remove
both housing plugs (1 ) and drain the l Irom the
gearing belore beginning disassembly Ihe starter.
lnspect Ihe magnelic housing plugs (1) lor metal
particles. Very l e metal particles are normal. Re-
move particles and reinstall plugs. Large particles
chips are an indicalion a problem . Disassemble
gear case (28) and inspect.
2) Using a screw driver, unscrew the exhaust

cover (67) Irom the housing exhaust cover (1).
Fig 2.
3) Using an 8 mm hex-head wrench, unscrew

and remove the starter assembly cap screws (6) 6) Tap the motor housing with a plastic hammer
and washers (7), See fig 1. dislodge l Irom the intermediate gear case (13).
4) u the housing exhaust cover (1) Irom Ihe 7) Grasp the rearofthe motor assembly (12) and
motor housing (8). dislodge the housing exhaust ll Irom the rear the motor housing (8).
cover, rotale l the ears clear the motor housing. 1I the motor assembly (12) is difficult remove , lightly
Using a plastic hammer, tap the ears alternately l push the motor which is the the
Ihe housing cover can be removed Irom Ihe motor motor assemblyloward the exhausl side the motor
housing. housing order Iree the motor assembly.
03.47 - ESO-G
',lI,.., MAN DieseII

Page 3 (9) OverhauI, Test and Inspection ofTurbine Starter Edition 0 1
23/30
8) Tap the intermediate gear case (13) with a 13) Remove Ihe planet gear Irame assembly Irom
plastic hammer dislodge Irom the gear case Ihe inlermediale gear case. Using a sleeve that con-
(28). lacls Ihe ouler race Ihe Ironl gear Irame bearing
(17) , pre ss the planel gear Irame shalt seal (16) and
9) Position the intermediate gear case (13) on a Ihe Iront gear Irame bearing (17) Irom the Ironl end
bench in a copperfaced vice so that th e inlermediale and Ihe rear the inlermediate gear case.
pinion (26) is secured in the jaws the vise. Tighten
Ihe vice only enough 10 hold the inlermediate pinion 14) Remove Ihe rear gear Irame bearing (24) Irom
securely. the planet gear Irame (18), using a bearing puller
and remove Ihe gear shaf1 relaining washer (23) ,
1 ) Loosen Ihe inlermediale pinion relaining screw see fig 4.
(27) 1-1 /2 turns only. 00 nol remove. Remove Ihe planet gear shaf1s (22), planet gears
(19), planet gear bearings (20) and bearing spac-
Warning: 1I Ihe inlermediate gear case is nol sup- ers (21).
porled on a bench and l the inlermediale pinion
retaining screw is completely removed , Ihe interme- 15) Remove Ihe Iront bearing spacer (25) , using
diate gear case and compomenls cou ld lall causing a bearing puller and Ihe gear shalt relaining washer
injury. (23) Irom Ihe Ironl Ihe planet gear Irame by press-
ing on Ihe Ironl th e planel gear Irame shaf1.
11) Tap the inlermediate pinion lighlly 10 back the Remove Ihe gear shaf1 retaining washer only l Ihe
planet gear Irame assembly Ihe inlermediale washer Ironl bearing spacer is damaged.
gear case.
12) Remove Ihe intermediale gear case assembly

Irom the vice and remove the inlermediate pinion
(26). Remove the rear gear case O-ring (14) and
Ironl gear case O-ring (15) Irom th e inlermediate
gear case (13), See fig 3.
14
Fig4.
Planet Gear Frame Drive Housing

Assembly
1) Grasp Ihe drive pinion (63) in a copper-Iaced
vice wilh the starter supporled on Ihe workbench.
Fig3.
03.47 - ESOG
513-01.30 WorkJng Card
EditIon 01 Overhaul, Test and Inspection of Turbine Starter Page 4 (9)
23/30
2) Remove the drive retaining screw (61) ment is necessary and new parts are available. The
which has a right-hand thread. bearing and/orthe seal always be damaged when
removed from the drive housing.
3) Remove the starter from the vice.
15) Remove the piston ring (55) from the piston
4) Remove the drive washer (62) and the (54).
drive (63).
16) Press the clutch spring cup (50) down and
5) Slide the spring sleeve (64) and the remove the clutch spring cup retainer (49).
spring (65) off the drive shaft (57).
17) Remove the clutch spring cup and clutch spring
6) Unscrew the drive gear screw (34). Using an (51 ).
impact wrench with a 5/16" (8 mm) 8" (203 mm)
log hex inserted the end of the drive shaft. 18) Remove the clutch jaws (52).
7) Unscrew and remove the drive housing cap 19) Remove the front drive gear bearing (30), drive
screws (38) and lock washers (39). gear cup (36), drive gear lock washer (35) , drive gear
screw ring (37) and drive gear screw (34).
8) Tap the drive housing (40) with a plastic ham-
mer help dislodge from the gear case (28). 20) Remove the large drive shaft bearing retainer
(53) using a screwdriver.
Warning: Failure followthis procedure could result

injury personnel. 21) Press the rear drive shaft bearing and drive
shaft (57) of the piston. If the rear drive shaft
9) Place the drive housing (40) an arbor press, bearing needs be replaced, proceed as follows:
piston end . Apply a load the piston (54) using
the arbor press compress the piston return spring a. Cut and remove the small drive shaft bear-
(59) before removing the bulkhead retainer (45). 00 ing retained the drive shaft, using a small
use compressed air load the piston. chisel.
b. Press the rear drive shaft bearing (58) off
1 ) Remove the bulkhead retainer (45). Using a the drive shaft.
screwdriver and the arbor press.
22) Place the gear case (28) a workbench.
Caution: Make sure the tension of the spring pushes
the bulkhead of the drive housing before removing 23) Remove the drive gear bearing retainer (32),
the drive housing from the arbor press. using retaining ring pliers and working through the
access holes the gear web, See fig 5.
11) Remove the bulkhead (46) from the piston
(54). 24) ll the drive gear (29) of the gear case.
12) Remove the bulkhead ring (47) and the Note: 00 disassemble the drive gear and clutch
bulkhead ring (48). parts ofthe turbine powered starters. lf the drive shaft
is defective, instaII a factory-rebuilt !.
13) Slide the drive shaft (57) from the drive housing
(40). 25) Remove the drive gear shaft bearing retainer
(33), using retaining ring pliers.
14) ll the piston ' spring (59) off the drive
shaft. 26) Remove the rear drive gear bearing (31) from
the drive gear.
Note: 00 remove th e front drive shaft bearing
(42) the drive housing seal (43) unless replace-
03.47 - ESO-G
Page 5 (9) Overhaul, Test and Inspection ofTurbine Starter EditJon 01
23/30
5) Install the drive gear bearing retainer, using

retaining ring pliers and working through the access
holes th e gear web.
6) lubricate the drive gear with approximately

32
240 ml SHELL I grease.
7) Press the rear drive shaft bearing (58)

the drive shaft.
8) Slide the small bearing retainer, convex side

lirst, the drive shalt. Press position
accordance with the instructions packaged with the
----'-- new retainer.
9) Assemble the drive gear Schrew (34) , drive

Fig5. gear lock washer (35), drive gear cup (36) and drive
gear screw O-ring (37).
Assembly the Starter 10) Grasp the drive shaft (57) a vice, external
splined end down. Place assembled drive shaft screw
1) Always press the inner ring a ball bearing the drive shaft, screwhead down. lubricate
when installing the bearing a shaft. the inside diameter the drive shaft with SHELL
I grease.
2) Always press the outer ring a ball bearing
when pressing the bearing a bearing recess. 11) Slide the drive gear bearing (30) the drive
shaft.
3) Whenever grasping a part a vice, always use
leather-covered, copper-covered vice jaws protect 12) lubricate with SHELL I grease
the surface the part and help prevent distortion. and install the driving clutch jaw teeth lacing and
This is particularly true threaded members. driven clutch jaw teeth lacing down the drive
shaft.
4) Always clean every part, and wipe every part
with a thin Iilm l belore installation. 13) Insert the clutch spring (51) the drive
shaft.
Gear Case 14) Insert the clutch spring cup (50) the drive
shalt.
1) Place the drive gear bearing retainer over the
rear end the drive gear. 15) Press the inserted parts the drive shaft,
and install the clutch spring cup retainer (49).
2) Press the rear drive gear bearing (31) the
rear end the drive gear, using an arbor press. Note: 1I is necessary replace the drive hous-
ing (40) and drive components, make sure that the
3) Seat the rear drive gear bearing the gear piston seal has been removed Irom the rear th e
case by tapping th e opposite end the drive gear, new piston (54).The piston seal must be removed
using a plastic hammer. prevent pressure build-up which ll cause move-
ment the planet gear Irame shaft seal (16). 1I this
4) Install the drive gear shaft bearing retainer conditions occurs, the piston cannot retract and the
(33), using retaining ring pliers. drive (63) ll remain engagement with the
Ilywheel, causing damage the starter drive train
03.4 7 - ESO-G
EditIon 01 Overhaul, Test and Inspection ofTurbine Starter Page 6 (9)
23/30
andlor starter motor. remove the piston seal, Warning: Make sure the bulkhead retainer is properly
sert a screwdriver inside the lip the seal and pry seated the motor housing groove belore easing 011
loose Irom the piston. the arbor press. Failure do so will allow improperly
retained parts separate when removed Irom the
16) Install the piston (54) the drive shaft til arbor press resulting injury personnel.
the rear drive shalt bearing seats the piston.
27) Remove the drive housing Irom the arbor
17) Coil the large drive shaft bearing retainer (53) press.
the groove the piston retain the outer race
the drive shaft bearing, using a thin Ilat blade 28) Lubricate and install the drive housing O-ring
screwdriver assist this operation. (41) the groove the drive housing.
18) Lubricate the piston O-ring (55) and install 29) Position the assembled gear case a work-
the groove the piston. bench. The as-sembled must be upright accept
the drive housing.
19) Position the drive housing an arbor press, Carelully position the assembled drive housing (40)
pinion-end down and install the dri ve housing seal the gear case so as damage the piston
(43) intothedrive housing . Using a pressing sleeve seal. Align th e punch marks the gear case and
the proper size, press the seal the drive housing drive housing.
so that the lip the seal laces away Irom the drive
. 30) Install the drive housing cap screw lock wash-
ers (39) and the drive housing cap screws (38) and
20) Press the bearing the drive housing l tighten 28 Nm torque.
seats, using a sleeve that contacts the outer race
the Iront drive shalt bearing (42). Drop the piston 31) Tighten the drive gear screw (34) 77.3 Nm
return spring seat (60) Iront drive shaft torque, using an impact wrench with a 8 mm 203
bearing. mm long hex inserted the end drive shall.
21) Slide the piston return spring (59) the 32) Grease and slide the spring (65) and
drive shaft and snap the Iront the piston so the spring sleeve (64) the end
that is against the large drive shaft bearing retainer the drive shaft.
(53).
33) Grease the end the drive shaft and
22) Lubricate and insert the assembled drive shaft install the drive pinion (63).
the drive housing.
34) Grasp the drive a copper-covered
23) Lubricate and install the outer bulkhead 0- vice with the starter supported a workbench.
ring (47) and the Inner bulkhead O-ring (48) the
bulkhead (46). 35) Place the drive washer (62) drive
retain ing screw (61).
24) Slide the bulkhead the piston.
Note: The thread the drive retaining screw
25) With the drive housing the arbor press, press is right-hand thread.
down the rear lace the piston.
36) Install the drive retaining screw
Note: Feel the underside the drive housing make the end the drive shalt and tighten 108.5 Nm
sure the drive shaft passes through the bearing. torque.
26) Install the bulkhead retainer (45), using a

screwdriver.
03.47 ESOG
Page 7 (9) Overhaul, Test and Inspection ofTurbine Starter Edition 01
23/30
llermediale Gear Case, Molor Housig, Molor 6) Install the other planet gear shaft retaining
Assembly ad Housig Exhausl Cover washer over the shalt at the rear the planet
gear.
1) Press the gear Irame bearig (17)
the rear ofthe intermediate gear case (13), using a 7) Press the rear gear Irame bearing (24) the
bearing pressing 1001 the proper size. shaft at the rear the planet gear Irame, using the
proper size bearing inserting l.
2) Press the planet gear Irame shaft seal (16)
the rear the intermediate gear case over the Iront 8) Slide the planet gear Irame assembly, coupling
gear Irame bearing, using a sleeve which contacts end lirst, the rear the intermediate gear case
the ring the seal. (13) , making surethatthe planetgears mesh withthe
ri ng gear. Use care so as damage the seal.
: Make sure the Ilat side the seal is installed
against the beari ng. 9) Install the intermediate (26), making
sure that the notches at the rea r the align
3) Install the rear gear case O-ring (14) the with the notches and tangs the shaft the planet
groove al the rear the intermediated gear case gear Irame.
and the Iront gear case O-ring (15) the groove at
the Iront the intermediate gear case. Coat both 10) Clean the threads the intermediate
O-rings. retaining screw (27) and apply 2-3 drops Perm-
abond 118 the threads approximately 3 mm
4) Install gear shaft retai ning washer (23) Irom the end the screw. Install screw and tighten
the Iront the planet gear Irame (18). Press the Iront enough hold assembly together.
bearing spacer (25) the Iront shaft the planet
gear Irame hold the gear shaft retaining washer 11) For lna l tightening , position the intermediate
snugly position. gear case so the intermediate is secured
the jaws the copperfaced vice. Tighten the
Nole: Coal the Ironl bearing spacer with gear Lube mediate retaining screw 122 Nm torque.
belore installing . Be carelul gouge scratch
the Iront bearing spacer during installation as this 12) Remove the intermediate gear case Irom the
could resu lt leakage between the planet gear vice and set a bench.
Irame and gear case.
Nole: The intermediate gear case l l work only
5) Place planet gear Irame a bench, shalt side one orientation.
down. Place the planet gear bearing (20) inside
planet gear (19). Place bearing spacers (2 1) Align the punch marks the intermediate gear
and boom bearing and gear. Slidethecomponents case and gear case and tap the intermediate gear
the slots the side the planet gear Irame. case with a plastic hammer l seats the rear
Align holes spacers and bearing with holes the gear case. Make sure the intermediate
planet gear Irame and insert planet gear shaft (22), meshes with the drive gear.
integral keyed end down, through the spacers and
bearing so that Ihe larger Ihe keyed end Coat the O-rings the motor assembly and the
the shaft contacts the planel gear shaft retai n- inside the cylinder belore installing the motor
ing washer (23). Repeat the procedure lor the assembly.
remaining planet gears and components.
13) Install the motor assembly through the rear
Nole: move turn the planet gearlrame the motor housing with the geared end the rotor
l step 6 and 7 have been completed. Movement toward the Iront.
the planet gear Irame assembly could dislodge
assembled components, making necessary
repeat step 5.
03.47 - ESO-G
DieseII
EdiIIon 0 1 Overhaul, Test and Inspection ofTurbine Starter Page 8 (g)
23/30
Fig 6. TiIrbine Starter.
Note: Turn the intermediate so that the gear and tap the housing exhaust cover with a plastic
the rotor meshes with the planet gears. Make hammer l seats.
sure that the rear the motor assembly is installed
Ilush with the rear the cylinder. 18) InstaIi the housing exhaust cover the rear
the motor housing using the starter assembly cap
14) Align the punch marks the motor housing screws (6) and cap screw washers (7). Use an 8 mm
with the punch marks the intermediate gear case hex-head wrench tighten each a l ttl at a time
and tap the motor housing with a plastic hammer l a lna l torque 61 68 Nm increments.
seats the rear the intermediate gear case.
19) the exhaust cover (68) the housing
15) Install the splash dellector (3), dellector retain exhaust cover (1).
ing spring (4) and dellector retaining screw (5) th e
rear the housing exhaust cover. Note: Use Intersoll-Rand 5MB-441 sealant
all plugs.
Note: Coat the threads the deflector retaining
screw with Ingersoll-Rand 5MB-441 sealant. 20) Install the bottom housing plug (1 ) and the
housing plug l boss (11). the starter its
16) Coat the exhaust cover seal (2) and instaIi side with the side plug hole upward. Add 175 ml
the groove the housing exhaust cover. automatic transmission Iluid Iullilling 11 D
specilication, e.g. SHELL , through the
17) Align the punch marks the housing exhaust side plug hole.
cover with the punch marks the motor housing
03.47 - ESO-G
Page 9 (9) Overhaul, Test and Inspection of Turbine Starter EditIon Q1 H
23/30
Caution: Do overfill. Remove the pressure Irom the "" por!. Measure
Install the side housing plug (1) and tighten all plugs the distance lorm the lace the drive shaft
6.8 13.6 Nm torque. the the lace the mounting Ilange. should be
Test and Inspection Procedure 45.0 +2.0 mm.
1) CluIch Ratcheting: Turn the drive shaft 4) Action: Secure starter a vise and ap-
(63) by hand the direction the starter rotation. ply 90 psig (6.2 bar/620 kPa) pressure using a 3/8"
The clutch should rachet smoothly with a slight click- (9 mm) supply line the inlet the motor. starter
ing action. should smoothly.
2) and Gearing Freeness: Turn the 5) MotorSeals: Plugtheexhaustandslowlyapply

drive shaft (63) opposite the direction the 20 psig (1.38 bar/138 kPa) pressure the inlet
starter rotati on.The drive shaft should turn by the motor. Immerse the starter lor 30 seconds
hand. non-Ilammable, bubble-producing liquid. 11 Ihe starter
is properly sealed, bobbles w l l appear.
NoIe: Inadvertent application air pressure the
'" port wl l result drive mallunction ( w ll 6) Gear Case Seals: Plug the exhaust and slowly
la l retract).11this condition occurs, loosen the drive apply 20 psig (1.38 bar/138 kPa) pressure tothe inlet
housing cap screws (38) vent gear case (28). Also, the motor. Immerse Ihe slarler lor 30 seconds
loosen housing plugs (10) and (1 1) vent motor. non-Ilammable, bubble-producing liquid.
3) Engagement: Apply 50 psig (3.4 There should be leakage the housing joinls
bar/345 kPa) pressure the engagement " " por!. Ihe gear case area the shall seal the
drive shall (63) should move outward and air inlermediate gear system. 1I the starler is properly
should escape Irom the ' " por!. sealed, bubbles w ll appear.
Plugthe"OUT"portandapply 150psig (1 0.3bar/1034 7) Conlirm Drive : Apply l w pressure

kPa) pressure the " " por!. Check and make sure 10 the molor and observe rolalion. Drive (63)
that air is escaping. must rotate the direction slamped Ihe nameplate.
Chamler leelh should be Ihe trailing
Measure the dimension Irom the lace the drive edge the gear toolh.
shaft (63) the lace the mounting lIange.
1I should be 69.0 +2.0 mm).
03.47 - ESO-G
WorkIng Card 513-01 ,40
Page 1 (2) Main Starting Valve Edition Q1H
23/30

Stopped engine
Plate Item Note
Shut-off fuel l
Shut-off cooling l
Descriplion:
Lubricating , disassembly and reassembly main

starting valve starting system. Hand lools:
Soft hammer.
Locking ring plier.
Allen key, 1/4' .
Slarling posilion:
Relaled procedure:
Working time hou r Plate Item Oty/

Capaci ty man
51310 104 1/eng
Dala:

Data for torq ue moment (Page 500.40)
Dec laration weight (Page 500.45)
94.22 - ESOSG
$%'!/ DieseII
513-01.40 Main Starting VaIve
WorkIng Card
23/30
Warning: Disassembly:
l aIIempl any mainlenance Ihe main slarl- 4) Clamp Ihe main slarling valve, a vice wilh
ing valve belore Ihe slarling air syslem has been Ihe locking ring (9) end up.
bled off.
5) Carelully remove Ihe locking ring (9). The end
plug (3) should spring .lf l does l , lap Ihe valve
Important: housing (1) lighlly wilh a soft hammer l does.
The main sl arling valve should be periodically lubr 6) Remove Ihe end plug (3), spring (8) and pislon
caled as lollows: (2) assembly.
1) Blend Ihe air pressure. 7) Remove and discard all used O-rings, O-rings
relainer (5), bumper (7) and spring (8).
2) Remove lhe plugscrew () . see fig 1and squirl
aboul 30 9 1 w l Ihe valve Ihrough Ihe plug 8) Wash all olher parls a clean, nonllammable
opening . so l ven.
3) Reinstall Ihe plug.

Reassembly:
9) Using O-ring lubricanl, lubrcale and inslall

Ihe piston O-ring (4) and the new upper pislon
O-ring (6) Ihe pislon (2).
6
1 ___________ _
Note: The upper piston O-ring (6) is slighlly larger
diameler Ihan Ihe end plug O-ring (11).
2 c 1) Turn Ihe pislon over and inserIIhe newbumber

(7).
4
11) Using O-ring lubr ca nl, lubrcale and inslall Ihe

new end plug seal O-ring (10) and Ihe end plug
O-ring (11) Ihe end plug (3).

12) Lubricale Ihe lower small bore the valve
housing (1) with O-ring lubrcanl.
10
13) Inserl Ihe piston assembly Ihe valve hou-
sing . Push Ihe pislon l Ihe piston O-ring seals
Plug screw aIr
againsl Ihe bevelied lace.
C SlartIng air oullet D Starti ng alr ll
14) Install the O-ring retainer (5) with Ihe large
1 Valve housing 2 Piston opening over Ihe piston O-ring.
3 End plJg 4 Piston o-ring
5 O-ring retainer 6 Piston o-ring
7 Bumper 8 Sp rng 15) Place Ihe piston spring (8) Ihe
9 AetainIng ring 10 O-ring slon.
11 O-ring
16) Place th e end plug assembly Ihe pislon
spring.
Fig 1. Main startIng va /ve.
17) Using a press hold down Ihe end plug as-
sembly, install Ihe end plug locking ring (9) .
94.22 - ESOSG
Page 1 (2) Check of Compressed Piping System Edition Q1H
23/30
Stopped engine Plate lIem Note

Shut-off fuel il
Shut-off cooling l
Check compressed l piping system. Screwdriver.
Slarling posilion:
Compressed air connected the engine.
ReIaled procedure:
Working time: V2 hour Plate Item Qty

Capacity 1 man
Dala:

94 .21 - ESOU-G
',.f DieseI!
513-01.90 Worklng Card
Edi!Ion 01 Check Compressed Piping System Page 2 (2)
23/30
With connected. With disconnected and stopped engine.
1) Examine the piping system for leaks. 6) Move aII valves and cocks in the piping system.
Lubricate valve spindles with graphite similar.
2) Retighten all boltsand nuts in the piping system.
7) Connect the air supply and make a function test
3) Drain the system for condensed water.. This of the emergency valve. See description 513.01.
should be based on observati ons.
4) Check flexible connections for leaks and dama-

ges.
5) Check manometers.
94.21 - ESOU-G
+ DieseII
Plate
Page 1 (3) Turbine Starter 51309-01
23/30
\
\,
)
96.26 - ESOS-G
l~HZ'IIIIMAN DieseII
Plate
51309 -01 Turbine Starter Page 2 (3)
23/30
Item Item
. aly. Oesignation Bencevnelse . aly. Designatlon Benrevnelse
014 I/S Housing exhaust Hus udsI0ds-drek- 254 I/S Bearing spacer LIgemellemstykke
cover sel
266 '/S Planet gea r s haft PlaneIgearaksel
026 1/S Exhau st c over seal Telningsr ing for ud-
sl0dsdreksel 278 2/S Gear shaft retalner Spcenderingsskive
wa sher gearaksel
038 1/S Spl ash deflector Stccnk doflcktor
291 ,/S Rear gea r frame Bagersle gearstelleje
051 I/S Deflector return Ret r fJeder for de- bearlng
spring Ilektor
301 I /S Front bearing spacer Forreste gearslelleje
063 1/S Deflector retaining Spcendeskive
sc rew deflektor 313 1/S Intermedl ate nl Mellemlandhjul
075 4/S Starter assembly cap Ocekselskrue lr mon- 325 1/S Intermediate Spendeskrue mel-
screw lage aI slarler retaining screw lemtandhjul
087 4/S Cap s crew washer Skive deksel skrue 337 1/S Gear case Gearkasse
099 I/S Motor housIng Motorhus 349 ,/S D gear Drivgear
109 I/S Housing plug Prop l molorhus 350 I/S Front drIve gear Forreste dr lvgearleje
bearing
110 1/S Housing plug Inlet Tilgangsknast p rop
boss molorhus 362 1/S Rear drive gear 8agerste drlvgearleje
bear/ng
122 1/S Motor as sembly Motor samling
374 ,/S D gear bearIng Sprendskrue driv-
134 2/S CylInder o-rlng seat. O- r ings letnlng retainer gearleje
cyllr1der
386 1/S D gear shaft Spen d skrue drlv-
146 2/S Housing o-rlng seal. O- r Ingste t n I ng for bearlng retalner g earakselleje
motorhus
398 1/S gear screw Drvgea r sk r ue
158 1/S Intermedlate gear Mellem gearkasse
case 408 1/S Drive g ear lock Skive drivgear
washer
171 1/S Rear g ear case - 8agerste gearkasse
ring o-rlng 421 gear cup Deksel for drivgear
' /S
183 1/S Front gear case Forresle gearkasse 433 I/S Drlve gear screw O-rlng drivgearskrue
o -rlng o-rlng o-rlng
195 I /S Planet gear fram e Tetnings r ing pla- 445 8/S houslng cap Dekselskrue driv-
shaft seal. netgearakselstel screw gear
205 I/S Spacer ring Afstandsring 457 8/S Drlve housing cap Skive drekselskrue
screw lock washer l l drivgearhus
217 l Front gear frame ForresIe gearstelleje
b earlng 469 1/S Drive houslng kit Drivgearhus
229 1/S Planet gear frame Planetgearstel 470 I/S houslng o-ring O-ring for drivgea rhus

230 I /S Planet gear Plalletgear 482 I /S Front shaft bearlng Forresle akselleje
242 1/S Planet gear needle

roller
Nalevalse p lanet- 494 1/S housing seal. Tretnll1gsring for driv-
gearhus
~"
~
gear
~
~
::

When ordering spare parts, see al so pag e 500.50. Ved bestilting af reservedele, 5 og$~ side 500.50. ""

On ly available a$ part ot a spare part$ kit. tilgreng elig som del af el reservedelsscet.
alyJ/E = Oty./Englne Oly./E Oty./Motor
alyJS = Oty.rrurbine Staer O' y./S Oty.rrurblneslar Ier
96.26 - ESOS-G
Plate
Page 3 (3) Turbine Starter 51309-01
23/30
Item Item
. Qty. Deslgnatlon Benmvnelse . Qty. Deslgnation Bencevnelse
504 1/8 Dr/ve hous/ng vent Aflflningsprop (or 768 Spare parts kit, Incl. Reservedelsscet ,nkI.
plug drivgearhus Item 026, 134, 146, ilem 026. 134, 146. 171 ,
171,183, 195,205, 183,195,205,217, 254,
516 1/S Bulkhead reta/ner SkoIholder 217,254, 278,291, 278,291,301,470.516,
301 , 470,516, 541 , 541, 553. 624, 685 og
528 1/8 BUkhead kit Skotscel 553,624,685 and 697
697
541 1//8 Outer bUkh ead Ydre skot o-rlng
o ring
553 1/S l bulkhead Indre skol o-rlng

o-rlng
565 1/8 Clutch sprIng cup FjedertaIIerken holder

retainer
577 1/S Clutch spring cup FjederIallerken
589 1/S Clutch sprlng KoblingsfJeder
590 1/S Clutch jaw kit KoblingssceI
600 1/8 Large drlve shatt Stor lejespcenderng

bearing retalner drivaksel
612 1/S PIston kit Selels;;e
624 1/S P/ston o-rlng Stempel o-ring
636 1/8 shatt kIt Drivakselsret
648 1/S Rear drIve shaft Bagerste drivakselleje

bearing
661 1/S Piston return sprlng Sternpel re\urfjeder
673 1/8 Seat Sredering
685 1/S Drive reta in- Tandhjursspcende

ing screw skrue
697 1/8 Drive l washer Talldhjulsskive
781 1/8 ll Tandhjul
707 1/S l spring sleeve Tandhjulsb0sning
719 1/S sprlng Tandhjursfjeder
720 1/8 !n let l lange klt Tilgangsflanges<eI
732 3/S Cover Da9ksel
744 1/S 5elt drllllng screws Selvborende skruer
756 1! Turblne starter, TurblnesIarter, klJel

comp lete
When orderlng spare parts, see also page 500.50. Ved besliIIlng af reservedele. ogsa side 500.50.
Only avalable as part a spare parts klt. tilgcengelig som del af el reservedelsscet.
Qty./E = OtyJMotor Oty./E Qly./Molor
QtyJS OtyJTurbIne Staer Oty./8 Qly./Turbfneslarter
96.26 . ESOSG
Plate
Page 1 (2) Main Starting Valve 51310-01
23/30
045'
021'
057' - ---1+--- - - - 033'
082' --J1---~~~~~;;jt
~~~---- 069'
094
070'
94.22 - ESOS-G
Plate
51310-01 Main Starting Valve Page 2 (2)
23/30
Item Item
. aty. Designation B e n ;ev n e l se . Qty. Designation Ben;evnelse
021 " 1 0-rln9 0- 0 9
033- 1 0 -rln9 retainer O-rlng holder
045 1 0-rln9 O-ring
057 1 Bumper SI0dfanger
069 1 Spri n g Fjeder
070 1 0-I9 O-rlng
082 1 0 -rln9 O-ring
094 1/ Maln startIng valve, Hovedstar!ventII,

complete kornplet
104 1 Spare part kit Aeservedetssret

Item . 021 , 033, I nr. 021, 033, 045,
045 , 057, 069, 070 057, 069, 070 and
and 062. 082.
When ordering spare parts, see al50 page 500.50. Ved bestillIng af reservedele, se ogsfl side 500.50.
Only ava iIable as part of a spare parts kit. Kun lilgrengelig som del reservedelssret.
Oty,/E QtyJEnglne Antal/E = Antal/MoIor
OtyJV = Qty.IValve AntalN = AntalNentil
94.22 - ESOS-G
'M,',"MAN DieseII
Plate
Page 1 (2) MuffIer I S1312-01H
23/30
r
010
J
-- - - - - - - - - - --- ----------
111 111
'\
94.22 - ESOS-G
',6' DieseII
IS1312-01H MuffIer Plate

Page 2(2)
23/30
Ile m Ilem
. aly. Deslgnation Bencevnelse . aty Oeslgnation Benrevnelse
010 lS Muffler Ocemper
When ordering spare parts, see also page 500.50. Ved besIilllng af reservedele, se ogsA side 500.50.
Only aval lable as part a spa re parts kit. Kun tilgcengelig 30m en del af reservedelsscet.
QtyJS = QtyJStartlng air motor Anlal/S = Antal/Startemotor
94.22 . ESOSG
',"i DieseII
Plate
Page 1 (2) Emergency Starting VaIve 51313-01
23/30
053'
01 6 .
089' 100'
090'
028'
041 ' 077'

065' .
100'
~~ 136
94. 22 - ESOS-G
l
51313-01 Emergency Starting Valve Page 2 (2)
23/30
Ilem Ile m
. Qty. DesignaIion Bencevne Ise . Qty. Designation Bencevnelse
0 16 1 / Emergency starti n g N0dstartevenlll,

va lve, complete kompler
028* 1/V Piston SIempel
041 * 1/V Washer SkIve
053' 4/V Screw Skrue
065 1/V M0trik
077 1/V Sprlng Fjeder
089 1/V Gasket Pakning
090 1/V Gasket PaknIng
100' 2/V Gasket Pakning
11 2 1/V R kit, in c. ilem ReservedelssreI, inkl.

053,089, 090 a nd 100 ilem 053, 089, 090
og 100
124 1/V kit, incl. Ilem Reservedelssret, inkl.

028, 041, 065 , 0 77 Ilem 028, 041,065,077
and 112 og 112
136 1/V Silencer Lyddcemper
When orderlng spare parts, see al50 page 500.50. Ved bestIlling af reservedele, se ogsfl side 500.50.
Only available as part of a spare parts kit. u tilgcengelig som del af et reservedelssa!t.
Qty./E QtyJEnglne AntalIE = Antal/Motor
QtyJV = Qt yJVa lve AnIa!N = ArJtalNentl
94.22 - ESOS-G
Dieserl
Plate
Page 1 (2) Starting VaIve 51314-01
L23/30
084'
011
059'
060
023'
072'
047'
035'
94.22 - ESOS-G
Plate
51314-01 Starting Valve Page 2(2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Designation Bencenelse
011 1/ Starting valve, Startevenlil,

complete klet
023' I Armature, compJete Anker, komplet
035' 1 Sprlng Fjeder
047" 1 Gasket PaknIng
059 1 Guide , complete Styrer0f, komplet
060 1 Solenoid Sole
072' 1 Gasket PaknIng
084- 1 l M0trik
096 I Repair kit, incl. Item ReservedeJsset , Inkl.

023 , 035, 047 , 072 ,1em023, 035, 047, 072
and 084 og 084
106 I Repair kit, incl. Item Reservedelsscet, inkl.

059 and 096 Ilem 059 og 096
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele. se ogsA side 500.50.
= Only avai lable as part of a spare parts klt. u tilgcengelig som en del af reservedelsscet.
Qly./E = Qty./Englne Antal/E = Antal/Motor
Qly.N QtyJVa lve AntalN = AntalNentil
94.22 - ESOS-G
":,, Dieserl
Plale
Page 1 (2) Main Stop VaIve 51315-03
L21/31 , L21/31CR
L23/30, L27/38
066 - -
vaIves and fittings

has 10 be approved by
cIassificalion sociely.
042
00.41
,:, DieseI[
Plate
51315-03 Main Stop VaIve Page 2 (2)
21/31 , L21/31CR
23/30, 27/38
Item Item
. DesIgnation Benrevnelse . Qty. Deslgnation Benrevnelse
042 1/ Stop alve, Stopvelltil,

comp tete komplel
066 1 Gasket PaknIng
078 I Gasket PaknIng
When orderlng spare parts, see page 500.50. Ved bestilling af reservedele, se ogsfl sId e 500.50.
On ly available as part of a spare parts kit. u tilgrengelig som del af el reservedelsscet.

aIyJE Qty./Englne Antal/E:;;: Antal/Motor
aIyJV Qty.Na lve AntalN = AntalNentil
00.4 1
i( DieseI!
Plate
Page 1 (2) Strainer I S1316-01H
23/30
012- _____
----..._.-
085
048 -__
---FT-(;-'',,,,,--r~~
__ 1 t
024--------- /
061 \
097 107 ~
073- ________ _
94 22 - ESOS-G
I,IIl$N MAN DieseI!
Plale
51316-01 Strainer Page 2 (2)
23/30
Item Item
. Designatio n Bencevnelse . aty. Des ignation Bencevnelse
012 1/F Houslng
024 l/F Cover Dcekse!
036 I/F Filter Filter inds8ts
048 4/F Stud
061 4/F M01rIk
073 / Alr strainer, Filter, komplet

complete
085 1/F Gasket PaknIng
097 1/F Plug screw Propskrue
107 1/F Gasket PaknIng
When ordering spa re parts, see al50 page 500.50. Ved bestilling af reservedeJe, se og5a side 500.50.
= Only available as part of a spare parts klt. Kun tilgcengelig som del af et reservedelssrel.
atyJE Qty./Engine. Antal/E = Antal/Motor.
atyJF atyJFiIter. AntaljF = Antal/Filter.
94.20 . ESOSG
PlaIe
Page 1 (2) Safety Valve 1 51319-01
23/30
019
'- -
h D h D r
WUr " - - - 020 uru r
r----J ~ -JI
------_.---- 044
032
94.22 - ESOS-G
IS1319-01H Safety Valve Plate
Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Bencevnelse . Qty. Designation Bencevnelse
019 1 Safety valve. Sikkert1edsventil,

(10 bar) ( 10 bar)
020 1/ Safety valve, Sikkerhedsventil,

(15 b ar) (15 bar)
032 1 Protective devlce Beskytlelsesh<:etle
044 3/ Screw Skrue
When ordering spare parts, see al50 page 500.50. Ved beslillrng af reservedele, se 0958: srde 500.50.
On ly avallable as part a spare parts kIt. trlgrengelIg som del af el reservedelsscet.

QtyJE Qty./Englne. ArJtal/E = Anlal/Motor.
94.22 ESOSG
'M'NI/fMANDieseIJ
Plale
Page 1 (2) ON-OFF VaIve for Jet System 51320-01
23/30
.=====>
11
014
V
026
/
J
/
J !
/
[ -[ 1/,
!
~
/ 038
'-- 051
063
075
~
087
---
r--
/ \
---
f---
- '----
94.22 - ESOS-G
Plate
51320-01 ON-OFF Valve for Jet System Page 2 (2)
23/30
Item Item
. Deslgnation Bencevnelse . . Designation Bencevnelse
014 1 Coi l Spole
026 1 Housing
038 1/ Va lve, complete 3) " l. kompleI 3,.'

connecting branch IIlsltningsstuds
051 1/ Valve, complete 1" l, komplet l '

Connecting branch Tilslutningssluds
063 1/ Valve, complete 1 %" l. kompler V4'

Connecting branch T ilsltnIngsstuds
075 1/ Valve, complete 1 Ih " l , komplet 1 V;>'

Connectlng branch TilslutnIngsstuds
087 1/ Valve, complete 2" Ventil, kompleI 2'

Connecting branch Ti l sltnIngssluds
When ordering spare parts, see al50 page 500.50. Ved besliJlIng aI reservedele. se ogsa stde 500.50.
= Only avaiiabIe as part of a spare parts kit. u tilgoongelig som en del af et reservedelsseet.
OtyJE = QtyJEngine. An1al/E = Antal/Motor.
OtyJV QtyJValve. AntalN = AnlalNentII'
9422 - ESOS-G
f,l,j,$N'iMAN DieseII
Plate
Page 1 (2) FiIter 51321-02
GeneraI
177 - - ,
02.46 - ESO
Plate
51321-02 Filter Page 2 (2)
General
Item Item
. DesIgnatlon Bencevnelse . aty. Des ignation Bencevnelse
177 1 / Filter complete Filter komple!
189 1/F Repalr kit Reparalionsscet

(fiJter and O~ring) (filIer og O-rlng)
When ordering spare parts, see a l50 page 500.50. Ved beslilling af reservedele, se 095.3. side 500.50.
OnJy available as parI of a sare parIs kit. Iilgrengelig 50m del af el reservedelssret.
aly.lE = Qly.lEngine. Antal/E = AntalJMotor.
02.46 - ESO
Mi4'IMAN Dieserl
PlaIe
Page 1 (2) Pressure Reduction VaIe 51322-02
16/24
23/30
039*
218
015 ~ 027
039* :;'6,"~
231
172 ~ (j "" ""
243 184* ~~;;~
~~- 040
064* ~ 052*
076* ----=::-~::-
_c:>
~--
-C>
088* ------~~~-
valves and fittings

has 10 be approved by
classification society. 206
255
111
r-----
123* --c:::>
135* = - - f I
(2) (2)
147* ---------=c;
159* -----c=::>
160' ~
70 - Inlel 10 engine
99.03 ESOG
"li/(MAN DieseII
Plale
51322-02 Pressure Reduction VaIe Page 2 (2)
L16/24
L23/30
Item Item
Designation Benrevnelse Qty. Deslgnatlon Benrevnelse
015 1 Cover Dceksel
027 10 Screw Skrue
039* 2 Fi lter Filler
040 1 Tube incl. owring A0r, inkl. -"9
052* 1 0-rl"9 0- 9
064* 1 Diaphragh Membran
076' 1 0-rl"9 O-rlng
088' 1 O-rl"g 0-ri"9
111 1 Valve, complete l, komplet
123' 1 0-rl"9 0-rln9
135" 1 Valve spring Ventilfjeder
147" 1 0 -rl"9 0- 9
159' I O-rl"g 0- 9
160 I Bottom plug, incl. Bundprop, inkl.

o-rl"9 - 9
172 2 I plug Rorprop
184 2 0-rln9 0- 9
196 1 Repalr klt, incl. Itern ReparaIionssrel, inkl.

039,052,064, 076,088, ilem039, 052, 064, 076,
123, 135, 147, 159, 088,123,135, 147,159,
and 184 and 184
206 1/ Reduction valve, RedukIionsvenlil,

complete komplet
218 1 / Pllot valve, complete SIyrevenlil, kompIet
23 1 1 Repair kit for Item Reparalionssoot for

218 item 218
243 2 Screw Skrue
255 1 Manometer Manometer

0-25 bar - 70 0-25 bar - 70
267 1 / Pressure reductlon Trykreduklionsvenlil,

valve, complete komplet
When orderlng spare parts, see also page 500.50. Ved beslilfing af reservedele, se ogsA side 500.50.
= Only availabIe as part of a spare parts kit. lilgrengeJig som en del af et reservedelssret.
/ = Oty/Englne Anlal/E = Anlal/Molor
OtyNalve AnlalN = AntalNenlil
99.03 - ESO-G
5ection 514
InternaI FueI System
Description
Internal Fuel O l System 514.01
Working card
Fuellnjection Pump and Fuellnjection 514-01.05

Fuel Injection Valve 514-01.10
Fuel Ol Split Filter 514-01 .15
Check of Fuel l Piping System 514-01.90
Adjustment of The Maximum Combustion Pressure 514-05.01
Fuel l Feed Pump 514-10.00
Plates
Fuellnjection Pump 51401-10

Fuel Injection Valve - NICO 51402-16D
Fuel Injection Valve 51402-16
Fuellnjection Valve 51402-17
Fuel Injection Valve, Cooled - NICO 51402-18

Fuellnjection Valve, Uncooled - NICO 51402-19
Fuel Ol Flter Duplex 51403-03D
Fuellnjection 51404-01
Fuel Ol Feed Pump 51410-01
Pipes Cylinder Section 51430-01
DescripIion 514.01
Page 1 (3) Internal Fuel l System Edition 01
23/30
Flywheel end
Cyl.1
Leak from

FueI - ilvalv~
feed
pump " "',-~
Drain -
from cyl.
head
"""
pipe
-~
pressure
pump
_ _ Fueloil
inIet
'-4+r-",
~~--t=~=-=========:=::j ~/-----f
FuelIeakage alarm ILeak from
Fueloil fuel pump
filter
3 2 1
WasIe , FueI l, FueI ,
inieI outlet inIel
Fig. 1. Diagram for Fuel l System
General
The internal built-on luel l system consists the The salety l l ter is a duplex Iilter the split type with
lollowing parts: a llter lineness 50 my. The llter is equipped wi th a
common three-way cock lr manual change both
the luel l leed system the inlet and outlet side.
the high-pressure injection equipment,
comprising luel l injection pumps, luel l During normal operation both lilters should be
injection valve and luel l high pressure operation. Single operation only to be used when
dismantling the llter s lr manual cleaning
the waste l system inspection.
The leed pump (l part the delivery,) which is the

Inlernal Fuel l Feed Syslem gear wheel type, is equipped with a spring-Ioaded
adjustable by-pass valve.
The luel l is led to th e injection pumps through a
salety lilter by means the engine driven leed pump The outlet pressure the leed pump can be adjusted
(l part the delivery). by means an adjusting screw the by-pass valve
assembly.
94.26 ESOS
514.01 Descrjplion
Internal Fuel System Page 2 (3)
Edilion 01
23/30
Forcirculation luel duri ng stand-still the engine, The injection valve is lor "deep" building-in 10 the
a by-pass l ne iS mounted with a non-return valve centre Ihe cylinder head.
parallel to the leed pump.
FueI Injection VaIve

FueI Injection Equipment
The luel il injeclion valve consists a nozzle holder
Each cylinder unit has its own set injection equip- and a nozzle connecled by a union nu!. The nozzle
ment, comprising injection pump, high-pressure holder includes a threaded stub lor mounling
and injection valve. the high-pressure . is led Ihrough a boring in
the cylinder head , togelher wilh an adjusting screw,
The injection equipment and the distribution supply a spring and spring spindle lor Ihe inilial tensioning
pipes are housed in a lully enclosed compartment Ihe nozzle needle.
thus minimizing heat losses Irom the preheated
luel. The inilial tension Ihe spring, which delermines Ihe
opening pressure the nozzle, can be adjusled by
This arrangement reduces external surface tempera- means Ihe cenlra lly-mounled adjusling screw.
tures and the ri sk l caused by l uel leakage.
On the uppermosl Ihick parl Ihe holder, there are
Ihree sealing O-rings.
FueI Injection Pump
Between the w lowest O-rings, Ihe leak l Irom Ihe
The luel il injeclion pump is inslalled on the roller nozzle needle is led out inlo Ihe space belween the
guide housing directly above the camshaft, and is high-pressure and the proleclion tube.
aclivaled by Ihe cam on the camshaft Ihrough roller
guides l " ed in Ihe roller guide housing. The nozzle and needle are lapped logelher as a
pair, and cannol be replaced individually. The noz-
The injeclion amounl the pump is regulated by zle is controlled by w pins allached 10 Ihe bottom
Iransversal displacement a toolhed rack in the Ihe holder.
side Ihe pump housing.
The joinl surface belween Ihe nozzle and holder is
meansol a gear ring, the pump plunger wilh Ihe w machine-Iapped make oil-ligh!.
helical millings, the culting-off edges, is turned.
The l uel injeclor is mounted in Ihe cylinder head by
Hereby Ihe length Ihe pump slroke is reckoned means the inlegral flange in Ihe holder and w
Irom when the plunger closes Ihe inlel holes until the studs wilh dislance pieces and nuts.
cutting-off edges again uncover Ihe holes.
bore in the cylinder head venls Ihe space below
The release high pressure Ihrough the cu"ing-off the bottom rubber sealing ring on Ihe injeclion valve,
edges presses Ihe l wilh greal lorce againsl Ihe wall thus prevenling any pressure build-up due to gas
the pump housing. Ihe spot, w exchangeable leakage, but also unveiling any malfunction Ihe
plug screws are mounted. bottom rubber sealing ring lor leak l.
Th e amounl luel injected into each cylinder unit

is adjusl ed by means Ihe governor.
1I mainlains Ihe engine speed al Ihe presel value

by a conlinuous positioning the luel pump racks,
via a common regulating shall and spring-Ioaded
linkages lor each pump.
94.26 - ESOS
Description 514.01
Page 3 (3) InternaI FueI System Edition 01
23/30
Fuel l High Pressure Waste System
The connection between injection pump and l Waste leak l from the compartm ent, l valve and
injector is a shielded high pressure . The high engine leed pump is led ( a lel leakage alarm
pressure is equipped with connection tapers uni!.
matching ( simiular taper facing s on the threaded
connectors on the injection pump and the l in- The alarm unit consists a box with a Iloat switch
jector. for level monitoring. ln case a larger leakage th an
normal leakage, the float switch l l initiate alarm.
The supply l l the engine is led through the
unit in order ( keep this heated , thereby ensur-
ing free drainage passage even for high-viscous
waste/leak l.
94.26 - ESOS
'( DieseII
Working Card
FueIInjection Pump and FueI Injection Pipe 514-01.05
Page 1 (4) Edilion 1 2
L23/30
Safety precaution5: Special tOOI5:
! Stopped engine Plate . Item .

Shut-ofl cooling water 52014 013

Shut-oll luel l 52014 025
Stopped lub. l circul . 52014 253
52006 261 20-120 Nm
52006 273 80-360 Nm
De5cription:
Dismounting, inspection/overhaul and mounting

luel
injection pump. Inspection fuel injection
.
Hand tOOI5:
Starting 05n:
Ring and open end spanner 13 mm
Cover Iron! luel injection pump has been Ring and open end spanner 14 mm
removed. Ring and open end spanner 17 mm
Allen key 8 mm, 10 mm
l' lor lock ring.
Tools lor cleaning.
Related procedure: Clean kerosene or gas l.
Clean lubricatin g l.
Inspection roller guide lor ! seize product (Copaslip, Molykote GN Plus
luel injection pump, 508-01.05 or similar).
Manpower:
Spare and wearing part5:
Working time : 4 hours
Capacity 1 Man Plate . Item . /
51401 189 1/pump

51401 190 1/pump
Data: 5140 1 236 1/pump
51401 248 1/pump
DaIa lor torque moment (Page 500.40)
Declaration weigh t (Page 500.45)
08.03 - ESOS
',l DieseII
514-01.05 FueI Injection Pump and FueI Injection Pipe Working Card
23/30
Dismounling luel injeclion pump 8. Take out the plunger spring () , upper spring plate
() and (J) . 1I necessary remove the lock ring ()
1. Dismount the le l injection pipe pos. 1 fig 1 and guide () and dismount the regu lating rod () as
and the lel inlet pipe pos 2. well as the cap screw the opposite end the regulating
rod () .
2. Separate the spring loaded lever Irom the
regulating rod the luel injection pump.
D,F
2
G

3
5
6
J R

Fg 1 View from Contro/ Side

3. Remove the pipe lor lb. ol and drain.

4. Remove the screws the botom Ilange (4

pieces) and take th e lel injection pump away.
2. O-ring inside dia. 37 mm 3
Separalion fuel injeclion pump.
5. 1I necessary, clean the exterior the injection

pump. Fig 2 Cross Secton ( Fue//njection Pump
6. the injection pump the clamping

bracket PYO-W020 (see p/a/e 52014 i/em 037),
9. Unscrew the lor screws () and remove the
the test pump.
connecting piece (8) . Take the valve spring ()
and the non-return valve (F).
7. Press the thrust cap () lig. 2 downwards and
remove the securing ring (). Remove the thrust cap
10. Loosen and remove the lor screws (C) and
() with lower spring plate () and plunger (). Be
take the barrel () .
sure l 10 damage Ihe plunger.
11. Remove all the O-rings Irom the injection
pump.
06.03 ESOS
Working Card
Fuel Injection Pump and Fuel Injection Pipe 514-01.05
L23/30
12.
par ts must be cleaned, using kerosene Assemblng luel injection pump:
gas l
and a hand bru sh ( a steel brush).
l through the holes lor sealing l th e pump 17. When assembling the injection pump, proceed
houses and th e barrel (). the reverse ord er disassembling. PayattentIon
the lollowing:
Inspection luel injection pump: . initial tightening new parts the lollowing
(C) lr barrel ().
13. Insert plunger () and non-return valve (F) Tighten screws 55-65 Nm.
the barrel () alter wetting with clean gas l. Plunger
and non-return valve must slide the barrel by . Renew all sealing rings. For placing the rings,
their weigh!. see fig 2.
14. The axial clearance between lower spring plate C. Coat all the threads with an anti seize pro-
and plunger l t must exceed 0.25 mm. Th e duc!.
clearance between lower spring plate and plunger
l t is 0.05 0. 1 mm when new. See fig 3. D. dry with paper plane sealing surlace
barrel () and connecting piece ().
. Belore inserting the (J), the easy mo-

th e plunger () the barrel () must be
checked.
Plunger ()

~ Spring ()

~' ==iE~;~i~gr- Lower

~ Plate
spring
()
t Marking on
regulating rod
Tooth with chamfer
Fig 3 Clearance between Lower Spring Plate and P/LInger Marking on pinion
15. Check the cavitation plugs (G) lor wear and

renew l necessary.

Fig 4 Mounting of Regulating Rod Mechanism
16. Barrel (), plunger () and non-return valve
(F) are manulactured very close tolerances.
Any attempt relini sh th ese parts causes altera- F. Wh en assembling the n (J), ascertain that
tions the tolerances and must therelore be the tooth (recognizable by th e chamler) ll enter
carried !. the space the regulating rod ( ) marked by
1I during the visual inspection the parts, heavy sings, see fig 4.
abrasion symptoms damage can be observed,
the par t question must be replaced.
08.03 - ESOS
514-01.05 Fuel Injection Pump and Fuel Injection Pipe
Working Card
23/30
G. The marking Ihe guide cam Ihe plunger 20. Reconnect the regulating rod ( ) the spring
(), must be l ne with the marking the slots loaded lever and all the pipes the luel pump.
the (J). ( shown lig 4).
18. After assembling, the easy motion the re Fuel injection pipe:
gulating rod (), must be checked and the plunger
() must be moved Irom the noload stop lulHoad normal working conditions the luel injection
stop. require very lttl maintenance ecept replacement
O-rings and gaskel connection with the normal
overhaul luel injection equipment.
Mounting luel injection pump:
19. Belore mounting the luel injection pump, clean

the roller guide spring and washer lor spring the
roller guide housing.
08.03 - ESOS
Working Card
Fuel Injection Valve
514-01.10
Pag. 1 (4) Edilion 02
23/30

Stopped engine
Plate
52006
Item
26 1
Note
20- 120

Shut-off fuel l 52014 013
Stopped lub. l circul. 52014 204
520 14 300 Et ra tools
52014 361
52014 407
Descriplion:
Dismounting, overhaul, pressure testing and

mounting fuel injection valve.
Slarling posilion: Hand 10015:
cover the cylinder head and cover Ring and open end spanner 12 mm
the fuel injection pump has been dismounted . Ring and open end spanner 24 mm
Fuel injecti on pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools cleaning.
Clean kerosene gas l .
Antiseizure product.
(Copaslip, Molykote GN Plus similar).
Relaled procedure:

Capacity 1 man
51402 11 6 3!valve
Dala:

95.50 - ESOS
+' DieseI[
Edilion 02 FueI Injection VaIve Page 2 (4)
L23/30
The luel injection valve is the single component that 3. Clean the lower part Ihe nozzle (J) Irom
has the greatest influence the diesel engine con- carbonized oil deposits belore dismantling the nozzle
dition. Various lorms operation and quality luel ! (). Remove the nozzle ! () and th e nozzle
oil aHect the overhaul intervals.ln some cases ! may (J).
be necessary shorten the prescribed intervals.
DismounIing and cleaning: D
1. Dismount the lel injection valve Irom the cy-

l nder head by means the special tool as shown
in lig. .
. Lock F
c. Sealing ring
D. Adjusling screw G
. Sealing ring
F. Nozzle spring
G. Spring spindle
. Nozzle ul J
J. Nozzle
Fig 2 Fuel injection valve.
AIIenIion!
! damage the lapped surface.
4. The nozzle spring (F) and the spring spindle

(G), are to be taken by loosening the adjusting
Fig 1 Dismounting fue/ injection vafve !a) cylinder head. screw (), completely.
5. parts must be cleaned with kerosene gas

2. Mount the luel injection valve the clamping oil and a hard brush (! a steel brush).
bracket VTO-W020 (see p/ate 52014, item 025)
the pressure Iesting pump, and loosen the lock ! 6. Clean the nozzle holes charred coke by
() lig 2. means the supplied special drill (see p/ate 52014-
Unstress the nozzle spring by Urning the adjusting I item 108) wiIh holder.
screw ().
7. Clean the cooling chamber and th e cooling
ducts the nozzle guide and injector body by placing
these a cleaning liquid and then blow through the
parts with dry working air.
95.50 ESOS
',.f DieseI!
Page 3 (4) FueI Injection VaIve Edition 02
23/30
Inspeclion Ihe parls: Pressure lesling luel injeclion valve:
8. Nozzles are matched by lapping and are the- 14. The most effective checking the luel valves
relore only interchangeable as units. Insert nozzle is obtained through pressure testing, prelerably
needle with gas l the needle guide. It must be carried alter each overhaul and also in case
controlled whether the nozzle needle slides down irregularities in operation. The pressure testing
by its dead weight on its seat. is carried in the lollowing way by means the
pressure testing apparatus supplied.
9. 1I the holes are oval worn. which is checked
with a magnilying glass, the nozzle must be scrap- 15. Mount the luel injection valve in the bracket
ped. VTO-W020. (see p/ate 520.14 item . 25) again. The
bracket be in such a position that the nozzle
10. The best way, however, check l the holes the injector is pointing downwards.
are worn is control the Ilw rate the nozzle
which, in general, only can be made at the manu- 16. For test the injection pressure and ato-
lacturer's works on a special test stand. mizing mount the test VTO-W0.21 (see p/ate
520.14 item 0.49), increase pressure by means
11. Every ellort relinish w l l result in alterations the lever on the test pump, and adjust the opening
these values and mallunction the nozzle. 1I pressure 320. bar, by the adjusting screw (D), see
heavy abrasion symptoms, respectively damages fig 2, then tighten lock nut () and check opening
are observed at the visual inspection the parts, pressure again.
the parts in question must be replaced . Do not epect chattering, but make sure that the
nozzle spray Irom all holes in the same angle. The
nozzle might chatter l the lever is worked very last,
Reassembling: actually by hitting .
Do not expect a nozzle with more than 10.0.0.
12. When all parts have been overhauled, lound running hours perform l ke a new nozzle in the
in good order and carelully cleaned, assemble the test pump.
luel injection valve again. Then increase the pressure 30.0. bar and keep the
pressure by working the leer slowly downwards.
13. When assembling the injection valve, proceed When the pressure is kept at 30.0. bar, there should
in the opposite order compared the disassembly. be no more than one drip Irom the nozzle lor
Pay attention the lollowing: approx. 3-5 sec.
. Lubricate the threads on the adjusting screw WARNING: Keep oul Ihe luel jets as they wll
(D) with lub. l, and the threads the nozzle holder penelrale Ihe skin. Fuel which has penelraled
lor the nozzle nut. The shoulder the nozzle which Ihe skin can cause painlul inllammalions (blood
is in contact with the nozzle nut, must be lubrcated poisoning).
with an antiseizure product.
. The sealing plane surface body and nozzle

must be wiped dry with paper.
C. Renew the sealing rings (C) and ().
D. Tighten torq ue lor nozzle nut (see page

50.0.40..)
95.50 - ESOS
: DieseII
514-01.1 FueI Injection VaIve Working Card

23/30
Mounting the luel injection valve n cylinder 19. ! the high pressure before tightening
head: the nuts then ! is easier to ! the threads.
20. ! the distance pieces, ! the nuts and

tighten with a torque spanner (( torque moment,
see page 500.40).
Fig 3 Grinding tool$ for seat and Iner lor (l injecton va/ve.
17. mounting th e l valve, clean and

inspect the valve sleeve the cylinder head.
cessary, grind the seating face with the grinding tool
(see (ig 3).
18. Coat the O-rings and the lower part the valve Fig 4 Grinding toofs for fue/ injection va/ve (exfra tools).
with an an tiseizure product, place the valve the
cylinder head and press ! down to the seat.
95.50 ESOS
"i( DieseII
Page 1 (2) Fuel SpIit FiIter Edition 01
23/30

11
Shut-off luel l
Shut-off cooling l
Descriplion:
Disassembly, cleaning and assembly luel l

split ll. Hand lools:

Kerosene, gas l similar.
Slarling posilion:
Relaled procedure:
Working time 1/2 hour Plate Item Qty. /

Capacity 1 man
Dala:

91.08 - ESOS-G
',, DieseI!
Edilion 01 FueI SpIit FiIter Page 2 (2)
23/30
1) During normal operation both lilters should be 3) Position three way cock, see lig 2.
in operation, single operation only be used when
dismantling one the llt ers lor manual clean ing or
inspection.
2) Normally the lilters are cleaned during opera- 4 5

tion by turnin g th e handle, (1) see lig 1, on th e llt er
housing a couple turns. (clockwise).
Simultaneously with turning the handle, the drain

cock, (2) in bottom the llter housing should be
opened in order drain the dirt being scraped
the l l ter element, (3).
-
left Filter 80th filters Right Fllter
This position is operalion. This posilion is
only cleaning only cleaning
the righl 'ilter, the left filIer,
l for conIinu- l co n
ous operaling. ous operating.
5
(c!f~I@~Foo
Fig 2 . Fuef splt filter ( view).
@
3
: Shut-off luel l , belore dismantling ll ' ele-
ment.
4) 1I no drainage occurs when the drain cock is

opened, the ll' housing should be dismantled lor
manual cleaning. Remove the nuts (5), and take !
th e l lt er element (3).
2
5) Clean the ll ' element in kerosene gas l or
similar and blow ! dry wi th working air.
Fg 1 Fuel / split flter 6) ! th e l l ' element again.
7) The Iilter element itsell should never be dis-

mantled, but has be replaced l damage or mal
lunction is experienced.
91 .08 - ESOS-G
',!,' DieseII
Page 1 (2) Check of FueI Piping System EdiIion 01
23/30
V28/32S
Safely precaulions Special lools

Shut-off fuel l
Shut-off cooling l
Descriplion
Check fuel il piping system.

Hand lools
Slarling position
Engine is running .
Relaled procedure
Manpower Replacemenl and wearing parts
Working time: 2 hour Plate no Item no Qty

Capacity 1 man
Dala

92.04 - ESOSG
MiM / DieseII
514-01.90 Check of FueI Piping System
Working Card
23/30
V28/32S
Fuel l System 4) Move all valves and cocks in the piping sy-
stem.
1) Dismount the covers the injection pumps. Lubricate valve spindles with graphite si-
Blow-through drain pipes. milar.
2) Examine the piping system for leaks. 5) Check flexible connecti ons for leaks and da-
mages.
3) Retighten all bolts and nuts in the piping sy-
stem. 6) Check the condition of the lower O-ring for the
fuel injectin g valves by means of th e venting
.
For fuel l condition, see section 504.
Venting ipe
Fg 1. Cross section ( cylinder head
92 .04 - ESOS-G
',:,' DieseII
Working Card
Adjustment ofThe Maximum Combustion Pressure
514-05.01
23/30

D Shut-off cooling water 52006 261 20 - 120 Nm.
D Shut-off l l 52010 01 1
D Shut-off cooling l 52008 058
11 Stopped lub. l circul.
Descriplion:
Adjustment olthe maximum combustion pressure

the cylinders by and all cylinders
total.
Hand l ools:
Slarling posilion: Ring and open end spanner, 19 mm.

Camshaft mounted and adjusted Depth gauge.
relation the crankshaft (Iead), 507-01.20 Plastic hammer.
Intermediate wheel mounted.
Relaled procedure:
Worki ng time 2-5 hours Plate Item Qty

Capacity man
50801 124 1 setJcyl
Dala:

91.45 - ESOS-G
,, DieseII
514-05.01 Adjustment of The Maximum Combustion Pressure

Working Card
23/30
Iffuel l valve, piston, inlet and exhaust valves as well Thinner and/or lewer shims (increase the distance
as turbocharger and charge air cooler are working "") results in a delayed injection timing and a lower
correct and the compression pressure comp iS normal ma~
the maximum combustion pressure will indicate the
injection timing the luel l pump. Thicker and/or more shims (reduction the distance
"") results in an advanced injection timing and a
", is too low it indicates that the injection timing higher 3 '
is delayed.
the distance "" is to be changed the trigger (1) is
",
is too high it indicates that the injection timing used dismantling the thrust piece (2), where-
is advanced. after the thickness and/or the number shims (3)
can be changed.
The injection timing can be altered by inserting
removing shims under the thrust piece on the roller changing "X"with 0.1 mm the maximum combu-
guide, thus changing the measu re "", see lig 1. stion pressure is changed with - see page 500.35.
After replacement shims the thrust piece is re-

mounted in the roller guide (4) with a soft hammer
(5).
Measure ~"
2
{~5

Total height 3
3
4 . / 4
Exlractor 2 Thrust piece

3 Shims 4 Roller guide
5 Soft hammer
Fig 1
Fig3
Action AU
Total height Distance InjecIion Max. combustion

roller guide " " Iiming pressure
increased t Aeduced .j. Advanced l' increased l'

- -
Reduced .j. increased l' Delayed .j. Aeduced .j.
Fig2
91.45 - ESOS-G
Working Card
Adjustment ofThe Maximum Combustion Pressure
514-05.01
23/30
When changing "" must be ensured that the di-

stance between the upper edge the rol ler guide
housing and the thrust piece on the rollerguide is not
exceeded, when the roller is resting on the circular
part the luel cam, see page 500.35.
l
In aII cases "" must be checked and adjusted, l
necessary, when luel l pump, rol ler guide,
guide housing and/or camshalt section have been
replaced/dismantled.
Note: /1 several luel l pumps, guides, rol-

ler guide housings and/or camshaft secti ons are
dismantled at the same time is advisable num-
ber the parts in order lacilitate remounting and
adjustment.
Ilthe maximum combustion pressurediffers Irom the

test bed records alter adjustment each individual
pump the camshafts placement can be changed,
as the camshalts gear wheels are provided with
oblonged holes so that they can be turned in relation
Fig.4
the hub.
The gear wheel is provided with an engraved scale,

see lig 4, and the hub the cam shalt is provided 1I the crankshaft is turned in the engines normal
with a mark. direction rotation the maximum combustion pres-
sure - is reduced.
mII~ .
When the screws, which lasten the gear wheel, are

loosened the gear wheel is turned (by turning the Ifthe crankshaft is turned againstthe engines normal
crankshaft) in relation the camshaft. reading direction rotation the maximum combustion pres-
the angle in which the gear wheel is displaced in
relation the camshalt the altered m" can be
calculated. ln e on the scale corresponds : see
page 500.35.
9 1.45 - ESOSG
'IIII@,iI'JMANDieserl
Page 1 (3) FueI Feed Pump Edi!ion 01
23/30
Safely precaulions: Special 1001s:

Stopped engine
Plate no. IIem no. Nol e.
!! Shut-off fuel il
Shut-off cooling l
Stopped lub. l circul .
Descriplion:
Disassembly. overhaul and assembly luel l

leed pump. Hand lools:
Adjustment luel l pressure.
Allen key, 8 mm, 10 mm , 22 mm .
Ring and open end spanner. 17 mm.
Slarting posilion: Big screwdriver.
Adjuslable spanner.
conneclions 10 Ihe leed pump have been Puller.
disconnecled . and Ihe leed pump is removed Hard brush.
Irom Ihe engine. Gas l .
Relaled procedure:
Working lme 4 Hours Plale no. IIem no. Oly. /

Capacily 1 man
514 10 049 1/pump
Dala: 51410 050 4/pump
51410 108 1/pump
Dala lr pressure and lolerance (Page 500.35) 51410 265 1/pump
Dala lor lorque momenl (Page 500.40)
Declaralion weighl (Page 500.45)
96.26 ESOS
Plate
Page 1 (2) Fuellnjection Pump 5 140 1- 10
23/30
189 ~ 1"
236 ~" ~
190 ~' '~, 021
033
045

082 -.
/ A(J
~
261 -', ~ 045
273 ~~
\
Wr.:-..1-----1-fly ~ 033
116 ~~ '1?
~
~ \ [ 104
,.. ~
~_ \ \ 057
,.
356+ - ~. "-
069
----- 319
368 --~ ~-- 141
153
-.------
~ _ _- ' 65
U
~,__ 177
Qi-- 200
03.36 ESO
Plale
51401-10 Fuel Injection Pump Page 2 (2)
23/30
Item Item
. Qty. Designatlon Benrevnelse . Qty. Oesignation Bencevnelse
021 1 / Pump housing Pumpehu5 319 l Gear rlm Tandkrans
033 21 Screw Skrue 344+ 1 / Screw Skrue
045 21 Packlng ring Paknings ring 356+ 1/ Packing ring Pakningsring
057 1/C Fu el injection pump, Fuel indspr0jInings- 368 2/ Screw Skrue

complete pumpe, kompleI
069 1 / Plunger and barrel Slempet 09 cytinder

Incl. non-return alve inkl. kontravenlil + Are not Included + Indgar ikke fuel ind
fuel injection pump, sprojtningspumpe,
070 1 / Jolnt washer Pakning complete komplet
082 21 Washer Skive
094 4/ Screw Skrue
104 1 / Circllp L~sering
116 1 / Regulating rod Reguleringssla ng
128 1 / Guide SlyreIap
141 l Upper spring plate " verste fjederplade
153 1/ Sprlng Fjeder
165 1 / Lower spring plate NedersIe fjederplade
177 1 / hrust cap TrykhreIte
189 1 / 0-rl"9 0 - "9
190 1 / 0-rl"9 O-ring

200 1 / Circ/lp L1ser ing
212 1 / Sprlng Fjeder
224 1 / Connecting piece Forbindelsesstykke
236 1 / 0-rl"9 0 -ri"9

248 1 / 0-rl"9 0-rl"9
261 1 / Pointer Viser
273 1/ ! MIGIIrik
285 4/ Screw Skrue
297 1 / Cap screw Hcelleskrue
307 1 / Sec urlng rlng BeskytIeIsesring
When ordering spare parts, see also page 500.50. Ved besIilling af reservedele, se ogsA side 500.50.
Only ava il able as part of a spare parts klt. tilgcengelig som del af res ered el ssce I.
Qty./P QtyJPump Antal/P = AntaVPumpe
QtyJC QtyJCyIInder Antal/C = Antal/Cylinder
03.36 ESO
Plate
Page 1 (2) Fuel Injection Vale - NICO 51402-16D
23/30
273
285
297
177
221
224--+--(
,.,."'-_- 307
236 ---. 319
248"---
320
261
'When ordering , please state I 1 7,02

"I+M!:IfMAN DieseII
Plale
51402-16D FueI Injection VaIve - NICO Page 2 (2)
23/30
Jtem Item
. Qty. Designatlon Bencevnelse . Qty. Designatlon Bencevnetse
221 1 Injector body. Brmndslofsventl , ven-

please state - ligstoplys I-17.02
17.02
224 3 0-rl"9 0-"9
236 2 Dowel Slyreslift
248 1 Atomizer, complete, ForslVef, kompleI, ven-

please state - ligst oplys I-1 7.02
17.02
261 1 Nozzle nut Forslove r
273 3 Ca nut Hcetlemolrik
285 1 Nut M0trik
297 1 Adjustlng screw Jusleringsskrue
307 1 0- rin 9 0-rln9
319 1 Sprlng Fjeder
320 1 $ pind le Spindel
177 1 Fuel InJection Valve, BrcendsIofsvenIiI,

Complete komplet
When ordering spa re parts, see al50 page 500.50. Ved besIilling af reservedele, se ogsA side 500.50.
Only available as part a spare parls kit. tilgengelig som del af el reseredelsseI.
Qty.N Qty.Nalve Qly.N QIy.NenIil
QtyJG QtyJCyllnder. Qy./C QIy./CyHnder.
Plale
Page 1 (2) Fuel Injection Valve 51402-16
23/30
153
165 - ------------~I .-------.

.. -----

021*
~--
._-....;..-:
._~
~ ..
~
~~ 094
177
116
045
033*
1/ ~
057
l .----.--.
~ '"
-----_
* When ordering, please state I -17 . 02
07.20 - ESO
Plale
51402-16 Fuel Injection Valve Page 2 (2)
23/30
Item Ilem
. Deslgnation Bencev nelse . Qty. Designation Ben e vne l se
021 1 Injectorhouslng, plea- Venlilhus, enligst oplys

state I -17. 0 2 I-17.02
033 1 Nozzle, complete, Forsloer, komplet, -

pl ease state - ligst IsI-17.02
17.02
045 2 Dowel StyresIifl
057 1 Screw cap Omlober
069 1 Thru st splndle Tryksi ndel
082 1 Sprlng Fjeder
094 1 AdJusting sc rew Justeringsskrue
104 1 l MoIrik
11 6 3 0-rl"9 0-rl"9
141 1 Cap HceIIemotrik
153 1 l Boll
165 1 Washer Skive
177 1/C Fuel injectlon valve , Brrendselsvenlii,

complete kompleI
189 2 Washer Skive
When orderlng spare parts, also page 500.50. Ved beslilling af reservedele, se ogsf side 500.50.
= Only aval lable as part of a spare parts klt. Kun tilgrengelig som del af et reseredelssre l.
QJV QtyJValve Qly.N Qty.Nentil
QlyJC QtyJCyllnder. Qy./C Qty./Cylinder.
07.20 - ESO
Plate
Page 1 (2) Fuel Injection Valve 51402-17
L23/30
__
153 ----- -~ ~ ,,,
------ ~

189
165 ---------
----------,
------ ~/
. /'
104
189
~
021*
~,-
~~ 094
177
116
045
033*
1/ ."
057
" "- ~
"_._'"
....... ,.
:. :.'
r- ~
._------- ---.,

* When ordering, please state I -17_06
07,20 - ESO
Plate
51402-17 Fuellnjection Vale Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Bencevnelse . Qty. Designation Bencevnelse
021 I Injector houslng,plea- Venlilhus, venligst oplys

se state 17.06 IMQ-17.06
033 I Nozzle, complete , forsl0Ver, komplel, ven-

please state IM Q- lig51 oplys I - 17.06
17.06
045 2 Dowel Styrestift
057 I Screw cap mlber
069 I Thrust sp/nd le Trykspindel
082 I Sprlng Fjeder
094 I Adjustlng screw Justeringsskrue
104 I M0trik
116 3 0 -rl"9 0- rin 9

141 I Cap n Ha: lle m0tri k
153 I 8011 ll
165 I Washer Skive
177 I/C Fuel injectlon alve , Bre ndsel sven tii ,

complete kompleI
189 2 Washer Skive
When ordering spare parts, see al50 page 500.50. Ved besIilling af reservedele, se ogsA side 500.50.
Only available part a spare parts kit. u tilgcengelig som en del af et reservedelssce
QtyJV Qty.NaIve Qly.N Qty.Nentil
QtyJC = QtyJCyllnder. Qly./C Qty./Cylinder.
07.20 - ESO
l( Dieserl
Plate
Page 1 (2) Fuel lnjection Valve - NICO 51402-18
23/30
273
190----~
200 --------- 285
297
325
22 1
224 --f--<
,.,.'--_- 307
236---_ 319
248~ _ _
320
Wh en orderin g, please state I - 1 7. 0 3
07.20 -
Plale
51402-18 Fuel Injection Valve - NICO Page 2 (2)
23/30
Item Item
. Qty. OesJgnation Bencevnelse . Qty. Design atlon Bencevnelse
221 1 Injecto r body. Br;;endslofsvenlil, -

p lease st ate - l951 oplys I-17.03
17.03
224 3 0-rl"9 0- 9
236 2 Dowel Styrestift
248 1 Atomizer, complete, ForsIover, kompleI, -

please state - l 951 oplys I- 1 7.03
17.03
261 1 Nozzle nut FOSI<.3ver
273 3 Cap nut Hceltem0trik
285 1 ! Molrik
297 1 AdJustlng screw Jusleringsskrue
307 1 0 -rl"9 0- "9
319 1 Sprlng Fjeder
320 1 Spindle Spindel
325 1 Fuel Injection Va lve, Brrendslofsventil,

Comptete komplet
When ordering spare parts, see also page 500.50. Ved besIilling af reservedele, se ogs<1t side 500.50.
= Only available as part a spare parts kit. IiIgengelig som en del al et reservede l sset.
QtyJV QtyJValve Qly.N I.l l
QtyJC QtyJCyli nder. Qly./C Qly./Cylinder.
07.20 -
'/ DieseI[
PlaIe
Page 1 (2) FueI Injection VaIve - NICO 51402-19
23/30
273
190-----
200 -------- 285
297
325
221
224 --(--<
,.,-"'--_- 307
236--. 319
248*--_
320
261 --...
* When ordering, please state I 17.05
07.20
Plale
51402-19 Fuel Injection Valve - NICO Page 2 (2)
23/30
Item Ilem
. Qty. Designation Bencevnelse . . Deslgnation Ben<evnelse
221 1 InJecto body, BrrendsIofsenlil,

please state - lig51 oplys I-17.05
17.05
224 3 O-ring O-rl"g
236 2 DoweJ SIyresIj(t
248 1 Atomlzer, complete, Forsloer, komplel,

please state - lig51 olys I-17.05
17.05
261 1 Nozzle FrSIer
273 3 Cap reemtrk
285 1 Nut M0trik
297 1 Adjusting screw Justeringsskrue
307 1 0-rl"9 O-,ing
319 1 Spring Fjeder
320 1 S in d l e Spindel
325 1 Fuel Injection Valve, Brendslofsvenlil,

Complete komplet
When ordering sp3re parts, see al50 page 500.50. Ved besIilIing af reservedeJe, se ogsl side 500.50.
= Oniy avai lable as part of a spare parIs kit. Kun tilgrengelig som deJ af et reseredelssGe
QtyJV QtyJValve Qty.N Qty.Nenlil
QtyJC QtyJCylinder. Qty./C Qly./CyJinder.
07.20
Plate
Page 1 (2) FueI FiIter DupIex 51403-03D
23/30
02.08 ESO
''!:f DieseII
Plate
51403-03D FueI FiIter DupIex Page 2 (2)
23/30
Item IIem
. Designation Benrevnelse . Qty. Designation Bencevnelse
lIF Housing
2 2/F Cover
3 1/F Valve
4 2/F cover
5 2/F Flter cap
6 16/F Filter guide
7 2/F Support
8 2/F Screw cap
9 21F NuI
10 4/F Stud bolt
11 4/F Stud bolt
12 420F Flter
13 360/F Filter
14 1/F Screw
15 2/F Hand leer
16 1/F OMring
17 2/F U ~pack ing
18 4/F Spacer
19 4/F Snap ring
20 2/F Bush
21 2/F Spring
22 8/F Hex bolt
24 8/F Spring washer
25 2/F 0-rin9
When ordering spa re parts, see al50 page 500.50. Ved bestilling af reservedele, se Og5<\ side 500.50.
Only available as part of a spare parts kit. jilgcengelig $om del a1 et reservedelsscet.
atyJE = QtyJEngine. Oty.lE Qty./Engine .
atyJF QtyJFllter Oty.lF Qly./Filler.
02.08 - ESO
II' DieseII
PIate
P_ge 1 (2) Fuel Injection Pipe 51404-01
23/30
130
237
010
250
262
142
130
178
154 262
142
154 - - '
166
095
~
.;
~
~
201
89 213
'"
'"
225
94,22 ESQS
Plate
51404-01 Fuel Injection Page 2 (2)
23/30
Item
. Qty. Designatlon Benrevnelse . Q Designation Ben cevnelse
010 1/C Fuel injectio n pipe, Hojtryksror,

comp lete kompler
095 1/C S le ee SlyrebeIsning
142 21C Flange Flange
154 4/C Screw Skrue
166 2/C Sea llng rlng Tetningsring
201 21C Sleeve l 212 80sning 2-dell
213 21C Wlre lock ring lasering
225 1/C Motrik
237 1/C Screwed socket Gevindmuffe
250 1/C M0trik
262 4/C Locking washer Laseskive
When ordering spare parts, see a tso page 500.50. Ved bestilling af reservedele, se ogsfl side 500.50.
Only aval lable part of a spa re parts kit. tilgengelig som del af el reseredelsset.
Qty./C QtyJCy linder. Qty./C QIy.lCylinder.
94.22 - ESOS
Plate
Page 1 (2) FueI Feed Pump 51410-01
23/30
013
1'- 300
/~ ~
049 -
241
025 - -___
'-----=~/ / ~ 108 ~
098 \ ~~. ~/ 265
086 "---~ 062
~::f:
~ : --r-:~~~;~./
--- 074228
277
121-169 - 289
204 216
- - - 194
145 312
170
182
-"--/_~ ----- 253
290
96.20 - ESOS
Plate
5 1 410-0 1 FueI Feed Pump Page 2 (2)
L23/30
Item Item
. Oesignation Benrevnelse . Oty. Designati on Bencevnelse
013 1 / Housi ng Hus
025 1/ Cover Dreksel
049 l Gear wheel Tandhjul
050 4/ Bush Foring
062 1 / Key Feder
074 1/ Cou pling, complete Kobling, komplet
086 2fP Cap Kapselm0trik
098 21 Gasket Pak nirlg
108 l Rotating sea llng Roterende pakning
121 6/ Screw Skrue
145 1 / Plug screw Propskrue
169 21 Cylindrical Cylindrisk slift
170 1/ Cap Kapselm01rik
182 1 / Nut Molrik
194 1 / SprIng housing Fjederhus
204 1/ PIunger Stempel
216 1 / Spring Fjeder
228 1/ FIange Flange
241 31 Screw Skrue
253 6/ Screw Skrue
265 1/ Sealing rl"g TreIningsring
277 1/ Cover Offiksel
289 4/ Screw Skrue
290 1 / Pump, complete Pumpe, kom let
300 1 / Circllp Sikringsring
312 1/ CyIinder Cylinder
When ordering spare parts, see al50 page 500.50. Ved bestiliing af reservedeie, se ogsf side 500.50.
Only ava lla ble as pa rt of a spare parts kit. tilgrengefig som del af et reseredeissret.
OtyJP OtyJPump. Qty./P Qty.lPumpe.
OtyJE OtyJEngine. Qly./E Qty./Motor
96.20 ESOS
~
~
;g
m"
~"
:
132
144
Section - ;
""
~.
i
156 168
~
. , 1 } 384
~~~~~
107 -
372 "tI
(1)

181 396
406
::
' 418
(")
~:::
'<
::
215 024 a.
, . 239
073
061
...
(1)
097 fJ)
(1)
n
288 ~ , / 431 !:!.
311 .~
;+~~_'!-_-_. ::
323 ?t C
---r /
335 / 276
311
---
347
443
. \,-'~@.
[ ~@-+ "
~~211
\i' ,., U ....
U
~
\)
359 360
~ ,

::
....

::
':' DieseI[
Plate
51430-01 Pipes CyIinder Section Page 2 (2)
523/30
Item Item
. Qty. Deslgnation Benrevnelse . Qty_ Designation 8encevnelse
01 2 1/ Fueloll .l 240 1/C Clamp Holder

dlstributor forde1ingsr0r
252 21C Spring lock LAsefjeder
024 1/C Branch SIikr0r
cyllnder sectl on cylindersektion 264 2/C Nut M0Irik
036 1/C Straight male Ligeforskruning 276 1/C Bracket BesJag

stud coupling
288 1/C Plpeclamp R0rholder
048 1/ Fuel 011 return Br.oHe
0 311 2/C Plpe c lamp A0rholder
061 lIC Branch SIikrer 323 1/C Plpe clamp A0rholder

cylinder section cylindersekIion
335 1/C Hexagon screw Skrue
073 1/C Screwed Vinkel-
connectlon forskruning 347 21C Heagon screw Skrue
085 1 / FueloI! Br.oHe 359 2/C Hexagon sc rew Skrue

097 1/C lub. 011 SmQJreolieror
372 1/C Screwed connectlon Forskruning
107 1/C Branch pipe SIikr0r
cylinder section cylinderseklion 384 lIC Screwed connection Forskruning
119 1/C Straight male Ligeforskruning 396 1/C Screwed connectlon Forskruning
stud coupling
406 1/C Screwed connectlon Forskruning
120 1/C Straight male Ligeforskruning
stud coupling 418 1/C Screwed con nec tlon Forskruning
132 21C Plug sc rew Proskrue 431 lIC Plpe clamp A0rholder
wlth SRG
443 1/C Bracket, complete Beslag, komplel
144 21C Packlng ring Pakningsring
156 1/ lub.OII Smoreolie-

dlstributlon pipe fordelingsr0f
168 1/C Branch pipe Slikr0r

cyIinder sectlon cylindersekfion
181 1/C Stralght male Ligeforskruning

stud coupling
193 1 / Sealing Srerreolie-

dlstrlbution plpe Iordelingsror
203 1/C Branch pfpe Stikr0r

/ub.oll sm0reolie

s tud coupllng
227 1/C Pipe from fuel Aer

pump draln br. olie pumpedrcen
239 1/C Banjo coupllng Banjo forskruning
Only avallable as part of a spare parts kit. filgrengelig som en del af el reserede i sscel.
QtyJE EngIne Anlal/E = Motor
QtyJC QtyJCyllnder AntaVC = AntaVCylinder
07.17

:-<
"
;?
"'."
"
-a;
:
132 ;;:
144
Section - !;
f
c. -
156 168
384
"'tJ
.W-I.--- 107
181 -~- 396

372 "

l~*p~~ '--' 406
418
j
036
'<
j
203
239
a.

061
....
097 n
288
311
323
~+,
L::"::!9:l-e'
iJ ~ _
/ 431 -

n
"
j
/ .
335 276 ~443
311 347
~ "'- __ L1.
\ @:@
193 . ~-I +--""
r-..~
'@; ~\
~ 240
t'\ -\j --- U1
.....
252
264
359
360
,::..

.....,
Q
U1
:::::
"'I DieseII
Plate
623/30
Item Item
. Designation Ben e nel se . Deslgnation Bencevne lse
012 1 / Fu e loI 8r.olie 240 1/C Clamp Holder

dlstrlbutOf plpe fordelingsror
252 21C Spring lock LAsefjeder
024 1/C Branch SlikrOf
cylinder sectlon cylindersektion 264 21C MoIrik
036 1/C Stralght male Ligeforskruning 276 1/C Bracket Beslag

stud coupling
266 1/C clamp A0rholder
046 1 / Fuel 011 return . l
plpe 311 21C P/pe clamp Aorholder
061 1/C Branch Slik ror 323 1/C Pipe clamp Rorholder
cylinder sectlon cylindersektion
073 1/C Screwed Vinkel
connection forskruning 347 21C Hexagon screw Skrue
065 1 / Fueloll .l 359 21C Hexagon screw Skrue

return plpe lU
360 21C Hexagon screw Skrue
097 lIC Lub. 011 SmoreolierOf
372 1/C Screwed connection Forskruning
107 1/C Branch pIpe SIikror
cylinder sectIon cylindersekIion 364 lIC Screwed connectlon Forskruning
119 1/C Straight male Ligeforskruning 396 1/C Screwed connection Forskruning
stud coupH ng
406 1/C Screwed connection Forskruning
120 1/C Stralght m ale Ligeforskruning
stud coupling 416 1/C Screwed connection Forskruning
132 21C Plug screw Proskrue 431 lIC Plpe c lamp R"rholder
with SRG
443 1/C Bracket, complete Beslag, kompleI
144 21C Packlng rlng Pakningsring
156 1 / lub.oll Sm0reolie

distrlbutlon fordelingsror
166 lIC Branch pIpe SIikror

cyIinder sectlon cylindersektion
161 1/C Stralght male Ligeforskruning

stud coupllng
193 1 / Sea ling 01 1 Smrreol ie-

dlstrlbullon fordelingsror
203 1/C Branch pipe SIikr"r

Iub.ol l smoreolie

stud coupllng
227 1/C Pipe from fue l R"rfor

pump drain br. olie pumpedrcen
239 1/C Banjo coupling Banjo forskruning
Only aai/ab/e as part a spare parts kll. tilgaengelig som del af el res eredelssa! 1'
OtyJE Englne AntalfE = Molor
OtyJC QtyJCylinder AnIaVC = AnlaIICylinder
07.17
~
....
cl'
<"
"'"
'::(6"
.!'J
;;:
132
144
Section -
i!i:
f
156
"tI
"
n

~
(")
'<
~
215 024 a.
061
...

097 (J)

n
288 ~~
. . ~V'
.;,- 431 ::!:

311 ' __ , ~
323 ---.4 C--.. -1

---,,- 276
.' -----.-:""4 43
335 /
..3~
" . ---T~-t ~
240
~ @ -~
252
-\ ,.
\ 1 \!
-.-!-
-...

....
c.n
.;:.
264 J\)
35'9 360
~
....

:::
'':'I. DieseII
Plate
51430-16 Pipes Cylinder Section Page 2 (2)
723/30
Item Item
. Design ation Benmvnelse . Designation Benm vn else
012 1/ Fuelol l .l 240 I /G Clamp Holder

dlstributo r pipe fordelingsror
252 21G Spring lock Lasefjeder
024 I/G Branch pipe Slikrof
cyllnder section cylindersektion 264 21G Molrik
036 1/G Straight male Ligeforskruning 276 I /G Bracket Beslag

stud coupling
288 I /G Pipe clamp R0rholder
048 1/ Fuel 011 8r. olie
plpe relurrOf 311 21G Plpe clamp Rorholder
061 I /G Branch pipe Stikr0f 323 I /G Plpe clamp Rorholder

cyli nder section cylinderseklion
335 I /G Hexagon screw Skrue
073 I/G Screwed Vinkel
connectlon fOskruning 347 21G Hexagon screw Skrue
085 / FueI / .l 359 21G Hexagon Screw Skrue

return plpe U
360 2/G Hexagon screw Skrue
097 1/G Lub. 011 plpe Sm0reolier0f
372 1/G Screwed connectlon Forskruning
107 I /G Branch plpe Stikror
cylinder section cylinderseklion 384 1/G Screwed connection Forskruning
119 I/G Straight male Ligeforskruning 396 I /G Screwed connectlon Forskruning

stud coupling
406 I /G Screwed connection Forskruning
120 I /G Stralght male Ligeforskruning
stud coupling 418 I/G Screwed connection Forskruning
132 21G Plug screw Proskrue 431 I /G Plpe clamp A0rholder

with SRG
443 I /G Bracket, complete Beslag, komplet
144 2/G Packing ring Pakningsring
156 1/ Lub. OII Sm0reolie-

distribution pipe frdel ngsrr
168 I /G Branch SIikr0r

cyIInder sectlon cylindersektion
181 I /G StraIght male Ligeforskruning

stud couplln g
193 1/ Seallng 011 Sprerreolie-

distrlbutlon pipe fordelingsr0r
203 I /G 8ranch Stikr0r

lub.OII sm0reolie
215 I /G SIralght male Ligeforskruning

stud coupling
227 I /G Plpe from fuel R for

pump draln br. olie pumpedrren
239 I /G Banjo coupling Banjo forskruning
= Only avallable as part of a spare parts kll. tilgrengelig som en del af l reseredelssret.
QtyJE Englne Antal/E =
QtyJC QtyJCylinder AntaVC = AnlaVCyJn der
07.17
~
" "

"
"'"
~;;
:
:;:
132
144 Section - i!i
,, ''1 ~
::
156
"tJ
-
(!)

181

;::,
(")
'<
;::,
.
073 120
061
...
(!)
097 (J)
-ho.3
(!)
288
n
/ 431 :::!:
311 ,. . . , . ,')
;::,
2
048
323
--' ~ +-
335 / 276 ~443
311 347
\
r;j, ' "-,,
&"
\ ' ~
[(0)~ +-
- 240 '~ \,f\',_
-\
! . ....
U'I
252
~
~ 264 359 360

....

......
:::::
1':II'[ Dieserl
Plate
823/30
Item Item
. Qty. Designation Benrevnelse . Qty. Designation Bencevnelse
012 1 Fuel oll 8.l 240 1IC Clamp Holder

dl st ributo pipe lordelingsror
252 2fC Spring lock LAsefjeder
024 1IC Branch Stikr0f
cyllnder section cylindersekIion 264 2fC Nut M"Irik
036 1IC Stralght male Ligeforskruning 276 1IC Bracket 8e$la9

stud coupling
288 1IC l clamp R0rholder
048 1 Fuel l return Br.oJie
l 311 2fC Plpe clamp Rorholder
061 1IC Branch plpe SIikrOf 323 1IC Pipe clamp Rorholder
cyllnder sectlon cylindersektion
335 1IC Hexagon screw Skrue
073 1IC Screwed Vinkel-
connectlon forskruning 347 2fC Hexagon screw Skrue
085 1/ Fueloll .l 359 2fC Hexagon screw Skrue

return pipe t0
360 2fC Hexagon screw Skrue
097 1IC Lub. l plpe Smoreolier0r
372 1IC Screwed tonnection Forskruning
107 1IC Branch pipe Stikror
cylinder section cylindersekIion 384 1IC Screwed connection Forskruning
119 1IC Straight ma le Ligeforskruning 396 1IC Strewed connectlon Forskruning

stud cou pling
406 1IC Sc rewed connectlon Forskruning
120 1IC Straight male Ligeforskruning
stud coupling 418 1IC Screwed connection Forskruning
132 2fC Plug screw Propskrue 431 1IC Pipe c lamp Aorhoider
wlth SRG
443 1IC Bracket, complete Besiag, kompiet
144 2fC Packlng rin g Pakningsring
156 1 Lub.oi l Sm0reolie-

distrlbutlon fordelingsr",
168 1IC Branch plpe SIikr0r

cyIlnder sectlon cylindersekIion
181 1IC StraJght ma le LigeIorskruning

stud coupll n g
193 1 / Seallng l Sprerreolie-

dIstrlbutlon fordelingsr0r
203 1IC Bra nch SIikror

lu b . o ll sm0reolie
215 1IC Straight ma le Ligeforskruning

stud coupHng
227 1IC Irom l uel Ror for

pump draln br. l pumpedrren
239 1IC BanJo coupling Banjo forskruning
On ly avai lable as part a spare parts klt. IiIgrengelig som del af reseredelssret.
QtyJE Engine AnIal/E = Motor
QtyJC = Qty./Cyllnder Antal/C = AnIal/CyJinder
07.17
Section 515
Intemal Lubcatng l System
Description
InternaI Lubricating System 515.01

Lubricating CooIer 515.06
CentrifugaI By-Pass FiIter 515.15
Working card
Lubricating Pump, Engine Drien 515-01.00

PreIubricating Pump 515-01.05
Lubricating FiIter 515-01 .10
Lubricating , hermostatic VaIe 515-01.20
Check of Lubricating Piping System 515-01 .90
Lubricating CooIer 515-06.00
CentrifugaI By-pass FiIter 515-15.00
Plates
Lubricating Ol Pump (CentraI drien) 51501-01

Lubricating Pump (CentraI drien) 51501-02
Lubricating Pump (Gear drien) 51501-10
Lubricating Pump (Gear drien) 51501-11
Lubricating Ol Pump (Gear drien) 51501-22
Lubricating FiIter (ype ) 51502-07
Lubricating FiIter (Suppl. for PIate 51502-6/07) 51502-02
Lubricating hermostatic VaIe 51503-01
PreIubricating Pump with EI-Motor 51504-02
PreIubricating Pump with EI-Motor 51504-08
Lubricating CooIer 51506-01
Combined Lubricating CooIer 51506-02
PIates
Combined ubcatng CooIer 51506-13

Combined ubcatng CooIer 51506-14
CentrfugaI By.pass FiIter 51515-01
Hand Wing Pump 51525-01
Lubricating Separator 51530-04
"ll'( DieseI!
Descrition
23/30
C3
C16 C15
,, ---.,,
- - - - ......
Drain 110m
vapoor
dischargo
,,

'
cyshaII G9'lernor
"~
,.~
,
,, -'-
''' ---- -.J .... C4 C9
,,, ,,
,
" Sepcf(l.Ie ll Ilow \
r- _:::;:. _ ., Whcn ul tow filtor
\,..:;'"
SIandard
\~1-~~:~~-::~-~7 [] 1 ploco lor 5-6 cyl. enginos.
2 pcs.lor 78 cyl. engines OplionaJs
C7 ' , - - - - - ' C8
Fig 1 Dagram for internal fubricating system.
GeneraI
Plpe descrIption for connectlon at the engIne
C3 Lubricating l from separator DN25 As standard the lubricatin g l system is based

C4 Lubricating l l separalor DN25 wet sump lubrication_
C7 Lubricating l from separate filIer DN65

moving parts the engine are lubr cated with
C8 LubricaIing l 10 separate DN65
lcircu lating under pressure a closed built-on
C9 Back-flush from full-flow filter DN20
system.
C13 l vapour d i scharge~ DN50
C15 Lubricating l overflow DN50 The lubricating l is lurthermore used lor the purpose
C16 Lubricaling l suPply DN25 cooling the pistons.
The standard engine is equipped with built-on:

F/ange cannections as standard according to / 2501
Engine driven lubricating l pump

Lubricating l cooler
For external pipe connection. please see section
Lubricating l thermostatic valve
lor crankcase ventilation _
l l u ll-l w depth l ilter
Pre-Iubricating il pump
07.47 - ESO
515.01 Internal Lubricating l System Description
Edition 1 1 Page 2 (5)
23/30
Quantities 3 - Camshafl drive

4 - Governor drive
The approximate quantities ! l necessary for a new
engine, before starting are given in the table, see 5 - Rocker arms
" t 2 1 1 504 .06 Lubricating l in Base Frame"
6 - Camshaft
(max. l 3)
! there are connected external , - l w filters etc. , 1) For priming and during operalion, theturbochar-
the quantity ! l in the external piping must also be ger is connecled 10 the lubricating l circuit !
taken into account. the engine, the l serves lorbearing lubrcat on
and also lor dissipalion ! heat.
Max. velocity recommendations for external lubrica-
ting l pipes: The inlet lne 10 Ihe turbocharger is equipped
with an orifice in order adjusl Ihe il lw and
Pump suction side 1.0 - 1.5 m/s a non-return valve to prevent draining during
- Pump discharge side 1.5 - 2.0 m/s stand-still.
The non-return valve has back-pressure func-

Lubricating Consumption tion requiring a pressure slightly abovethe prim-
ing pressure open in normal l w direction.
The lubricating l consumption is 0.6 - 1.0 g/kWh , In Ihis way overflooding ! the turbocharger is
see "Specific Lubricating l Consumption - SLOC, prevented during stand-slill periods, where the
1215 0 / 504.07" pre-Iubricaling pump is running.
should, however, be observed that during the ru n- 2) Lubricating l for Ihe main beari ngs is sup-plied
ning in period the lubricating l consumption may through holes drilled in the engine frame. From
exceed the values stated. the main bearings l passes through bores in
the crankshaft 10 the connecting rod big-end
bearings.
QuaIity
The connecting rods have bored channels for
Only D lubricating l (Detergent Lubricating l) supply ! l from the big-end bearings 10 Ihe
should be used, characteristic stated in "Lubricating small-end bearings, which has an inner circum-
l Specification 12 15 0/504.01". ferential groove, and a pocket for distribution
l in the bush itself and lor supply ! l 10
Ihe pin bosses and Ihe piston cooling through
System FIow holes and channels in the piston pin.
The lubricating l pump draws l from the l sump From Ihe front main bearings channels are
and presses the il through the cooler and l bored in the crankshaft for lubricating ! the
the main lubricating l , from where the l is pump drive.
distribu ted 10 Ihe individual lubricaling poinls. From
the lubricaling poinl s Ihe il returns by gravity 10 3) The lubricaling l pipes, for the camshaft drive
the l sump. gear wheels, are equipped with nozzles which
are adjusled apply Ihe l at the points where
The main groups ! components 10 be l ubrcated the gear wheels are in mesh.
are:
4) The lubricaling l , and the gear wheels
for Ihe governor drive are adjusted to apply the
1 Turbocharger
l at the points where the gear wheels are in
2 - Main bearings, big-end bearing elc. mesh.
07.47 - ESO
Description
23/30
5) The lubricali ng l 10 Ihe rocker arm s is led

Ihrough pi pes 10 each cylinder head. It con-
linuous Ihrough bores in Ihe cylinder head
and rocker arm 10 Ihe movable parls 10 be
lubrcaled al rocker arms and valve bridge.
Furlher, lubricaling l is led 10 Ihe movable
parls in need lu br calon.
6) Through a bore in Iheframe lubricaling l is led

lothefirst camshaft bearing and Ihrough bores
in Ihe camshaft Irom where l is dislributed 10 c
Ihe olher camshaft bearin gs.
Lubricating l Pump
The lubricaling l pump, which is Ihe gear wheel Fig 2 TI)ermosfafic Valve
Iype, is mounled on Ihe fronl end Ihe engine and
is driven by means the crankshalt Ihrough a cou-
pling. The l pressure is conlrolled by an adjuslable 1I Ihe llt chamber in operalion needs 10 be servi-
springloaded ll valve built-on Ihe il pump. ced, Ihe operalion can be swilched 10 Ihe olher llter
chamber wilhoul any inlerruplion in lubricaling l
supply 10 Ihe engine.
Thermostatic Valve
Servicing is generally reslricled 10 replacing th e
The Ihermostalic valve is designed as a T-piece wilh paper carlridges, cleaning Ihe radial mesh inserl
the inlel in Ihe cover () underwhich Ihe thermoslatic and inspeclion sealings, Ihe laer 10 be replaced
elements are localed. l damages observed .
The outlel 10 the engine (by-passing cooler) is Each Iillerchamberis equipped wilh 1 2 replaceable
marked () and outlel 10 Ihe cooler is marked (C). paper carlridges lineness 10-15 microns.
In Ihe warming period, the il is by-passing the
cooler. When th e l Irom Ihe engine reaches Ihe In Ihe cenlre each llt chamber a llter baskel
normal lemperature see "Operation dala & sel poinls (cenlral element) is situated. Thi s l basket is
500.30" a controlled amounl al il passes Ihrough acling as a safely llt, having a lneness aboul
Ihe cooler. 60 microns.
The thermoslalic elemenls musl be replaced l the During operalion an increased pressure drop across
temperature during norm al operati on deviales es- the llte r ll be observed as dirl parlicles ll deposit
senlial from Ihe one slaled in Ihe lesl report. on Ihe lltralon surfaces Ihe paper cartridges and
Ihus increase Ihe l resislance Ihrough the lt.
The valve cannot be set adjusled, and l requires
maintenance. 1I Ihe pressure drop across the ll eceeds 2.0
bar, a release valve ll open and by-pass Ihe 10-15
microns l element, and Ihe engine ll run wilh
l-n Full-flow Depth Filter only Ihe 60 microns salely lt.
The lubricaling l llter is a double llter which is ensure safe filtering Ihe lubricating l, none
generally used wilh only one t chamber being in the by-pass valves musl open during normal service
operalion, Ihe olher llter chamber being sland-by. and the elements should be replaced al a pressure
drop across Ihe ll 1.5 bar.
07.47 - ESO
515.01 Internal Lubricating System Descriplion
23/30
Servicing iS essential the exchange the paper However, a manilold arrangements is used, its
cartridge s. arrangements are be as follows:
When exchanging cartridges, iS advisable release 1) The vent pipe Irom each engine is run
any old l remaining in the lilter housing by means indepently the manilold, and be litted with
the drain plug provided lor this purpose, and corrosion resistant flame screen within the
w the housing with a cloth. manilold.
The llterchambers can be serviced successively du- 2) The manilold is be located as high as practi-
ring operation when the engine iS at standstill. cable so as allow substantial length piping
separating the crankcase.
iS essential lllw the instructions in work card
515-01.1 closely when replacing l ilter cartridges. 3) The manilold is be vented the open air,
such that the vent outlet is litted with corrosion
Filter cartridges must under no circumstances be resistant Ilame screen, and the clearopen area
cleaned and used again. the vent outlet is not less than the aggregate
area the individual crankcase vent pipes
entering the manilold.
Pre-Iubricating
4) The manilold is be provided with drainage
As standard the engine is equipped with an electric- arrangement.
driven pre-Iubricating pump mounted parallel the
main pump. The pump must be arranged lor automatic The ventilation should be designed eliminate
operation, ensuring stand-still the pre-Iubricating the risk watercondensation in the pipe Ilowing back
pump when the engine is running, and running dur- into the engine and should end in the open air:
ing engine stand-still in stand-by position.
- The connection between engine (C13) and the
Running period the pre-Iubricating pump is preler- ventilation must be Ilexible.
ably be continuous. 11intermittent running is requi- - The ventilation should be con tinuously
red lor energy saving purpose, the timing equipment inclined (min. 5 degrees).
should be set lor shortest possible intervals, say 2 - continuous drain has be installed near the
minutes running, 1 minures stand-still, etc. engine. The drain must not be lead back the
Further, is recommended that the pre-Iubricating engine.
pump is connected the emergency switch board Dimension the Ilexible connection DN50.
thus securing that the engine is not started without - Dimension the ventilation after th e flex-
pre-Iubrication. ible connection min. DN65.
Draining the l Sump Optionals
It is recommended use the separator suction pipe Besides the standard components, the lollowing
lor draining the lubricating l sump. optionals can be built-on:
- Level switch low/high level in l sump

Crankcase Ventilation (L 28)
- Centrifugal by-pass t
The crankcase ventilation is not be directly con- (standard lor stationary engines)
nected with any other piping system. It is prelerable - Hand wing pump
th at the crankcase ventilation from each engine
is led independently the open air. The outlet is Pressure dilferential transmitting
be litted wi th corrosion resistant flame screen - 21-22 Lubricating l inlet across filter
separately lor each engine.
07.47 - ESO
Description
Internal Lubricating l System 515.01
Page 5 (5) EdilIon 1 1
23/30
Temperature alarm high

- 20 Lubricating l inlet before cooler
Pressure transmitting
- 22 Lubricating l inlet after cooler
Temperature element
- 20 Lubricating l inlet before cooler
Temperature element
- 22 Lubricating l inlet after cooler
Temperature element
- 29 Lubricating l inlet main bearings
Branches for:
- External fine filter

- E t e rn a l ful l/flow t
Branches for separator is standard .
07.47 ESO
Oescripllon
Lubricating CooIer
515.06
Page 1 (1)
Edition 01
23/30
Principle Ihe PIale Heal Exchanger Ptales
The built-on lubricating cooIer iS a pIate heat Alter cIamping the pIate pack, the pIates - which
echanger. are litted gaskets - ensure an eflective seaI between
IIuids andatmosphere. addition, intermiing olthe
The pIate heat echanger consist a number IIuids iS eIiminated by a double gasket seaI around
coId pressed pIates which are compressed between the inIet ports.
a Irame pIate (head) and the pressure plate (l)
by means boIts. Every second pIate iS turned through 1800. This
means that the doubIe gasket seaI occurs around
The pIates are made with speciaI cOugations, every second inIet the channeis between the
which ensures turbolent and high heat transler pIates.
cofficients.
The pIate pack lorms a series paraIIeI
channeIs which the fIuids a counter cur-
rent regime.
96.26 - ESOU-G
Description 515.15
Page 1 (1) Centrifugal By-Pass Filter
EdiIion 01
23/30
V28/32S
DescripIion
The cenlrilugal liller is a bypass liller mounled directly For proper liltration, l is imporlant that the rolor is
al Ihe engine base Irame. The cenlrilugal liller is a always correctly balanced.
supplemenl , Ihe main Iiller.
out-ol-balance condition can occur as a result
During service, a parl Ihe lubricaling l supplied an uneven built-up sludge or as a result
Irom Ihe engine driven lubricaling l pump enlers cessive bearing or spindle wear.
Ihe cenlrilugal liller and returns 10 'he l sump
Ihe base Irame.
The cenlrilugal liller relies Ihe cenlrilugal lorce

and can Iherelore remove high densily, sub-micron
parlicles.
Principle of OperaIion
l en' ers Ihe base Ihe ll' and depresses Ihe

cul-off valve () which has a pre-sel pressure valve. -----
The cul-off valve is litted ensure 'hat al lw pres-
sure and Il condi tions the enlire l pump output
is supplied th e engine working parts. Having
depressed the cut-off valve 'he l 'ravels the
centre ' he spindle. Through holes at the ' (8)
and enters th e rotor (C) at the maximum height above F ----
the sland tube. The l complelely l ll s Ihe cleaning
chamber () and travels through the strainer ()
th e dri ve chamber (F), leaving under pressure
via diamelrically opposed tangential nozzles the

bottom the rotor.
The reaction the l leaving the nozzles provides

Cut-off valve D Cleaning chamber
the driving lorce causing the rotor spin about the
SIrainer
spindle at high speed. The l leaving the nozzles is C F Drive chamber
Ihen allowed drain back 10 the sump, by gravily
at a'mospheric pressure.
Fig 1. Diagram showing Principle Operation.
The centrilugal lorce l eld wilhin the spinning rotor
lorces th e contaminants 'ravel Ihe ' wa ll
the rotor, where they lorm a dense rubber-like sludge
which is easily removed.
96.03 - ESOS-G
':' / esel!
Page 1 (3) Lubricating l Pump, Engine Driven EdiIion 01
L23/30
D
Stopped engine
Plate no
52005
Item no
273
Note
80 - 360 Nm.
D Shut-off fuel l
Descriplion:
Disassembly, overhaul and assembly l ubrca

ting l pump, engine driven.
Adjusment lub. l pressure. Hand lools:

Slarling posilion: Ring and open end spanner, 46 mm.
(Socket spanner, 46 mm).
connections to the lub. l pump have Allen key, 8 mm, 4 mm.
been disconnected, and the lub. l pump is re- l for locking ring.
moved from the engine. Soft hammer.
Big screw driver.
Adjustable spanner.
Puller.
Relaled procedure: Silastene similar.
Hard brush.
Working time 6-8 hours Plate no Item no Oty/

Capacity 1 man
5150 1 234 1/pump
51 501 055 5/pump
Dala: 51501 151 1/pump
Data for pressure and tol erance (Page 500.35)

96. 26 - ESOS-G
515-01.00 Worktng Card
Editlon 01 Lubricating Pump, Engine Driven Page 2 (3)
23/30
Disassembly: Before the gear wheels (7 and 8) can be mounted

the bearing bush must be adjusted with a reamer
1) Remove the coupling part gear wheel (1), a bearing scraper, so that the gear wheel can
see fig. 2, by means a l l a soft hammer. easi ly when the pump is assembled.
2) Remove screws (2) and dismount the cover 8) Inspect all other parts for wear and damage,
(3). and renew. necessary.
3) Dismount the locking ring (4), screws (5) and

remove the cover (6) with the overspeed device.
4) Remove the gear wheel (7 and 8).
5) Dismounting of the spring loaded adjustable

by-pass valve.
Remove the cap nut (9), nut (10), spring housing

(11), spring (12) and the cylinder (13). If the pi ston
(14) cannot be pulled Irom the same side, the
plug screw (15) can be removed and the piston can
be pressed out Irom this side with a screw driver
the like.
,----_._--- ------,
1::;g. 2.
Assembly:
9) the gear wheel (7 and 8).
Coat the sealing l with silastene similar and

Fig. 1. mount the cover (6) with gear wheel and locking
ring (4).
Overhaul. 1 ) the cover (3) wi th gasket.
6) Clean all the parts with gas l and a hard 11) the gear wheel coupling part (1).
brush, (never use a steel brush) . The partsare blown
clean with working air. For tightening the lor gear wheel, see page
500.40.
7) If the bearing bush is be removed the
existing bearing bush is plugged out by means 12) Mount the spri ng loaded by-pass valve, nut
a mandrel, the bores are c leaned and W bearing (10) wi th gasket, cap nut (9) and plug screw (15).
bush is mounted, see fig. 1.
96.26 - ESOS-G
,:,' DieseII
Working Card
Lubricating Pump, Engine Driven
515-01.00
23/30
Adjusting lub. l Pressure. turning the spring housing clockwise the pressure
is raised and reverse the pressure is lowered by
13) The outlet pressure the lub. l pump. can turning the spring housing (11) anticlockwise. When
be adjusted by means a adjusting screw the the correct pressure is reached . see page 500.30.
by-pass valve. the spring housing (11 ) is locked with U (1 ) and
finally the gasket and cap (9) are mounted.
Remove the cap U (9) and loosen the (10).
96.26 - ESOS-G
Workrng Card 515-01.05
Page 1 (3) Prelubricating Pump Edrlion 08
General
Safe\y precau\ions Special\ools

11

Stopped engine
Plate Item Note.
Shut-ofl fuel l

Hand \ools
Descrip\ion
Bench vice.
Dismounting, replacement the rotary shaft seal Spanner.
and assembly prelubricating pump. Torque spanner.
l lr lock ring.
Soft hammer.
S\ar\ing posi\ion
Rela\ed procedure:
Man power: Replacemen\ and wearing par\s:
Working time 2-3 Hours Plate Item Qty./

Capacity 1 man
See plate 51504.
Da\a:

02.39 ESO
,.{ DieseII
Edilion 08 PreIubricating Pump Page 2 (3)
GeneraI
Oerhauls We advise l change Ihe bearing bushes.

connectin with damages Ihe bearings is normal
Overhauls lr the purpose avoiding lunctional Ihal also the shafts and Ihe parls Ihe gear bo wll
trouble are normally necessary lor the prelubri be damaged.
cating pumps, when properly used, Ihere is very lttle
wear Ihe pump gear shaft. When orderin g spare parls, do forget 10 state
Ihe lactory no. Ihe pump.
Spare Parts
Replacement mechanical seal
Belore any overhaul is done, please nole Ihe 101-
lowing: 1) Disconnecl Ihe cable and connection
Ihe pump.
1I a pump gets unusable by wear, l musl be repla-
ced. Inslallation spare parls cannol bring l back 2) Remove the pump from the engine base
10 normal condilion. Irame.
1I pays keep el ra pumps stock orto have repairs 3) Separate Ihe pump and Ihe el-molor.
(overhauls) carried out at our repair shop.
4) Remove the coupling parl and key (109), see
The shaft seal needs only 10 be replaced case fig. 1, Irom Ihe driving gear shaft (051).
leakage after dismounting drive shaft. Th e
marks Irom the seal do necessarily mean that 5) Tighten Ihe pump tothe Ilange. Pressure conlrol
Ihe sealing is deleclive, but there is a risk leakage valve (038) upwards.
after rep lacement sealing.
6) Loosen screws (075) and take 011 Ihe pressure
conlrol valve (038).
109 099 122 014 051 026 038 075
Fig 1. Pre/ubricating Prp
02.39 - ESO
'+I@",'fMANDieserl
Page 3 (3) PreIubricating Pump Edition 08
Genera!
7) Take off the gear box (026), necessary use Mounting
a soft hammer for separation.
13) The mounting process follows reverse order,
8) Remove the gear wheels from the cover (014). it is stressed that an exact cleaning works is
Dismounting is only possible by disturbing the necessary.
rotor shaft seal and by breaking the bearing
bush. Especially the sealing faces must be clean.
9) Remove the security ring (099) and take off Tightening screw pos. (075):
the rotary shaft seal (122).
25 10Nm
1) Press out the driving gear shaft bearing bush, 3 5 50 Nm
ll ! the running bearing bush with the '
wheel puller. connection with the bearing bush, attention must
be paid to the placement th e butt joint and the
11) Gear box (026) . Dismounting is only possible mounting depth.
by damaging the shaft bush. Press out the
shaft bushes. The shaft seal cannot be pressed into the pro-
tection cover before exact mounting the pump.
12) Pressure control valve (038). The pressure
control valve can be dismounted also Wi tllOut O-ring must be changed.
dismounting the pump.
02.39 - ESO
Working Card
Lubricating l Filter
515-01.10
23/30
Safety precautions: Special tools:

Stopped engine
Sht-olf starting air
Sht-off cooling water
Plate no Item no Note
Shut-off luel l
Shut-oll cooling l
Stopped lub . l circul.
Description:
Replacement paper l element(s).

Cleaning safety l and fil ter housing. Hand tools:
Ri ng and open end spanner, 22 mm.

Starting position: Adjustable spanner.
Related procedure:
ro Manpower: Replacement and wearing parts:

'"
~
~
Working time 2 hours Plate no Item no Qty. /
~
Capacity 1 man
39 51502 01 3 See plate 51502
ro
Data: 51502 290 1/Filter.

'"~
Data for pressu re and tolerance (Page 500.35)
9 1.45 - ESOS-G
515-01.10 Lubricating FiIter
Worklng Card
EctitIon 01 Page 2 (3)
23/30
The lubricating l l is dimensioned so that each ! 4) Filter housing cap is dismantled .

the w il parts has sufficent capacity treat the
amount ! lubricating l delivered by the pump. 5) Remove the inner saIety element. Clean the
element with detergent. Check that is intact.
The three-way valve positioned is determining
whether the left hand the right hand l chamber 6) Removethe outer element(s). Filter element is
is in operation, and also gives the possibilityof having disposable type. It change always new original
both l chambers in operation simultaneously I.
The three-way valve is marked with lw directions 7) Clean the l housing and the cap. Be careful
and the figure indicates the operation modes accor- not let the l from the dirty side go into the
ding valve positions. clean l channel in the middle bottom.
Three-way valve pcsitions 5 6 5
Left hand fll cam- Right hand jilter

ber operalion. camber oera-
1100. 8 2 8
-~~o'-
..
-
t
80th filter camber
operation.
1 Left hand IilIer camt)er 2 Right hand l chamber

Fig 1. TIJree-way vafve positiOfJs. 3 l l 4 Outlet
5 Vent screw 6 Three-way vaJve/
switch valve
7 Fifl-up valve 8 Drain lug
Service Procedure.
1) Turn the Ihree-way valve, see fig 2, into the

position setting the stand-by l chamber in ope-
Fig2.
ration and the l chamber requiring service out
! operation.
2) Open Ihe vent screw (5) on the the l 8) Check the seal on the bottom the l hou-
get the pressure the filter half. sing and in the cap. Change needed.
3) Open the drain plug (8) underthe filter housing 9) Assemble the t in opposite order.
and drain off oil.
9 1.45 - ESOS-G
Workin~J Card
Lubricating FiIter
515-01.10
Page 3 (3) Editlon 01
23/30
1) Let the air valve be open and lll the l hou-

sing with l by means ! the slow ll l - valve (7)
FIf-up vafve ositions in position FILL, see fig 3. This valve is inside the
three-way valve and by using , th e filling can be
Operallon Changlng over made so slowly that the pressure the other part
FILL ! the l does drop much.
"
W
'"
~
U
r
'"
m
"
11) Close the vent screw (5) after the housing is
filled with l.
111::1
12) Open the three-way valve (6) and close the
Switch in normaJ SwJtch IiJl l ll -
valve (7) by trning position CLOSED,
operation positlon osition see lig. 3.
13) The llter just serviced is w ready be set

in operation.
Fig 3. FI/l-U vafve ositon.
Inspect lor l leakages in order ascertain all

sealings be ti ght.
Check that pressure drop across l l ter is correct.
Clean the other side the l correspondingly.
91.45 - ESOS-G
Page 1 (2) Lubricating l, Thermostatic Valve Edition 01
23/30
Safely precaulions : Specialloofs:

11

Stopped engine
Plate Item Note
Shut-off fuel l
Shut-off cooling l
Descriplion:
Inspection thermostatic valve and replacement

elements. Hand lools:

Copaslip
Tools and cleaning preparation for cleaning.
Slarling posilion:
Lubricating l drained from engine ( neces-

sary).
Relaled procedure:
ro
Manpower:
"
~
~
Working time 2 hours Replacemenl and wearing parls:
~
Capacity Man
~
:: Plate Item No Qty/
ro Dala:
51503 020 2/engine

Data lor pressure and tolerance (Page 500.35) 51503 044 2/engine
Data for torque moment (Page 500.40) 51503 093 3/engi ne
92.05 - ESOS-G
EditIon 01 Lubricating l , Thermostatic Valve Page 2 (2)
23/30
The thermostatic valve cannot be adjusted and Replacement elements:

der normal working conditions maintenance is
required. However, some cases is necessary 1) Remove nuts (1) and washers (2), 4 6 pcs.
repl ace the elements the thermostatic valve. See fig 1.
2) Disconnect and lower part the hou-

sing.
2 3) Remove the assembled elements (3) and th e

3 elements O-ri ng sealing.
5 4) Remove the gaskets between the and

r - - - .. - r-f---1f--
,, lower part the housing.
4
5) The and lower part the housing are
thoroughly cleaned inside and the gasket sur-
faces.
- ,, 6) The sealing rings (4) the elements Ihe
housing are replaced and lb r cated with a thin layer
copaslip.
7) Remount Ihe assembled elements Ihe hou-

sing by wriggling these somewhat over side.
---' 8) Upper and lower par t the housing are as-

sembled with a new gasket (5), the nuts (1) are
1. 1
mounled and lighlened cross-wise.
2. Washer
3. Element
Note:
4. O-rings sealIng
5. Gasket
After inspection replacement the elements the
l b. lemperature is checked ensure that the
elements are working correclly.
Fig 1 Thermostatic valve
92.05 - ESOS-G
Working Card
Check of Lubricating l Piping System
515-01 .90
Page 1 (2) EditIon 01
23/30
Safely precaulions : Speciallools:
Stopped engine Plale Item Note

Shut-oll luel l
Shut-off cooling l
Descriplion:
Check and examination the lubricating l

piping system. Hand lools:
Slarling posilion:
Engine running.
Relaled procedure:
Working time V2 hour Plate Item Oty

Capacity 1 man
Dala:

92.04 - ESOU-G
"llM,, DieseII
EdiIIon 01 Check of Lubricating Piping System Page 2 (2)
23/30
Checks 10 be carried !. 4) Blow-Ihrough drain pipes.
1) Examine Ihe piping syslem for leaks. 5) Check fle i ble conneclions for leaks and dama-
ges.
2) Retighten all boltsand nuts in the piping system.
6) Check manometers and thermometers for pos-
3) Move all valves and cocks the piping system. sible damages.
Lubricate valve spindles with graphite similar. For lubricating l condition, see section 504.
92.04 - ESOU-G
l' DieseII
Page 1 (4) Lubricating CooIer Edilion 02
23/30
Safety precaulions: Speciallools:
Stopped engine
Plate ItemNo Note

Shut-off fuel l
Shut-off cooling l
Descriplion :
Separation, cleaning and assembling.

Replacement of plates and gaskets. Hand lools:
Ring and open end spanner 10mm

Stang position: Adjustable spanner
Cooling water and lub. l have been drained from

cooler/engine. pipes are disconnected.
Related procedure:
Manpower:
Working time 4 hours Replacement and wearing parts:

Capacity 1 man
Plate Item Oty.1
Data:
51506 111/279 4/cooler
96.39 - ESOS
Edition 02 Lubricating CooIer Page 2 (4)
L23/30
lntroduction Manual Cleaning
Cleaning the cooler has take place, when the Clean the plates with a solt brush and a suitable
pressure drop the l and water side is larger detergent . case dense coating scale
than allowable and/or l the l cannot be sufficiently organic materials, the plates must be ul a bath
cooled. detergent.
: use a steel brush , metal scraper

Separation the like.
Cooling and Pressure l high-pressure cleaner can be used with care, how-
, with sand oth er abrasives added.
Belore opening the plate heat ec h a n ge r, has
be cooled down below 40' C and be without
pressure! Detergents
The cooling must exceed 1 ' C per minute. detergent is suitable, l ll remove any coating
The pressure drop must eceed 1 bar per the plates without causing any damage plates
minute. and gaskets.
: 1I th ese norms are exceeded, the guarantee : It is great importance that decomposition
ll cease be valid. the protective Iilm the stainless steel
does take place - the llm preserves the
corrosion resistancy the steel.
Separation Edgeclamped Frame
use chlorine-containing agents such
Upon completion the procedure "Cooling and as hydrochloricacid (HCI)!
Pressure l l", separate th e Irame by retaining
lour diagonally placed bolts. l and lats are removed by using a water emulsify
ing l solvent, e.g. BP-system cleaner.
: Take care that the pressure plate does
l ! Organic and greasy coatings are removed by using
sodium hydroxide (NaOH):
Loosen the bolts unilormly and diagonally (ma. 1
mm at a time), then push the pressure plate towards m a.concen1ration 1.5%
the end support. When the pressure plate is tight (1.5% concentration corresponds 3.75
anymore, the plates can be removed. 130% NaOH per 100 water).
ma. temperature 85' C.
: When using plate heat echangers board
ships, th e pressure plate have be secured Stone and lme/ca lcareo us deposits are removed by
orderto avoid danger due th e movements using nitric acid (,) :
the ship.
ma. concentration 1.5%
(1.5% concentration corresponds 1.75
Cleaning 62% , per 100 water).
max. temperature 65' C.
The capacity and corrosion resistance the plate
heat echangers depend the the plates. Note:The nitric acid has an important constructi ve el-
Any coating the plates can be removed manu- lect the protective llm stainless steel.
ally.
96.39 - ESOS
P_ge 3 (4) Lubricating CooIer Edilion 02
23/30
Conlrol Cleaning Fluid Concenlralions Replacemenl Glued Gaskels
Sodium hydroxide (NaOH) solution is tritrated with Plate 51506 are stated gasket and glue quan-
0.1 n hydro-chloric acid (HCI) with methyl orange
methyl red as indicator.
Please use a degreasing agent the new gas-
Nitric acid (,) solution is titrated with 0.1 n sodium kets.
hydroxide (NaOH) with phenolphtalin as indicator.
The lirst plate alter the end cover and the connector
The concentration the cleaning Iluid % can be grid must have gaskets all grooves. The gaskets
calculated from th e titration result by means th e are be cut according th e existing gaskets.
lollowing lormula:
Loosen the glued gaskets by heating the plate
Concentration = b n m % water at 100" C. Clean the plates and remove the
ax 10 coatings, l any.
a ml cleaning Iluid taken lr titration

b ml titration Iluid used as cover Cleaning New Gaskels and Plales
n the molecular concentration titration Iluid
m: The molecular weight the cleani ng Iluid New gaskets and gasket grooves the plates are
(NaOH) molecular weight 40, 03 molecular cleaned with a cloth moistened with degreasing
weight 63) agent. The glue surfaces must be absolutely clean
- without linger prints etc.
Replacemenl Plales and Gaskels Please use our cleaning Iluid, which is according
suppliers recommendations.
Marking
Alternatively, please use:
The plates are marked with material codes and reler-
ence numbers at each end, plus codes lor non-glue Trichloroethylene
gaskets, l any, and stamped with the letter V and Chlorothene VG
at either end (Fig 1). Acetone
Methyl ethyl ketone
Looking towards the gasket side, the plate is des- Ethylacetat
ignated as a lelt plate, when the letter V is turning
upwards - and a right plate when th e letler is turn- is importan t that all degreasing agen t has evapo-
ing upwards. Inlets and outlets th e V-plates are rated, belore the glue is applied. This ll normally
taking place Ihrough the corner holes Nos 1 and 4. take approx. 15 min. at 20" C.
Inlets and outlets the H-plates are taking place
through th e corner holes Nos 2 and 3. Clean the new gaskets the glue surfaces with
line-grain sandpaper instead the degreasing
agent supplied.
Replacemenl Plales
Belore mounting a spare plate the plate stack,

please make su-re that the spare plate is identical
with th e delective plate.
Note: The same corner holes must be and the

letters V and must be placed correctly.
96.39 - ESQS
+ DieseI[
515-06.00 Lubricating CooIer Working Card
23/30
Gluing Assembling
Pliobond 25, which is a l rubber glue solvent th e plates have been dismounted, they have
basis (25% solids). Th e glue is applied with a brush be correctly assembled according the plate item
a thin layer th e backs the gaskets and the numbers.
gaskets are dry a clean place free dust.
The fixed cover has number 1 and the serial numbers
Apply a thin layer glue the gasket grooves for the subsequent plates and intermedi ate frames,
the plates and press the gaskets down the any, have the numbers 2, 3, 4, 5 etc.
gasket grooves.
The serial number are stamped the right corner
The insertion gaskets starts at both ends the th e plates. Further, please n that the gasket
plate - and continues with the straight sections along side must face the fixed cover.
the edges.
Th e gluing process is most easily effected by placing

the gaskets and the plates a table. After having Serial number
pressed the gaskets the grooves a plate, (please state when
is stacked. Material Code ordering single plates)
A487G
The plates with the gaskets are mounted
the frame which is Iightly clamped. case use
rubber grooves, they are assembled the mini-
mum measure stated th e engine sign plus 0.2
mm per plate.
Heat the plate heat exchanger 90- 1000 C by

means water steam.
Four last digits are Ihe
FOU~~:St~~;~~ ref. number of Ihe plate.
Please note: number plate ~ (only plates for non-
glue gaskel)
The temperature must be kept for 1 2-2
~ffi . ~1
Th e liquid pressure must be kept as l as
possible.
Fastening
th ere is possibility heating the plate heat
exchanger, must be placed a spot as warm as Fasten th e plate heat exchanger l the movable
possible with dismounted connections. cover touches the duct spacers.
Th e drying time ll at 200 C be approx. 48 hours.

for instance 400 C, the drying time is reduced
approx. 24 hours.
96.39 - ESOS
Page 1 (3) Centrifugal Bypass Filter EditIon 01
L23/30
Safety precaution5: Special Iools:
Stopped engine Plate no item no Note

Shut-off fuel l
Shut-off cooling l
De5cription:
Cleaning proced ure, cleaning inIervals.

Maintenance intervals and procedures. Hand I5 :
Big adjustable spanner.

Tools for cleaning.
Starting 05n:
Isolate the filter for lub. l inlet
Related procedure:
~
ro Manpower:
"~
v
~
Working time hour
~
Capacity man ReplacemenI and wearing parI5:
:\
Data: Plate no Item no Qty/

"
00
"
Data for pressure and tolerance (Page 500.35) 51515 398 1/Filter
DaIa for torque moment (Page 500.40) 51515 408 1/Filter
Declaration weight (Page 500.45) 51515 421 1/Fiiter
96.03 - ESOS
',' DieseII
515-15.00 CentrifugaI Bypass FiIter
WorkIng Card
EdiIion Q1H Page 2 (3)
23/30
Cleaning Procedure, see Plate 51515 Note: Failure do so could cause an - '
balance condition which wiII acce/erate bearing
and spindle wear.
1) Isolate the l by closing the valve for lbr
cating l inlet the I. 7) Clean nozzle with brass . Examine and
bottom bearings in tbe assembly. If damaged
2) Slacken cover clamp ring (266). Unscrew worn - re l ace tbe assembly comlete. Examine
cover fixing nut and l ! cover. O-ring (063) and renew ! damaged.
3) Lift off rotor assembly having allowed l 8) Reassemble rotor complete and tighten
drain from nozzles. The rotor should be removed and nut.
replaced on the spindle with ex treme care in order
ensure that the bearings are not damaged. 9) Examine spindle journals. If damaged worn
- relace with body assembly comlete.
4) Unscrew rotor cover nt (026) and sear ate
cover (038) from body. 1) Reassemble l com l ete checking that rotor
revolves freely. Then relace l bodycover. Tighten
cover nut and secure safety clam . The clam ring
should be securely fitted at all times and the l
026 should not b e run withot the clamp ring fi tted.
038 11) Open for lubricating l.
12) With l running check all joints for leakage.

Check for excessive vibration.
Maintenance - Bearings and Spindle

075
rotors are correctly balanced before leaving the
266 factory. An out-of-balance condition can occur as a
result an uneven build ! sludge in the rotor
as a result excessive bearing s i ndle wear.
Dependent on the conditions. wear ll eventally

take place on the spindle and bearings and these
should be relaced with lactory fitted assemblies
only.
Fig 1 Centrifugal 8ypass Fi/ter
5) Remove stand tbe (075) and clean.
6) Remove sludge from inside the rotor by means

! a spatla and clean. Ensure that all rotor
comonents are throughly c leaned and free from
d eos its ! dirt before reassembling the rotor.
96.03 ESOS
Page 3 (3) Centrifugal Bypass Filter Edition 01
23/30
Check Bearing Clearances The maximum clearances when new are 0,08 mm at
and 0,06 mm at bo tom bearing. 1I the clearance
This is most easily done by applying a dial gauge exceeds 0,25 mm 0.2 mm bo tom then check
the outside the roOr opposite each bearing in the sizes the individual components and replace
turn and measu rin g the total play thus: as necessary.
1) Apply dial gauge and measure play. Spindle journal diameter 14,98 mm Min.
Spindle bottom journal diameter 21,63 mm Min.
2) Turn rotor 900 and repeat meas ure ren. bearing bore diameter 15,06 mm Max.
Bottom bearing bore diameter 21,69 mm Max .
3) Re-apply dial gauge at 900 previ ous posi tion
and repeat. The spi ndle and body assembly and the rotor
bea ring tube assembl y are lactory assembled
4) urn 900 and repeat. items and should only be replaced wi th complete
assemblies.
The highest reading is the play in the beari ng.
96.03 - ESOS
PlaIe
Page 1 (2) Lubricating Pump (CentraI driven) 51501-01
5-6-7L23/30H 72050
L23/30H-900
079
317
067
018 - ______
163
234
175
234 199
187 305
210
209 329
330 - ----
234
~-- 043 222
~- 031
258 ~
~
:: ~
114
126
<ri
'~"
~ 092 342
'''~
~
f)I 080
i 354 102
"
------. ~
295
94.22 - ESOS
+.. DieseII
Plale
51501-01 Lubricating Pump (CentraI driven) Page 2 (2)
5-6-7L23/30H 72050
L23/30H-900
Item Item
. aly. Designatlon Benaavnelse . aly. Oesignation Bencevnels e
018 / Pump hou sing Pumpehus 317 6/ Screw Skrue
031 / Shaft with gear Aksel med tand- 329 2/ l M0trik

wheel , long hjul, lang
330 1/ Lub. 011 pump, Sm0reoJlepumpe.
043 / Shaft wlth gear med tand- complete kompiet
wheel , short hjul, kor!
342 / End cove r Endeda!ksel
055 5/ Bush 83sning
354 1/ Cover Dreksei
067 1 / Coupllng KoblJng
366 1/ Feder
079 / D09 Medbringer
080 / Cog wheel Konisk tandhjul
092 / Cog wheel KonIsk landt1jul
102 / Circllp SikringsrIng
114 / Circlip SikrIngsring
126 2/ 8a ll bearing Kugleleje
136 1/ Socket Muffe
151 / Gasket Pakning
163 1/ Cap ! Hcellem01rk
175 1/ l M0trik
167 / AdJustlng screw JLlsterskrue
209 1/ Piston Stempel
210 / Cylinder Cylinder
222 / Plug screw Propskrue
234 3/ Gasket PaknIng
246 2/ Cylindrlcal Cylinclrisk 51
256 / l 511ft
271 1 / Feder
263 1/ Screw Skrue
295 6/ Screw Skrue
305 2/ GUde Styrestft
When orderlng spare parts, see also page 500.50. Ved bestllling af reservedele, se ogsf slde 500.50.
On ly avallable as part of a spare parts kit. Kun tilgrengelig som en de af et reseredelssret.

alyJE aty.lEngine Anlal/E = Antal/Molor
atyJP = aty.lPump Anlal/P = AnlaJ/Purnpe
94.22 ESOS
l 'l DieseII
Plate
Page 1 (2) Lubricating Pump (CentraI driven) 51501-02
8L23/30
72050
079
317
067
163
234
175
234 199
305
187 210
209 329
330 - ..../'
234
:L-- 043 222
031
258~
~
::~
114
126
.;
.; 092 342
~
'''~
~
-
080
354
102
9
~
295--4
94 .22 - ESOS
Mi'M.lfMAN DieseI!
Plate
51501-02 Lubricating Pump (CentraI driven) Page 2 (2)
823/30
72050
Item Item
. Qty. Deslgnatlon Bencevnelse . Qty. Deslgnatlon Benrevnelse
018 / Pump housing Pumpehus 317 6/ Screw Skrue
031 / Shaft with gear Akse! med tand- 329 ?/ M0trIk

wheel , long hJul,lang
330 / Lub. 011 pump, Sm0reolIepumpe,
043 / Shaft wit h gear Aksel med tand- complete klet
wheel,short hjul, kor!
342 1/ End cover Endedcekse!
055 S/P Bush B0sning
354 1/ Cover Dreksel
067 / Coupllng Kobling
366 1/ " Feder
079 / D09 Medbringer
092 / Cog wheel Konisk tandhjU
102 / Clrclip Sikringsring
114 / Circlip Sikrrngsring
126 2/ 8all bearlng Kugleleje
138 / Socket Muffe
163 / Cap H:ettemetrik
175 / Nut 0
187 / Adjusting screw Justerskrue
199 1/ SprIng Fjeder
209 / Piston SlempeI
210 1/ Cyl nd er Cylinder
246 2/ Cylindical Cylrndrisk 511ft
258 1/ Stift
271 / " Feder
283 10/ Screw Skrue
295 6/ Screw Skrue
305 2/ Guide StyresIifl
When orderlng spare parts, see also page 500.50. Ved bestillIng af reservedele, se ogsA side 500.50.
Only avai lable as part a spare parts kit. tiIgcengelig som en del af et reservedelssret.
QtyJE OtyJEnglne Antal/E = Antal/Motor
QtyJP OtyJPump Antal/? = AnIal/Pumpe
94 .22 ESOS
Plale
Page 1 (2) Lubricating Ol Pump (Gear driven) 51501-10
5-623/30-72050 RPM
6-7-8L23/30H-900 RPM
6L23/30H-900 RPM (High Capacily)
079 - -
163
234
175
234
: -:::..... ~
..
25 ~ ~ ~
:~: ~~ ~246
~~: ~. 283
092 342
354 ~
151 080
102
295~
07.01 ESO
+' DieseII
Plate
51501-10 Lubricating Pump (Gear driven) Page 2 (2)
5-6L23/30-72050
6-7-8L23/30H-900
6L23/30H-900 (High Capacity)
Item Item
. aty. Designation Benrevnelse . aty. Designation Bencevnelse
018 l Pump housing Pumpehus 354 1 / Cover Dceksel
031 1/ Shaft wlth gear Aksel med tand 366 1 / Feder

wheel, IO"9 hjul,lan9
043 1 / Shatt with gear Aksel med tand-
wheel, short hjul , kort 401 1 / Piston, complete Trykregulerings-
slemple, komplel
055 51 Bush Besning
079 1 / ! M0trik
080 1 / Cog wheel Konisk Iandhjul
092 1/ Cog wheel Konisk tandhjul
102 1 / Clrcllp Sikringsring
114 1/ Clrcllp Sikringsring
126 21 6a ll bearing Kugleleje
138 1 / Socket Muffe
163 1 / Cap nut HcetlemeIrik
175 1 / ! Metrik
222 1 / Plug screw Pakning
234 31 Gasket Cylindrisk 51ift
246 21 Cyllndrlca l 51ift
258 1/ Feder
271 1 / Key Skrue
283 10! Screw Skrue
295 6/ Screw Cylinder
305 21 Gulde Styreslift
317 6 Screw Skrue
329 21 ! M01rjk
330 1/ Lub. 011 pump, Smereol iepume ,

complete komplet
342 1 / End cover Endedceksel
When orderl ng spare parts, see also page 500.50. Ved beslilling af reseredele , se ogsf side 500.50.
; Only aval'ab'e as part of a spare parts kit. lilgcengelig som en del af eI reseIVedelssrel.
atyJE OtyJEngine Antal/E = Antal/Motor
atyJP ; OtyJPump Antal/P = Antal/Pumpe
07.01 - ESO
',:,,.( DieseI!
Plale
Page 1 (2) Lubricatig Pump (Gear drive) 51501-11
7-823/30-72050
5-623/30-72050 (High Capacity)
7-8L23/30H-900 (High Capacity)
079 - ____
067
163
234
175
234
234
401 --
222
330 -----
305
329
391
07.01 - ESO
I,,lM" MAN DieseII
Plate
51501-11 Lubricating Pump (Gear drien) Page 2 (2)
7-823/30-72050 RPM
5-623/30 -72050 RPM (High Capacity)
7-8L23/30H-900 RPM (High Capacity)
Item Item
. Oesignatlon Bencenelse . Desig natlon Benrevnelse
018 / Pump housing Pumpehu5 354 , / Cover Dreksel
031 l Shaft with gear Aksel med tand- 366 / Key Feder
wheel , IO"9 hjul , lan9
043 / Shaft with gear Aksel med land-
wheel, short hjul , kort 401 / Plston , complete Trykregulerings-
stempel, komplel
055 5/ Bush 80sning
067 / Gear wheel Tandhjul
079 / MeIrik
080 / Cog wheel Konisk landhjul
102 / ClrcIlp Sikringsring
114 / Clrcll p Sikringsring
126 21 Ball bearing Kugleleje
138 1/ Socket Muffe
163 / Cap Hcellemetrik
175 / MoIrik
222 / Plug screw Pakning
234 31 Gasket Cylindrisk 51ift
246 21 Cyllndrical pl" 51
258 / Feder
271 / Key Skrue
283 / Screw Skrue
295 6 Screw Cylinder
305 2/ Guide l Styrestift
317 6/ Screw Skrue
329 21 l t r k
330 / Lub. 011 pump, Smereoliepumpe,

complete kompleI
342 / End cover Endedeksel
When orderIng spare parts, see a ls o page 500.50. Ved beslilling aI reservedele, se 09S.3 side 500.50.
= Only avai lable as p art of a spare parts klt. Kun lilgrengelig som del af l res erede l s srel.
aIyJE QtyJEnglne Anlal/ E = Anlal/Molor
aty./p = atyJPump AnlaVP = AnlaVPumpe
07.01 - ESO
Plate
Page 1 (2) Lubricating Pump (Gear driven) 515 0 1-22
7-823/30-72050 (High Capacity)
079 - __
163
234
175
234
401 234
222
330 - - - -
366 \ <:N',~
258 ~
~
..
.;
a ::: 1
114
126
89'" 092 342
ro
~~
151 080
ro
354 102
295
07.01 - ESO
Plate
51501-22 High Capacity Lubricating Pump (Gear driven) Page 2 (2)
7 -823/30-72050 (High Capacity)
Item IIem
. Qy. Des ignati on Bencevnelse . Qy. Deslgnation BencevneIse
01 6 / Pump ho using Pumpehus 354 1/ Cover DaakseI
031 / Shaft wlth gear Aksel med land- 366 / " Feder
wheel, lo ng hjul,lang
043 / Shaft wlth gear Aksel med land-
wheel, short hjul, korl 401 / PI ston, co mplete Trykregu1erings-
sIempel, koml eI
055 5/ Bush Bsn i ng
067 / GearwheeJ Tandhjul
079 / Nu' MeIrik
060 / Co nical wheel Konisk tandhjul
092 / Conica l wh ee/ Konisk tandhjul
102 / Clrcllp Sikringsring
114 / Clrcllp Sikringsring
126 2/ 8all bea ring Kugleleje
136 1/ Socket Muffe
163 / Cap Hretlem0Irik
175 1/ Nu. Metrik
222 / Plu g screw Propskrue
246 2/ CyllndrIcal l Cylindrisk 51ift
256 / l 81ift
271 1/ " Feder
263 100 Screw Skrue
295 6/ Screw Skrue
305 2/ Gulde pi" Styres!ift
317 6/ Screw Skrue
329 2/ Nul M0trik
330 / Lub. 011 pump, Sm0reoliepumpe,

complete komplet
342 1 / En d cove r EndedrekseI
Wh en orderln g spare p arts, see also page 500.50. Ved bestiIling af reservedeie. se 09S8. side 500.50.
Only ava 'ab' e as par t of a spare parts klt. liIgrengeIig sorn dei af eI reservedeIsscet.
QlyJE OtyJEnglne An!aIfE = AntaIfMoIor
Qty./ P = OtyJPump AnIal/? = AnlaIfPume
07.01 - ESO
PlaIe
Page 1 (2) Lubricating Ol Filter (Type ) 51502-07
L23/30
182 -------, 169

157 - - - ,
133 ------, 121
013 204 ----, """711 _ _- - - 062
037+
050+
,,
11
,,
11
,,
086+ 300
145
108
' - - - - 170 241
228
289
+ For deta/jer se / for detai/s see P/ate 5 1 502 -02
02.16 - ESO-G
1,Ji,z'lMAN DieseII
Plate
51502-07 Lubricating FiIter (Type ) Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnel se . Oty. Des ignation Bencevnelse
013 2/F Paper element Papirelement 300 1 / lub. l filter, Sm0reoliefilter, kom-
comptete ptel
025 2/F Safety element SikkerhedseIement
037+ 1/F Valve houslng , In cl. Ventilhus, inkl.

Item 074 and 216 ilem 074 09216
049 2/F Housing. lcl . O-rl"g Hus, inkl. 0-rin9
050+ 2/F Cap, comp lete, incl.Dekse l , komplel, inkl.

Item 133,348,361,373 itern 133, 348, 361, 373
and 407 09407
062 1/F Spindle, inCI.item 121, Spindel, inkl. ilem 121,

312 and 444 31209444
074 2/F Thrust ring rykri ng
086+ 2/F By-pass code, incl. 8y-passvenIiI. inkl. ilem

item 324. 336, 385, 432 324, 336, 385, 432
and 493 09493
108 2/F Vent screw, inc!. Item Luftskrue, inkl. ilem 228
228 and 241 09241
121 1/F Fill -up vaIve Opfyldningsventil
133 4/F Sealing ring Tretningsring
145 12/F Stud SI011ela
157 12/F Screw Skrue
169 4/F Screw Skrue
170 12/F M01rik
182 4/F Washer Skive
216 5/F
228 61F l
241 2/F Gasket Pakning
277 2/F Opening guard, Incl. Abni gsbe sk ylle ses-

vent sc rew sk39:rm, inkl. lutlskrue
289 2/F Drain plug Dr39:nskrue
290 lIF SeaI klt, not shown Pakningsscel , ikke l

the front side
forsiden af plalen
the pIate
When orderlng spare parts, see also page 500.50. Ved besli tling af reservedele, ogsA side 500.50.
= Only available as part of a spare parts kit. Iilg39:ngelig sam del af l reservedelsscel.
OtyJE QtyJEngine =
II! Anlal! Molar
OtyJF QtyJFi lter AnlaVF = Antai!Fiiler
02.16 - ESO-G
+ DieseII
Plate
Page 1 (2) Lubricating FiIter (SuppI. for PIate 51502-06/7) 51502-02
23/30
V28/32S
312 - - ,
444 - _____
~~~::;j~~-~-- 51502/037+
468
rl\0
456
397
515021050+
361
419
11
-~
~~ 385
324
420
373
\ ----- 336
407
493 -J- --- 515021086+

432
481
+ se/see Plate 5 1 502-07 (Type ), Plate 51502-06 (Type )
02.16 - ESO-G
Plate
51502-02 Lubricating FiIter (Suppl. for PIate 51502-06/7) Page 2 (2)
L23/30
V28/32S
Item Item
. Qty. DesIgnation Benrevnelse . Qty. Designation Bencevnelse
312 1/F Cap Dceksel
324 2JF By-pass valve seat By-passvenlilsrede
336 2JF By-pass valve spoo l By-passvnelilspindel
348 2JF Flange Flange
361 2JF Flange Flange
373 2JF Screw Skrue
385 2JF By-pass vaIve spring 8y-assvenIilfjeder
397 8/F 5eal Tcetningsring
407 2/F Spring Fjeder
419 2JF S ring Fjeder
420 6/F Slift
432 2JF Gasket Pakning
444 2JF 0-rln9 0 -rin9
456 2/F 0- 9 0- rin 9

468 2JF O-ri "g 0- 9
481 4/F 0-9 0- rin 9

493 2/F 0-9 0- 9
When ordering s pare parts, see also page 500.50. Ved bestilling af reservedele, S0 ogsa side 500.50.
= Only available as part of a spare parts kit. Kun tilgrengelig som det af et reseredelsscet.
atylF = QtyJFiIter AntalJF = Anlal!Filter
02.16 - ESO-G
Plate
Page 1 (2) Lubricating l Thermostatic Valve 51503-01
23/30

019

~ ___ o

020
032
Note: When ordering new elements, state opening 044

temperature.
Husk: Ved bestilling af nye elementer at angive 056

abningstemperatu ren
115
@--... 068
\L 081
103
94 .23 ESOSL
Plate
51503-01 Lubricating l Thermostatic Valve Page 2 (2)
L23/30
Item Item
. Oly. Designation Bena:vnelse . Qty. Designation Bencevnelse
019 4 Screw Skrue
020 2f O~ rlng O-rl"g
032 2 Thermostatic F01erelement

element
044 2 O-ring 0-rl"9
056 2f Sleeve 80sning
068 4 Washer SkIve
081 16 Nul M0trik
093 3 GaskeI PaknIng
103 12/ Screw Skrue
115 1/ Thermostatic Termostatventil,

valve, compIete komplet
When orderlng spare parts, see a lso page 500.50. Ved beslilling af reservedele, ogs~ side 500.50.
Only available as part a spare kit. Kun tilgrengelig som del af l reservedelsscet.
OlyJE Qty./Englne Antal/E = Antal/Motor
OlyJ aty.IThermostatlc a lve = Anlal(Termostalsventil
94.23 - ESOS-L
Plate
Pa ge 1 (2) Prelubricating Pump with EI-Motor 51504-02
General
349 337 362 254 325 301 291 266 374 350 278 313
421
470
445
470
408
482
386
398
457
469
528
516
94.23 - ESOS-L
Plale
51504-02 Prelubricating Pump with EI-Motor Page 2 (2)
General
Item Item
. aty. Designat ion Benaavnetse . Oty. Designation Bencevnelse
254 1/ Driving cover Medbringerdeksel
266 1 / Gear casl ng Gearhu$
278 1 / End cover, complete, Endedreksel, komplet

incl. item 386,398,408, inkl. iIem 386, 398, 406,
421,433,445,457,469 421, 433,445,457,469
and 470 09470
291 1 / Dri v ing gea r shaft Drivende gearaksel
301 1/ Gear shaft Gearaksel
313 4/ Screw Skrue
325 21 Parallel Slyrestift
337 1/ Retainlng ring Sikringsring
349 1 / Parallel key Nol
350 21 0- r in 9 0 - 9
362 1 / Rotary shaft sea l RoIerende aksellreI-

ning
374 1/ Pumpe, com plete Pumpe, komplel uden

wit ho ut EI-motor el-motor
386 1 / End cover Endedreksel
398 1 / Pisto n SIempel
408 1 / Spi ndie Spindel
421 1 / Do me nut Lukkem0Irik
433 1/ Sprin g Fjeder
445 1 / nut Rrmrk
457 21 Screwed plug Propskrue
469 21 Sealin g ring Tretningsring
470 21 Sealing (In9 TreIningsring
482 1 / Coupling, complete Kobiing , kompiet
494 1/ E I ~ m oto r, complete EI-motor, kompiel
504 1/ Pre.lub 011 pum p, Forsm0repume,

c omplete w it h el- komplet med el-molor
moto r
516 1 / Ball bearing, rea r Kugleleje, bagside
528 1/ Ba ll bearl ng , f ront Kugleleje, forside
Wh en o rdering spare parts, see also page 500.50. Ved beslilling af reservedele, se ogs<'l. side 500,50.
available as part of a spare parts kit. ti lgenge l ig som en del af reseredelsset.

QlyJE Qty./En gine Anlal/E = Antal/ Motor
QIyJP = OtyJPum p Antal/P = AntaUPumpe
94.23 - ESOS-L
Plale
Page 1 (2) Prelubricating Pump with EI-Motor 51504-08
General
109 099 122 014 087 063 051 026 134 110 038 075
/'
266
-1-- -- - 183
l~!=~r== 230
_ - - 205
,~~~::==
L ' 230
171
242
hF==~~~~-- 195
,.-~~~", ~I--- 146
254 ~~~~~----- 158

1 :
~o 00)

:11 :=J
02.39 , ESO
PIate
51504-08 Prelubricating Pump with EI-Motor Page 2 (2)
General
Item Item
. Qty. Design atlon Benrevnelse . a ty. Desig nation Benre vnelse
01 4 1 / Oriving cover Medbringerdreksel
026 1 / Gear casing Gearhus
038 1 / End cover, complete, Endedreksel, komplet

i nc. item 21 29 inkI. Ilem 21 l 29
051 1 / Drlving gear shaft Drivende gearaksel
063 1 / Gear shaft Gearaksel
075 4/ Screw Skrue
087 21 ParalleI Styreslift
099 1 / Retainlng ring Sikringsring
109 1 / Parallel key 1
110 21 O~ in g 0 -rin9
122 1 / Rotary shaft sea l Roterende a kse lt<:et-

ning
134 1 / Pum p, complete
with out EI-rnotor Pumpe, komplet uden
el-motor
146 1 / End cover
EndedrekseI
158 1 / s
Stempel
171 1 / Splndle
Spindel
183 1 / Dome nut
Lukkemotrik
195 1 / Sprln g
Fjeder
205 1 / Pipe
R0rmotrik
217 21 Screwed plug
Propskrue
229 21 Seallng rln9
Tcetningsring
230 2/ Sea llng ring
Tretningsring
242 1 / Coupllng, complete
Kobling, kompleI
254 1 / EI-moto r, comp lete
EI-moIor. komplet
266 1 / Pre.lu b. l pump,
comp let e w ith el- Forsmorepumpe,
motor kompleI med el-motor
When ordering spare parts, see also page 500.50. Ved beslilling af reservedele, se ogS8. side 500. 50.
Only available as part of a sp are p arts ki tilgrengelig som en del af et reserede lssre t.
QtyJE = Oty.IEng ine Antal/E = Antal/ Motor
QtyJP Oty./Pump AntaIIP = AnIal/Pumpe
02.39 ESO
f,JII@!/fMANDieseI!
Plale
Page 1 (2) Lubricating CooIer 51506-01
L23/30
015
016
027 { 017
039 ~
040
Q
0Q
Note: When ordering

plates, please state
the serial numbers
th e plates. Th e seri al
numbers the plates
can be lound the
top right-hand corner
the plates. (See 052
Working Card 515-
06.00)
Husk: Ved bestilling

af plader angives
serienummeret
pladen. Serienum- 076
meret stemplet 077
toppen al pladen til 078
00
h,e. (Se arbejdskort 079
515-06.00) ( 080
081
082
088
172 / " 111
173 123
174 V-
175
176
Q j
177
178 160 L 159
~ 147
8--135
8-- 351
07.06 - ESOS-G
':'!'!I' DieseII
l
51506-01 Lubricating Cooler Pag. 2 (2)
23/30
Item Item
. Designation Benrevnelse . Deslgnatlon Benrevnelse
015 4/ Hexagon screw 8011 081 4/ Dlstance piece AIslandssIykke

5-6-7-8 cyl . engine 5-6-7-8 cyI. molor 7 cyl. engine 7 cyl. molor
(72050 rpm) and (7250 rpm) og (900 rpm) (900 rpm)
6 cyl. eng ine 6 cyl. motor
(900 rpm) (900 rpm) 082 4/ Dlstance piece Afstandsstykke
8 cyl. engine 8 cyl. molor
016 4/ Hexagon screw Boll (900 rpm) (900 rpm)
7 cyl. englne 7 cyl. moIor
(900 rpm) (900 rpm) 088 l Frame plate SIalivplade
017 4/ Hexagon screw ll 111 4/ Gasket Pakning

8 cyl. englne cyl. motor
(900 rpm) (900 rpm) 123 21 Screw Skrue
027 4/ Washer Skive 135 l Glue Lim
039 4/ Washer Skive 147 21 Gulde bar Slyrepind

(for dl smantling) ( demonlering)
040 l Pressure plate Trykplade
159 32/ Screw Skrue
160 / LubricatIng l cooler, SmGreoliekeler,
064 21 Gul de bar Styrepind complete komplel
5-6-7-8 cyl. englne 5-6-7-8 cyl. molor
(72050 rpm) and (72050 rpm) og 172 11 Plates Plader
6 cyl. eng ine 6 cyI. molor 5 cyl. englne 5 cyl. molor
(900 rpm) (900 rpm) (72050 rpm) (72050 rpm)
065 2/ Guide bar Slyrepind 173 11 Plates Plales

7 cyl. engine 7 cyl. molor 6 cyl. englne 6 cyl. molor
(900 rpm) (900 rpm) (72050 rpm) (7250 rpm)
066 21 Guide bar Styrepind 174 11 Plates Plates

8 cyl. englne 8 cyl. motor 7 cyl. eng lne 7 cyI. motor
(900 rpm) (900 rpm) (72050 rpm) (72050 rpm)
076 4/ Dlstance piece Afstandsstykke 175 11 Plates Plales

5 cyl. engine 5 cyl. molor cyl. englne 8 cyl. rnoIor
(72050 rpm) (72050 rm) (72050 rpm) (72050 rpm)
077 4/ Dl stance piece Afstandsstykke 176 11 Plates Plales

6 cyl. engine 6 cyl. moIor 6 cyl. engine 6 cyl. motor
(7205 0 rpm) (72050 rpm) (900 rpm) (900 rpm)
078 4/ Dlstance plece AfsIandssIykke 177 11 Plates PlaIes

7 cyl. engine 7 cyl. motor 7 cyl. englne 7 cyl. molo
(72050 rpm) (7250 rpm) (900 rpm) (900 rpm)
079 4/ Dl stance plece AfstandssIykke 178 11 Plates Plates

cyl. engine 8 cyl. motor cyl. eng lne 8 cyI. motor
(72 0 50 rpm) (720/750 rpm) (900 rpm) (900 rpm)
080 4/ Dlsta nce piece Afstandsslykke 351 Clea ning 11uid Rensevreske
~
6 cyI. englne 6 cy molor <
q
(900 rpm) (900 rpm) ~
~
~

~

i5

,

When ordering 5pare part5, 5 al50 page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.

= Only avallable as part of a spare parts klt. tilgcengelig som del af l reservedelss;;el.
OtyJE = atyJEnglne AnIal/E = Antal/Motor
OtyJK QtyJCooler AnIal/K = Antal/K01er
OtyJI = Qty./lndlvidual I/I = AnIalJlndividuel
07.06 ESOSG
M+"MAN DieseII
Plate
Page 1 (2) Combined Lubricating CooIer 51506-02
23/30
218 r - 321
Gasket, model ,
mounting between
frame plate and
Plate 2.
Note: When ordering

-~
the serial numbers !
the plates. The serial
numbers ! the plates
can be found the
top right-hand corner 321
! the plates. (See
Working Card 5 t 5-
06.00)
Gasket, model ,

mounting between
the rest ! the plates.
af plader angives
serienummeret
pladen. Serienum-
meret stemplet 00
af pladen l
he. (Se arbejdskort
515-06.00)
267
321
00 279
i----- 280 Gasket, model C,
mounting between
- 326 ~ 302 c plate 26 and

27.
8 - 292
8 - 363
00
the gaskets are delivered as model C. (

Gasket and must be unreeved from
model C.
96.26 - ESOS-G
'+HM'lMAN Dieserl
Plate
51506-02 Combined Lubricating CooIer Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Benrevnelse . aty. Designation Bencevnel se
184 411< Hexagon screw ll
196 4/ Washer Skive
206 4/ Was her Skive
218 1 / Pressure plate Trykplade

the Gaskets d e- Alle pakningerne leve-
Ilvered as model C. res som model C.
Gasket and must Pakning og 8 skal
be unreeved from mo- skceres ud fra model
dei C. c.
243 21 Guide bar Slyrepind
255 4/ Dlstance piece AfslandssIykke
267 1 / Frame plate Stativplade
280 21 Screw Skrue
292 111< Glue Lim
302 21 Guide bar SIyrepind

(Ior dlsmantling) ( demonIering)
314 321 Screw Skr e
326 1 / Lubricating 011cooler, Sm0reJiekler,

comp lete komplel
338 11 Plates Plader
363 n Cleaning fluid Rensevreske
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsf side 500.50.
= Only available as part of a spare parts kit. tilga3ngelig som del af reseredel ssa3t.
atyJE = Qty./Englne Antal/E = AnIal/Motor
atyJK QtyJCooler AntaVK = AntaVK01er
atyJI atyJIndlvidual l1l = AntaVlndividuel
96.26 - ESOS-G
PlaIe
Page 1 (2) Lubricating l Cooler 51506-11
L23/30
015
016
027 ( 017
039 ~
040
Q
0Q
Note: When ordering

the serial numbers
numbers the plates
can be lound in the
right-hand corner
Working Card 515-
06.00)

al plader angives
serienummeret
pladen. Serienum- 076
077
1 00
meret er stemplet
toppen al laden l 078
h,e. (Se arbejdskort
079
515-06.00) 080
081
082
172 --~~~ 088
173 0 0 111
174
175 123
176 -----
177 Q
178
160

L 159
~r- 147
07.06 - ESOS-G
''!" DieseII
Plate
51506- 11 Lubricating CooIer Page 2 (2)
23/30
Ite m Item
. Qty. DesignatIon Benmvnelse . Qty. Deslgnation Benrevnelse
01 5 4/ Hexagon screw Boll 081 4/ Dlstance plece Afstandsslykke

5-6-7-8 cyl. englne 5-6-7-8 cyI. motO 7 cyl. engine 7 cyl. motor
( 72 050 r m) and (72050 rm) og (900 r m ) (900 rm)
6 cyl. engine 6 cyl. mo'or
(900 rm ) (900 rm) 082 4/ Dl sta nce piece Afstandsslykke
016 4/ Hexagon screw Boll (900 rm ) (90 rm)
7 cy l. engine 7 cyl. motor
(900 r m ) (900 rm) 088 1/ Frame pIate Stalivplade
017 4/ Hexagon screw ll 111 4/ Gasket Pakning

(900 rm) (900 rm) 123 2/ Screw Skrue
027 4/ Washer Skive 147 2f Guide bar SIyrepind

(for dismantling) (for demonIering)
039 4/ Washer Skive
160 1/ Lubrlcating 011 cooIer, Smrel ekler,
040 1 / Pressure la te Trykplade complete komplet
052 11 Gasket Pakning 172 11 Plates Plader

064 2J Guide bar Slyrepind (72 050 rm) (72050 rpm)
5-6-7-8 cyI. engine 5-6-7-8 cyl. moIor
(7 205 0 rm) and (72050 rm) og 173 11 Plates Plates
6 cyl . englne 6 cyl. motor 6 cyl. englne 6 cyl. motor
(900 r m ) (900 rm) ( 7205 0 rm) (72050 rpm)
065 2/ Guide bar Styrepind 174 11 Plates Plales

7 cyl. engine 7 cyl. molor 7 cyl. engine 7 cyI. moIor
(900 rm) (900 rm) (72 050 rm) (72050 rpm)
066 2/ Gul de ba r SIyrepind 175 11 Plates Plales

cyI. englne 8 cyl. motor 8 cyl. engine 8 cyI. motor
(900 rm) (900 rpm) (72 05 0 rm) (72050 rm)
076 4/ Distance piece AfstandssIykke 176 11 Plates Plates

5 cyl. englne 5 cyl. motor 6 cyl. englne 6 cyl. motor
(72 05 0 rm) (72050 rm) (900 rm) (900 r m)
077 4/ Di stance piece Afslandsstykke 177 11 Plates Plales

6 cy/. engine 6cyl. motor 7 cy. eng ine 7 cyI. moIor
( 7205 0 rm) (72050 rm) (900 rm) (900 rm)
078 4/ Di stance piece Afslandsslykke 178 11 P/ates Plales

7 cyI. engine 7 cyl. motor 8 cyl. engine 8 cyl. motor
(720 5 0 rm) (72050 rpm) (900 rm) (900 rpm)
079 4/ Di sta nce piece AfslandssIykke

cyl. englne cy motor
( 72 0 50 rm) (72050 rm )
080 4/ Distance piece AfstandssIykke

6 cyl. englne 6 cyl. molor
(900 rm) (900 rpm)
When ordering spare parts, see al50 page 500.50. Ved besIi lling af reservedele, se ogS<3 side 500.50.
Only avall able as part a spare parts kit. Iilgrengelig som en del af et reservedelssret.
QtyJE = Oty./Englne Anlal/E = Antal/Molor
QlyJK = OtyJCooler l/ = AntaVK01er
QtyJI OtyJlndlvldual AnIaVI = AntaVlndividueI
07.06 - ESOS-G
',I,I@,I,IlMANDieseI!
Plale
Page 1 (21 Lubricating CooIer 51506-12
23/30
015
027 ~
039 --------.. Q
040
0Q
Note: When ordering

the serial numbers of
numbers of the plates
can be found in the
of the plates. (See 052
Working Card 515-
06.00)
I
g~~
066
399
Husk: Ved bestilling 411
r
af plader angives ./-:"""""'5;;,,-
serienummeret
pladen . Serienum- ~ /
076
meret stemplet
toppen af pladen til
h,e . (Se arbejdskort
gt~
~ r 079
d
515-06.00) 080
081
082
088
172 / 111
173 , 123
174 --
175
176
177
178 160 r-- 147
8 - 135
8-- 351
07.08 - ESO
1,:,:,'!I' DieseII
Plate
51506-12 Lubricating CooIer Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Des ign ation Bencevnelse
01 5 4/ Hexagon sc rew 8011 088 1/ Frame plate SI81ivplade

5~6~7cyl. engine 5-6-7-8 cyl. molor
(72 050 rpm) and (72050 rpm) og 111 4/ Gasket Pakning
6-7-8 cyl. englne 6-7-8 cyl. motor
(900 rpm) (900 rpm) 123 21 Screw Skrue
027 4/ Washer Skive 135 1 / Glue Lim
039 4/ Washer Skive 147 21 Gulde bar SIyrepind

(for dl smantllng) (for demonIering)
040 l ress ure plate Trykplade
159 32/ Screw Skrue
160 1 / Lubrlcatlng 011 coole r, Sm0re l e k ler,
064 21 Gulde bar Styrepind complete kompleI
5-6-7-8 cy. engine 5-6-7-8 cyl. motor
(72050 rpm) and (7250 rpm) og 172 11 Plates Plader
6 cyI. englne 6 cyl . motor 5 cyl. engine 5 cyI. motor
(900 rpm) (900 rpm) (72050 rpm) (72050 rpm)
065 21 Gulde bar Styrepind 173 11 Plates Plales

7 cyI. engIne 7 cyl. molor 6 cyl. engine 6 cyl. molor
(900 rpm) (900 rpm) (72050 rpm) (720S rpm)
066 21 Gulde bar Slyrepind 174 11 Plates PIales

8 cyl. englne 8 cyl. molor 7 cyl. engine 7 cyI. moIor
(900 rpm) (900 rpm) (72050 rpm) (720S rpm)
076 4/ Dlstance piece Afstandsslykke 175 11 Plates Piales

5 cyl. engine 5 cyi. moIor 8 cyl. englne 8 cyl. motor
(720S rpm) ( 7250 rpm) (72050 rpm) (7250 rpm)
077 4/ Dlstance piece AfsIandssIykke 176 11 Plates Piates

6 cyl. engine 6 cyl. molor 6 cyl. engine 6 cyi. motor
(720S rpm) (72050 rpm) (900 rpm) (900 rpm)
078 4/ Distance piece Afstandsslykke 177 11 PIates PiaIes

7 cyI. engine 7 cyi. moIor 7 cyl. engIne 7 cyi. moIor
(72050 rpm) (72050 rpm) (900 rpm) (900 rpm)
079 4/ Dlstance pIece AfsIandssIykke 178 11 Plates Piates

cyI. engIne 8 cyi. moIor cyl. engine 8 cyJ. motor
(72050 rpm) (72050 rpm) (900 rpm) (900 rpm)
080 4/ Dlstance plece AfstandssIykke 351 11 Clea ning fluid RenseVGe5ke

(900 rpm) (900 rpm) 399 21 Rubber Ilnning Gummipakning
081 4/ Dlstance p/ece Af5IandssIykke 411 21 Rubber linning Gummipakning

(900 rpm) (900 rpm)
082 4/ Distance piece AfsIandssIykke ~

8 cyl. englne 8cyl. moIor <
(900 rpm) (900 rpm)
"v
~
~

~
8
::

When ordering spare parts, see also page 500.50. Ved bestiIIing af re5ervedele, 5 Og58 side 500.50. "

"
= Only avai lable as part of a spare parts kft. lilgcengeJig som del af re5eredelssre l.
QtyJE = OtyJEnglne AnIal/E = AnIal/MoIor
QtyJK QtyJCooler AnIal/K = AnIal/K01er
QtyJI = Oty./Indlvidual l = AntaVindividuel
07.08 ESO
,+ Diesell
Plate
Page 1 (2) Combined Lubricating l Cooler 51506-13
23/30
00 321
218
Gasket, model ,
mounting between
Irame plate and
Plate 2.
Note: When ordering 00

the serial numbers
numbers the plates
can be lound in the
Working Card 515-
06.00)
Gasket, model ,
mounting between
the rest the plates.
al plader angives
serienummeret !.
pladen. Serienum-
( ~!~
meret stemplet
toppen al pladen til
0 0
he. (Se arbejdskort 258
515-06.00) 259
260
261
267
338 '
. J 11 r -- 321
339 279
340
341
------ 280
342 Gasket, model C,
mounting between
343
344
W- 302 c plate 26 and
27.
-- 292
8 - 363
00
the gaskets are delivered as model C.
Gasket and must be unreeved Irom
model C.
07.08 - ESO
1,:,!'!I' Dieserl ..
Plate
51506-13 Combined Lubricating CooIer Page 2 (2)
23/30
Item Item
. Qty. Designatlon Benrevnelse . Qty. Designatlon Ben;;ev nelse
184 4/ Hexagon screw 8011 326 l Lubrlcating 011 cooler, Sm0reoliekoler,

complete komplel
196 4/ Washer Skive
338 11 Plates, 72050 rpm Plader, 7201750 rpm
206 4/ Washer Skive 5 cyl. englne 5 cyl. motor
218 l Press ure plate Trykplade 339 r Plates. 72050 rpm Plader, 7201750 rpm
6 cyl. englne 6 cyl. rnoIor
the Gaskets de- Alle pakningerne l - 340 11 Plates, 7201750 rpm Plader, 7201750 rpm
Ilvered as model C. res som model C. 7 cyl. englne 7 cyl. motor
Gasket and mu st Pakning 09 skal
be unreeved from mo- skreres ud fra model 341 11 PIates, 7201750 rpm Plader, 720/750 rpm
del C. C. cyl. engine 8 cyl. motor
243 21 Guide bar, Slyrepjnd, 342 11 Plates, 900 rpm Plader, 900 rpm
72050 rpm 72050 rpm 6 cy. engine 6 cyl. molor
244 21 Guide bar, 6~7 cy l. Styrepind, 6-7 cyl 343 11 Plate5, 900 rpm Plader, 900 rpm
900 rpm 900 rpm 7 cyl. englne 7 cyl. molor
245 21 Guide bar, 8 cyl. Slyrepind, 8 cyl 344 11 Plates, 900 rpm Plader, 900 rpm
900 rpm 900 rpm cyl. englne 8 cyl. motor
255 4/ Dlstance piece. Afslandsslykke, 363 11 Cleaning fluid Rensevaaske

72050 rpm , 5 cyl . 7250 rpm, 5 cyl.
375 31 Rubber Ilnnl"g Gummipakning
256 4/ Distance piece, Afstand5stykke,
72050 rpm. 6 cyl. 7205 rpm, 6 cyl.
257 4/ Distance plece. Afstandsslykke,

72050 rpm , 7 cyl. 72050 rpm, 7 cyl.
258 4/ Distance piece, Afstandsstykke,

72050 rpm, cyl. 72050 rpm, 8 cyl.
259 4/ Distance plece. Afstandsslykke,

900 rpm , 6 cy l. 900 rpm, 6 cyl.
260 4/ Dl stance piece , Afslandsstykke,

900 rpm , 7 cyl. 900 rpm , 7 cyl.
261 4/ Di stance plece, AfstandssIykke,

900 rpm, cy. 900 rpm, 8 cyI.
267 l Frame plate SIaIivplade
280 21 Screw Skrue
292 l Glue Lim
302 21 Gulde bar Styrepind

{l
dJsmantllng} (for demonIering)
314 321 Screw Skrue
When ordering spare parts , see al50 page 500.50. Ved beslilHng af reservedele, se ogsf sjde 500.50.
Only avaiJab/e as part a spare parts kIt. Kun IIgaangelig som en del af eI reseredelsscet.
QtyJ E = OtyJEngine AnIal!E = Antal!Motor
QtyJK = OtyJCooler = naler
QtyJI OtyJJndlvidual l = Anlal! lndjviduel
07.08 - ESO
-',$ DieseI!
Plate
Page 1 (2) Combined Lubricating CooIer 51506-14
23/30
196
321
206
218
Gasket, model ,
mounting between
Irame plate and
Plate 2.
Note: When ordering 00

the serial numbers
numbers the plates
can be lound in the
right-hand corner
Working Card 515-
06.00)
Gasket, model ,
mounting between
the rest the plates.
al plader angives
serienummeret
pladen . Serienum-
meret er stempl et
toppen al pladen l
00
he . (Se arbejdskort
515-06.00)
267
338 ., -/1 1 . , - - - 321
339 279
340
341
----- 280
Gasket, model C,
342 mounting between
343
344
~ 302 c plate 26 and
02?
-- 292
-- 363
00

the gaskets are delivered as model C.
Gasket and must be unreeved Irom
model C.
07.08 - ESO
Plale
51506-14 Combined Lubricating l Cooler Page 2 (2)
23/30
Item Item
. Q Designation Benrevnelse . Qty. Des lgnatlon Bencevnelse
184 4/ Hexagon screw ll 338 11 Plates, 72050 rpm Plader, 720 50 rpm
5 cyl. engine 5cyl. molor
196 4/ Washer Skive
339 ; Plates, 72050 rpm Plader, 7 2050 rpm
206 4/ Washer Skive 6 cyI. e nglne 6cyl. molor
218 1/ Pressure plate Trykplade 340 11 Plates, 72050 rpm Plader, 720 50 rpm
7 cyl. e nglne 7 cyl. molor
243 2/ Guide bar, SIyrepind,
72050 rpm 72050 rpm 341 11 Plates, 72050 rpm Plader, 72050 rpm
6 cyl., 900 rpm 6 cyJ., 900 rpm cyl. engine 8cyl. molor
244 21 Gulde bar, 7~8 cyl. Styrepind, 7-8 cyl 342 11 Plates, 900 rpm Plader, 900 rpm
900 rpm 900 rpm 6 cyl. englne 6 cyl. molor
255 4/ Distance piece, Afstandsslykke, 343 11 PIates, 900 rpm Plader, 900 rpm
72050 rpm , 5 cyl. 72050 rprn, 5 cyf. 7 cyl. engine 7 cyl. motor
256 4/ Di stance piece, Afstandsstykke, 344 11 Plates, 900 rpm Plader, 900 rpm
720 5 0 rpm, 6 cyJ. 7250 rpm, 6 cyJ. 8 cyl. e nglne 8 cyl. moIor
257 4/ Dlstance piece, AfstandssIykke, 363 11 Cleaning 11uid Rensev<eske

7 2050 rpm, 7 cyl. 72050 rm, 7 cyl.
375 2/ Rubber linnlng Gumm iakning
258 4/ Di stance piece, Afstandsslykke,
72050 rprn, 8 cyI. 72050 rpm, 8 cyl. 387 21 Rubber Ifnning Gummipakning
259 4/ Dlstance piece, AfstandssIykke, 399 21 Rubber linning Gummipakning

900 rpm , 6 cyl. 900 rpm, 6 cyl.
411 2/ Rubber linning Gummipakning
260 4/ Distance piece, Afstandsstykke,
900 rpm, 7 cyl. 900 rpm, 7 cyl.
261 4/ Distance piece. Afstandsstykke,

900 rpm , cyl. 900 rpm, cyl.
267 1 / Frame pIate Stalivplade
279 4/ Gasket Pakoing
280 2/ Screw Skrue
292 1 / Glue Lim
302 2/ Gulde bar Slyrepind

(for di s mantling) (for demontering)
314 32/ Screw Skrue

the Gaskets are dell pakningerne leve-
livered as model C. res som model C.
Gasket and must Pakning og 8 skal
be unreeved from mo- skreres ud fra model
delC. c.
326 1 / Lubrlcatlng 011 cooler, Sm0reoliekoler,
complete komplet
When ordering spare p arts, see al80 page 500.50. Ved beslilling af reservedele, se ogsA side 500.50.
Only avaiIable as part a 8 parts kit. Kun lilgrengelig som del af reseredelssreI.
QtyJE OtyJEnglne AntallE = Antal/Motor
QtyJK OtyJCooler Antal/K = ntaVler
QtyJI atyJlndividu al AnlaVI = AntaVlndividuel
07.08 ESO
PlaIe
Page 1 (2) Centrifugal By-Pass Filter 51515-01
23/30
026 313 .---... ____-- 325

-----~~~
087 , 301
014 "-
"- "- 291
099 - .-
----- /' 038
~~ - 278
. .. ..
...... ..
... "
"
075 - 266
063
171 ~
171
109
____ 254
110
195
205 --------- 229
171
---- 337
386
1 ~- 386
~ ___ 349
-:\ ll----_ 350
374~ ~ 362
Plale
51515 -01 Centrifugal By-Pass Filter Page 2 (2)
L23/30
Item Item
. Oty. Deslgnatlon Benrevnel se . aty. Deslgnatlon Bencevnel se
014 1/1' Rotor, complete Incl. , krlet rnkl. I 291 1/F O-rIng O-flng
Item 026, 038, 063 , 026,038,063,075, 09 ,
075, 109,110, 171 , 195 110,171, 195 og 205 301 1/F Clrcllp LAsering
and 205
313 1/F Cover Da3ksel
026 1/F Cover nut Drekselm0Irrk
325 1/F Body cover, compl ete Dc:eksel. komplet inkI.
038 I/F Rotor cover HoIordreksel incl. Ilem 087,266,278, ilem087, 266,278, 291,
291 , 301 and313 301 and 313
051 1/F Body Sokkel
337 Centrifugal by-pass Cenlr f ugal by-pass
063 1/F O-rlng O-ring filter, complete filter, komple\
1 / 5-6 cyl. 5-6cyl.
075 1/F Stand tube Standr0f 2/ 7-8 cyl. 7-8cyl.
087 1/F l 811ft 349 4/F Nul M0\rik
099 1/F Pape r I"sert Papirindsats 350 4/F Screw Skrue
109 1/1' Rotor body Rotorsokkel 362 1/F Bracket for mountlng Kol,sol monlering
110 2/F Nozzle Dyse 374 4/F Screw Skrue
122 1/F Plug (cut ofl valve) (modtryksvenliJ) 386 1/F Gasket PaknlIlg
134 1/F Sprlng (cut off valve) Feder (modtryksventrl) 398 1/F Spare parts klt, Incl. Reservedelsscel, rnkl .
Item 087 , 278 , 291 ilem 087, 278, 291
146 1/F Gasket (cut Pakn ing (modI ryk s- and 301 og301
vatve) l)
408 1/F Spare parts kit, Incl. Reservedelsscel, lnkl.
158 1/F Shuttle (cut VenIilkegle (modtryks- Item 122, 134 , 146 122 , 134, 146
valve) I I) and 158 og 158
171 1/F Bearlng, complete Lejemontering, krlet 421 1/F Spare parts kit, Incl. Reservedelsscet. inkl.
Incl. Ile m 195 and inkl . item 19509205 Item 063, 146, 229, 230 ilem 063, 146, 229, 230
205 and 291 09291
195 1/F Circllp LAseril1g
205 1/F Stift
229 1/F Gaskel Paknlng
230 1/F O-rlng O-rlng
242 1/F Spindle Spindel
254 I/F Body, complete incl. Sokkel , kom plet lnkl.

Item 051, 122, 134, item051, 122, 134,146,
146, 158, 229, 230 158,229.23009242
and 242
266 I/F Cover clamp rIng Dcekselspcendering
278 1/F Cover fixing Dcekselm01rik
When orderlng spare parts, see aIso page 500.50. Ved bestilllng af reservedele, se ogsA side 500.50.
= Only available as part of a spare parts kit. lilgc:engelig som en del af eI reservedelssc:el.
QlyJE Qty./Englne An1al/E = Antal/Motor
QlyJF Qty./Fl lter Antal/F = Antal/FiIIer
94.23 - ESOS
Plale
Page 1 (2) Hand Wing Pump 51525-01
23/30
019
94.20 - ESOS-G
Plate
51525-01 Hand Wing Pump Page 2 (2)
23/30
Item Ilem
. Qty. Designation Bencevnelse . aty. Designation Bencevnelse
019 1/ Hand wlng pump, an dvlngeure ,

complete komplet
When ordering sare parls, see a/so page 500.50. Ved bestil llng af reservedele, 5 ogsa side 500.50.
= Only avaflable as of a spare parts kit. Iilgcengellg som del reservedelssrel.
. = Qty./Englne Qty./E = Qty./Motor
94.20 - ESOS-G
Plate
Page 1 (2) Lubricating l Separator 51530-04
23/30
~ 077
053
r'~ 089
~090
041~
-1----100
065~: ; ~ ~~ .--- 112

_____- 124
207
~~~~ ...._- 136
...,.,.~~__ ~-- 148
161
219
220
232
07.08 - ESO
PlaIe
51530-04 Lubricating l Separator Page 2 (2)
23/30
Item Item
. Qty. Designation Ben<evnelse . aty. DesIgnation Benrevnelse
041 1/F Breather with nder r med

Ilange ange
065 4/F Screw Skrue
077 8JF Screw Skrue
089 1/F Cover D ksel
100 1/F Insert fOf 011 IndsaIslor

separator o1ieudskilier
112 1/F Houslng 10r Hus

011 separator olieudskiller
124 4/F Screw Skrue
148 1/F Bend jning
161 4/F Irik
173 1/F Oil1rap Oliei s
185 1/F Unlon Forskruning
207 1/F Unlon Forskruning
219 4/F Screw Skrue
220 1 / 011 separator, com- Olieseparalor, kompieI

plete, incl item 077, inkl. ilem 077, 089,
089, 090, 100, and 090, 1000g 112
112
When orderlng spare parts, see also page 500.50. Ved besIilling af re5ervedele, se Og5 5ide 500.50.
= Only avai lable as part of a spare parts klt. Iilg ngelig som del af eI reservedelss
Qty.lE :: Qty./Englne Antal!E = AnIal!MoIor
QtyJF Qty.JFl lter AnIal/F = AnIal!FilIer
07.08 - ESO
Section 516
Cooling Water System
Description
Cooling Water System 516.01

Cooling Water Thermostatic Vale 516.04
Working card
Check of Coolng Water System 516-01.90

Cooling Water, Thermostatic Vale 516-04.00
Plates
Cooling Water Thermostatic Vale 51604-01

High Temperature Fresh Water Pump 51610-01
High Temperature Fresh Water Pump 51610-02
Temperature Fresh Water Pump 51610-05
Temperature Fresh Water Pump 51610-13
Pipes Cylinder Head 51625-01
Preheater - Fresh Water 51635-04
Description 516.01
Page1(1) Cooling Water System Edition 01
23/30
V28/32S
Description High Temperature Circuit
The cooling water system consists separate The high temperature circuit is used cooling
systems. The lw temperature (L) and the high the cylinder units.
temperature () circuits.
Cooling water is led through a distributing pipe
the bottom the cooling water space between the
Temperature Circuit lner and the frame each cylinder uni!. The water
is led ! through bores in the the frame via
The lw temperature circuit is used cooling the the cooling water guide jacket the bore.
charge air and the lubricating l , and the alternator
the latter is water cooled.
96.03 - ESOU-G
DescripIion
Cooling Water Thermostatic Valve 516.04
Pagel(l)
Edilion 01
23/30
V28/32S
Thermostatic VaIe The thermostatic valve cannot be se! adjusted,
and requires maintenance.
The thermostatic valve the high temperature cir-
cuit is mainly located imediately after the outlet some plants a corresponding thermostatic valve
the engine, but alternatively the external cooling is instaIIed th e lw temperature circuil. The ther-
system near the Iresh water cooler. mostatic elements this valve have an other tem-
perature range.
The cooling water enters through the cover () under
which the thermostatic elements are located.
The number elements depends the size

the valve.
The outlet ! the suction side the pump is marked

(8) and outlet the cooler is marked (C).
the warming-up period the cooling water is by-

passing the cooler. When the outlet water Irom the
cylinder heads reaches the normal temperature
(75-85' C) a controfIed amount water passes C
through the cooler.
The thermostatic elements must be replaced l the

cooli ng water temperature during normal operation
deviates essentiaIIy Irom the one stated the test
reporl. Fig. 1 Thermostatic Va/ve
94.26 - ESOS-G
',j,HM'(MAN DieseII
Page 1 (2) Check of CooIing Water System Edition 04
23/30
Safely precautions Special tools

Shut-off luel l
Check cooling wae r system.
Starting position
Engine is running
Related procedure

"
~
~
Working time % hour Plate no Item no Oty/
~
'" Capacity 1 man

::::
Data

05.4 1 - ESO
',I,I'!" DieseI[
Edilion 04 Check of CooIing Water System Page 2 (2)
23/30
Checks to be carried out

4) Check flexible connections for leaks.
1) Examine the piping system for leaks.
5) Check manometers and thermometers for pos-
2) Retighten all bolts and nuts the piping system. sible damages.
3) Move all valves and cocks the piping system. For check ! the fresh water condi tion , see section
Lubricate valve spindles with graphite similar. 504.
05.41 ESO
Working Card
Cooling Water, Thermostatic Valve
516-04.00
Page 1 (2) Edilion 0 1
23/30
Safety precaulions: Special lools:
Stopped engine
Plate Item Note
Shut-oll luel l
Shut-off cooling l
Descriplion:
Inspection thermostatic valve and replacement

elements. Hand lools:

Copaslip
Tools and cleaning preparation lor cleaning.
Slarling posilion:
Cooling water drained Irom engine (l neces-

sary).
Relaled procedure:
Manpower: Replacemenl and wearing pars:
Working time 2 hours Plate Item Qty/

Capacity 1 Man
51604 031 1/engine
Dala: 51604 055 2 or 4/engine
51604 092 3/engine
Declaration weigh t (Page 500.45)
94.29 - ESOS-G
516-04.00 Cooling Water, Thermostatic Valve
Working Card
23/30
The thermostatic valve cannot be adjusted and Replacement elements:

der normal working conditions maintenance is
required. However, some cases is necessary 1) Remove nuts (1) and washers (2), 4 or 6 pcs.
replace the elements the thermostatic valve. See fig. 1.
2) Disconnect upper and lower part the hou-

sing.
3) Remove the assembled elements (3) and the

3 elements O-ring sealing.
5 4) Remove the gaskets between the upper and

:---- --- lower part the housing.
___ __
4
5) The upper and lower part the housing are
thoroughly cleaned inside and the gasket sur-
faces.
6) The sealing rings (4) for the elements the

housing are replaced and lbrcated with a thin layer
copaslip.
7) Remount the assembled elements the hou-

sing by wriggling these somewhat over side.
8) Upper and lower part the housing are as-

sembled with a new gasket (5), the nuts (1) are
1. Nu
mounted and tightened "cross-wise".
2. Washer
3. Elemenl
:
4. O-rings sealing
5. Gasket After inspection replacement the elements the
cooling water temperature is checked ensure that
the elements are working correctly.
Fg. 1 Thermostatic va/ve
94.29 - ESOS-G
Plate
Page 1 (2) Cooling Water Thermostatic Valve 51604-01
23/30
018
031
_------ 043
055
~
Note: When ordering new elements,
state opening temperature
Husk! ved bestilling af nye elementer 067
at angive abningstemperaturen .
;~~
114
079
'~ 080
" - - 092
~ I02
94.23 - ESOS
,, Dieserl
Plale
51604-01 CooIing Water Thermostatic VaIve Page 2 (2)
23/30
Item Item
. Qly. Designatlon Benievnelse . aty. Designation Benmvnelse
018 4/ Screw Skrue
031 2/ 0-rl"9 O-rl"g
043 2/ Thermostatlc F01ereJement

element
055 2/ O-ri"g O-r;"g

067 2/ Sleeve 805"1[19
079 4/ Washer SkIve
080 16 l M01rik
092 3{ Gasket PaknIng
102 1 2{ Screw Skrue
11 4 / Thermostatlc Termosl atventII ,

l , complete komplet
When orderlng spare parts, al$o page 500.50. Ved bestilling reservedele, se ogsa side 500.50.
= Only available as part a spare parts kit. tIlgrengelig som del af e! reservedelssGet.
QlyJE QtyJEngIne I/ = Antal/Molor
QlyJT QtyJThermostatlc l Antal/T = AnlaI{Termoslatsventil
94.23 - ESOS
Plate
Page 1 (2) High Temperature Fresh Water Pump 51610-01
23/30
72050
178 - - - - -
~?'=~_
154-166 ------
010 - -_ _
046 - - - - --+-11-_.-'/
071 -
129
225 117 129 142

201
01 .36 - ESOS
,,'" DieseII
Plate
51610-01 High Temperature Fresh Water Pump Pag.2 (2)
L23/30
72050
Item Item
. Deslgnation Benrevnelse . Deslgnatlon Benrevnelse
010 1/ Pump houslng Pumpehus
022 1/ Bearlng houslng Lejehus
034 1/ Shaft Aksel
046 1/ Impetler L0behjul
071 1 / 5elf locking SeJvlasende rn0trik
083 1 / Rotaling seallng Roterende pakdflse
095 1 / Seallng ring Tretningsring
105 2/ 8all bearing Kugleleje
117 1/ Retainlng ring SikrrngsrIng
129 2/ Feder
130 1 / Locklng washer LAseskrve
142 1/ 5elf locking Selvlasellde m0trrk
154 2/ PUg screw Propskrue
166 2/ Gasket Paknrng
178 1/ 8 all vaIve Kugleventrl
191 / Screw Skrue
201 1 / Fresh water pump, Fe r s kandSue,

complete komplet
225 4/ Screw Skrue
When ordering spare parts, see al50 page 500.50. Ved besIillrng af reservedele, se ogsa sIde 500.50.
Onty available as part of a spare parts klt. Kun tilgcengetig som en det af reservedelsscel.
QtyJE Qty./E nglne Anta t/E = Antal/Motor
QtyJP = QtyJPump Anlat/P = Antal/Pum pe
0 1.36 ESOS
,,I( DieseII
Plate
Page 1 (2) High Temperature Fresh Water Pump 51610-02
L23/30
900
--1 083 191 095 022 034 105 058 130
178 -~~ / /
~ r " !
010 -__ -">V -~1-: ,; __! .J,
-~ '-i(' ~ - !
_ . -'- !
046
129 -
,- \
\
\
\ 117 129 142
93.05 - ESOS
Plale
51610-02 High Temperature Fresh Water Pump Page 2 (2)
23/30
900
Item Item
. Deslgnation Bencevnelse . DesJgnation Bencevnelse
010 1! Pump houslng Pumpehus
022 1/ Bearing housing Lejehus
034 1/ Shaft Aksel
046 1/ Impeller L0behju1
071 1/ 5elf locking nut Selvlasende m0IrIk
083 1/ Rotating sea ling RoIerende pakdase
095 1/ Sealing ring Tc:etningsring
105 2/ 8all bearlng KugtelejB
117 1 / Retaln lng ring SikringsrIng
129 2/ " Feder
130 1/ Locklng washer Lasesklve
142 1/ Self locklng nut Selvlasende m0trik
166 3/ Gasket PaknIrlg
178 1/ 8all valve Kgleventil
191 8/ Screw Skrue
201 1/ Fresh water pump, Ferskvandspumpe,

complete komplet
When order/ng spare parts, see a l so page 500.50. besIilling af reseNedele, se 09S;\ side 500.50.
Only avai lable as part a spare parts klt. tIlgrengelig som del af et reservedelssrel.
QtyJE = atyJEngine Antal/E = Antal/Motor
QtyJP = Q1yJPump Antal/P = Antal/Pump e
93.05 - ESOS
PiaIe
Page 1 (2) LowTemperature Fresh Water Pump 51610-05
L23/30
083 213 191 095 022 225 034 105 058
154-166 -===~=~~!!!
010 -----I-.~
046 ------ -----_
071
129
201 117 129 142

178 -
01.36 - ESOS
PlaIe
51610-05 Temperature Fresh Water Pump Page 2 (2)
23/30
Item Item
. Deslgnatton Bencevnelse . Deslgnatlon Ben revnelse
010 1/ Pump housing Pumpehus
022 ' / Bea rlng housing Lejehus
034 1/ Shaft Aksel
046 1/ Irnpeller L0behjut
058 1/ Gear w heel Tandhjul
071 1/ 5elf locking ! Selvlasende rn01rik
083 1/ Rotating sealing Roterende pakdase
095 1/ Sea Iing ring Tre tningsring
105 2/ 8all bea rlng Kugleleje
117 1 / Retalning ring Sikringsring
129 2/ Key Feder
142 1/ 5elt Iocklng nut Setvlasende m0trik
166 3/ Gasket PaknIng
178 1/ 8all va lve KugleventII
191 / $crew Skrue
201 1/ Fresh water pump, Ferskvandsumpe ,

complete komplet
225 8/ Screw Skrue
When ordering spare parts, see a l50 page 500.50. Ved bestilllng a1 reservedele, ogsA side 500.50.
Only ava il able as part of a spare parts klt. u tilgcengelig som en del af et reservedelsscet.
/ QtyJEnglne l/ = Antal/ Moto
QtyJP = atyJPump Antal/P = Antal/Pumpe
01.36 ESOS
,,!: DieseI[
Plate
Page 1 (2) Temperature Fresh Water Pump 51610-13
23/30
154-166 - 083 213 191 095 022 034 105 058
071 -
129 -
046
010
178 ------
201 11 7 129 142
07_06 - ESO
,+,.f DieseI[
Plate
51610-13 LowTemperature Fresh Water Pump Page 2 (2)
23/30
Ilem Ilem
. Qy. Designation Bencevnelse . Qy. Designatlon Bencevnelse
010 / Pump houslng Pumpehus
022 1/ Bearing houslng LeJehus
034 / Shaft Aksel
046 / Impel ler behjul
058 / Gear wheel TandhjuJ
071 1 / 5e!f locking l Selvlf.seIlde m0trik
083 / Rotatlng seallng Roterende pakdase
095 1/ Seaflng ring Tretningsring
105 2/ 6all bearing Kugleleje
117 1/ Retainlng rIng Sik ringsrIIlg
129 2/ Key Feder
142 1 / 5elf locking Sellasende m0trik
178 1 / BaH l Kugleventrl
191 / Screw Skrue
201 1/ Fresh water pump, Ferskvandspumpe,

complete komp let
225 / Screw Skrue
When ordering spare parts, see al$o page 500.50. Ved besti lling af reservedele. 5 ogsA side 500.50.
On/y available as part a spare parts kit. Irlgrengelig som del af el reseredelssret.
QlyJE OtyJEnglne Antal/E = Antaf/Motor
QtyJP OtyJPump Antal/P = AnIaf/Pumpe
07.06 ESO
Plate
Page 1 (2) Pipes Cylinder Head 51625-01
23/30
132 - - - - - - - - - ,
012
~-- 144
024
036
= ~-- 085
073 _ _--:::::=:r .-..-1- 1 - - - - 107

~@ 097
061 ~

,
':::,.,,-.-- -
Cylinder Head
Plate 50501, 50502,
50508 and 505 1
94.25 ESOS
'li$1'"#MAN DieseII
Plate
51625-01 Pipes CyIinder Head Page 2 (2)
23/30
Item Item
. Deslgnation Bencene l se . aty. Designation Bencevnelse
012 1!1 .. collecting pipe, . J". samler0r,

5 cyl. 5cyl.
024 / .. collectlng plpe, . sa1ler0r,

6 cyl. 6cyl.
036 '!1 .. collecting plpe, . . samler0r,

7 cy1. 7 cyl.
048 1/[ .. collectlng plpe, . . sacnler0r,

8cyl. 8 cyl.
061 l/C Packlng, l Pakncng,
073 2/C Screw Skrue
085 l/C Thermometer piece 'Iermometerstykke
097 1/C Packlng, ava l Pakncng, l
107 2/C Screw Skrue
119 2/C Screw Skrue
120 2/C Nut M01rIk
132 '/C Packing, l Pakning,
144 l/C Thermometer Termometer
When orderlng spare parts, see a/so page 500.50. Ved besliIling af reservedele, 5 ogS8. side 500.50.
Only avallable as part of a spare parts klt. tlgcengeJig som en del af et reservedelssret.
OtyJE QtyJEnglne './ Qty./Motor
OtyJE = QtyJCylinder O'y./C Qty./Cylinder
94.25 ESOS
Pla1e
Page 1 (2) Preheater - Fresh Water 51635-04
23/30
V28/32S
365
377
389
390 _~
400
412
424
436
353
07.46 - ESO
DieseII
Plate
51635-04 Preheater - Fresh Water Page 2 (2)
23/30
V28/32S
Item Ilem
. Designation Bencevnelse . Deslgnation Bencevnelse
353 1 / Pipe for preheater lor forvarmer
365" 1 / Preheater Forvarmer

5 23/30 , 5 L23130H,
stationary slaIioner
377* 1/ Preh eater Forvarmer

6, 7 23/30 , 6, 7 23130 ,
stationary sta l io ner
389* 1 / Preheater Forvarmer

8 23/30 , 8 23130 ,
stationary sIation.:er
390 1 / Preheater Forvarmer

5 23130, 5 23130,
marine marine
400 1 / PreheaIer Forvarme

6,7 23/30 , 6, 7 23/30 ,
marine marine
412" 1 / Preheater Forvarmer

8 2 3/30 , 8 23130 ,
marlne marine
424" 1/ Preheater Forvarmer

12V28/32S 12 V28132S
436' 1 / Preheater Forvarmer

16, 18 V28/32S 16, 18 V28/32S
ordering please Ved ordre olyses

inform of voltage (V) sre nd in g (V) og el-
and output (W) fekl (W)
When ordering spare parts, see al50 page 500.50. Ved bestifling af reservedele, se ogsc'1 side 500.50.
On ly aval/able as part of a spare parts kit. u ti lge nge li g som dei af et rese rve d e l sse t.
/ QtyJEngine AnIal/E = Anlal/Motor
/ = atyJPump AnIaVP = AntaVPumpe
07.46 - ESO
Section 519
Spec. plant
Description
ResiIient Mounting of Generating Sets 519.03

ResiIient Mounting of Generating Sets 519.03
Working card
Fitting Instructions for ResiIient Mounting of GenSets 519-03.00

Fitting Instructions for Resilent Mounting of GenSets 519-03.00
RepIacement of ConicaIs 519-03.05
RepIacement of ConicaIs 519-03.05
Maintenance of ConicaIs 519-03.1
Maintenance of ConicaIs 519-03.1
PIates
FIexibIe ExternaI Connections 51902-10

ConicaI EIement 51903-02
ConicaI EIement 51903-05
Descriplion
Resilient Mounting of Generating Sets 519.03
23/30
Resilient Mounting of Generating Sets 1) The supporl belween Ihe bottom Ilange Ihe
conical mounling and Ihe loundalon is made
resilienlly mounled generaling sels, Ihe diesel wilh a loose sleel shim. Thi s sleel shim is ad-
engine and Ihe allernalor are placed a common jusled 10 an exacl measuremenl (min. 75 mm)
rigid base Irame mounled Ihe ship's/machine lor each conical mounling.
house's loundal o n by means resilienl supporls,
Conical Iype. 2) The supporl can also be made by means
sleel shims, at the l a loose sleel shim
conneclions Irom Ihe generaling sel 10 Ihe exlernal al leasl 75 mm and below a sleel shim al
syslems should be equipped wilh flexible conneclions least 1 mm which are adjusled loreach conical
and pipes. Gangway elc. must l be welded 10 Ihe mounling and then welded the loundation.
exlernal part Ihe inslallalion.
Resilient Support
resilienl mounling Ihe generaling sel is made

wilh a number conical mounlings. The number
and Ihe dislance belween Ihem depend Ihe size
Ihe plant. These conical mounlings are bolled 10
Ihe l flange Ihe base Irame (see fig 1).
The setting Irom unloaded 10 loaded condilion is nor-

mally bel ween 5- 11 mm lor the conical mounling. Foundation
The supporl the individual conical mounling can MeIhod 2

be made one Ihe lollowing Ihree ways:
Stcel Shm~~:;:~~~;;:;:;:;:;;:::t==!:
Foundation
D once be de t ermi ned w Ih eng\h H()lD. DO\IIW 1S

I shim
. NECESSARY DISTANCE
TH ICKNESS OF CHOCK 75 mm SIeel shim
ChocklasI
Fig 1 Resilent n10uIlting generating sets.
Fig 2 5 conicaJs.
02. 10-ES1
' DieseI!
519.03 ResiIient Mounting of Generating Sets
Description
23/30
3) Finally, Ihe support can be made by means Adjustment Engine and Alternator
chocklast. is necessary use w steel Base Frame
shims, the steel shim should be loose and
have a minimum thickness 75 mm and the The resi liently mounted generating set is normally
bottom steel shim should be cast chocklast delivered Irom the lactory with engine and alternator
with a thickness at least 1 mm. mounted the common base Irame. Eventhough
the engine and alternator have been adjusted by the
Irrespective the method support, the 75 mm lactory with the alternator rotor placed correctly
steel shim is necessary lacilitate a possible luture the stator and the crankshalt bend the engine is
replacement the conical mountings, which are within the prescribed tolerances.
always replaced pairs.
02. 10-ES1
Descrilion
Page 1 (1) ResiIient Mounting of Generating Sets 519.03
Edition 10
L23/30
Resilient Mounting of Generating Sets 1) The support between the bottom Ilange the
conical mounting and th e loundat on is made
On resiliently mounted generating sets, the diesel with a loose steel shim. This steel shim is ad-
engine and the alternator are placed on a common justed an exact measurement (min. 1 mm)
rigid base Irame mounted on the ship's/machine lor each conical mounting.
house's loundaton by means resilient supports,
Conical type. 2) Finally, the support can be made by means
chocklast. lt is necessary use one steel shim .
connections Irom the generating set the external The steel shim should be cast in chocklast with
systems should be equipped with Ilexible connections a thickness at least 1 mm.
and pipes. Gangway etc. must not be welded the
external part the installation.
Adjustment of Engine and Alternator
Base Frame
Resilient Support
Th e resi lientl y mounted generating set is normally
Th e resilient mounting a generating set is made delivered Irom the lactory with engine and alternator
with a number conical mountings. The number mounted on the common base frame. Eventhough
and the distance between them depend on the size th e engine and alternator have been adjusted by the
the plant. The conical mountings are bolted the lactory with the alternator rotor placed correctl y in
Ilange the base Irame (see fig 1). the stator and the crankshaft bend the engine is
within the prescribed tolerances.
The setting Irom unloaded loaded condition is nor-
mally between 5-11 mm lor the conical mounting.
The support the individual conical mounting can Melhod 1

be made in ways:
CONICA L
---
"
Foundation
Method 2
. NECESSARY DI STANCE
" THI CKNESS OF CHOCK 10 mm
Sleel shim
ChockIasl
-~Pt:~~~~I!~~:r;==~
Fig 1 Resilent mounting of generating sets.
Fig 2 Support , conica/s.
04.24 - ES1
Working card 519-03.00
Page 1 (3) Fitting Instructions for ResiIient Mounting of GenSets Edition 22
23/30

Shut-off startin g air

Shut-oll luel l
Stopped lub. l circulation
Mounting and adjustmen t instru cti on lor new Ring and open-end spanner. 19 mm
GenSet and adjustment instruction lor eist i ng Rin g and open-end spanner. 24 mm
plants. Ring and open-end spanner. 41 mm
Ring and open-end spanner. 65 mm
Feeler gauge. 1-2 mm
Measurement tool
Starting position Hydraulic jack ( l necessary)
The loundaton should be welded and milled off

on shim surfaces.
Related procedure
Replacemen t conicals 519-03.05
Manpower
Spare and wearing parts
Working hours : 2 hours
Capacity 2 men Plate no Item no Qty/
Data

04.22 - ES 1
519-03.00 Fitting Instructions for Resilient Mounting of GenSets
Working card
L23/30
Mounting and Adjustment Instructions 5) Position th e fou r jacking bolts the tapped
New Generating Sets holes the bottom fl ange (6).
Make Ready Adjustment Conical Ele 6) Lowerthe generating set il rests completely
ments the foundation.
! the conical elements have been mounted by 7) Loosen the nut (1).
the factory, they must be mounted on the flange
! the base frame. In case they have been mounted 8) all the central buffers (3) by applying a
by th e factory, please start with item 4. spanner the h eago n (8 = 19) check that
they can move freely.
1) Remove nut (1) and washer (5) from th e conical
element. 9) Check with the feeler gauge that central buffer
is contact with the foundation .
2) Adjustment nut (2) has be turned down until
gets in contact with the surface ! the
casting. 1I aII internal buffers Then
3) Fit the conical element the bracket on the Can move freely Let conica l e leme nts
suspended equipment by means ! fi in g the settle for min 24 hous.
central buffer (3), the washer (5) and nut (1).
Cannot be moved Turn the jacking bolts
4) Tighten the nut (1) by hand and simultane- freely clockwise release the
ously block the central buffer (3) by applying internal buffer.
a spanner the heagon (8 = 19) on the
! the central buffer (3).
flange
7
4 3
Chockfast
Foundalion ~
.;
6
1.
"~
~
2. Adjustment
~

3. Cenlral buffer
Jacking
4.
5.
Jack-up bolt
Washer
"J:

6. Bollom flange "

boll
7. casting
"

8. Rubber elemenl
Mounting bolt
Fig 1 Conicaf fnounting. Fig 2 Conical e/ement.
04.22 ES1
Working card
Page 3 (3) Fitting Instructions for Reslient Mounting of GenSets 519-03.00
Edition 22
23/30
Adjustment Conical Elements after min 24 Adjustment lnternal Bu11er

Hours Settling
15) Turn the internal buffer clockwise until makes
After the con ical elements have been deflected un- contact with the found ation.
der static load ' min 24 hours, the loaded height (1)
see lig 1, should be measured and compared the 16) Turn the internal bulfer anticlockwise until
recommended loaded height. obtains contact with the base casting.
1 ) Care must be taken, during levelling th e This must be , /l turns.

installation, ensure that individual mountings
are not overloaded.Thevariation in laden height 17) Turn the internal buller 2 turn clockwise and
should not exceed 2 mm and should ideally check with a l ' gauge between the bottom
be less. The laden height can be measured Ilange on the conical element and the londa
between and base casting at , on w tion that the internal buffer (3) does not touch
sides (see fig 1). the foundation.
18) Tighten the nut (1) with a torque 300 Nm

Ex:Average = Number conIcal elements and block the central buffer (3) with a spanner
(8 = 19) during the tightening.
1I Then
Mounting Conical Elements the Foun-
Difference exceeds Level the conical element dation
2mm. by adjusting the jacking
bolts - commencing with 19) Drill lor mounting holes in the londaton lor
the conical element with each con ical element, either
the largest deviation.
a) Mark the positions the mounti ng holes on
Dilference does not ex- The height between the foundation through the conical element.
ceed 2 mm bottom flange and
londaton can be (Re)move the set completely so that the mark-
meaured. ingscan be reached bydrilling with conventional
tools.
The dilference between the w sides a conical Place the set on its lormer position by aligning
mounting should not be more than 0.5 mm. with the drilled holes.
or
Height adjustment
b) Drill the mounting holes in the foundation by
11) Turn the internal bufler anticlockwise until means the drilling pattern Irom the installa-
contacts the base casting secure the loaded tion drawing.
height each conical element.
The drilling has be done on belorehand and
12) Lift the generating set with crane or hydraulic the set must be aligned with the foundation
jack. holes before the work starts avoid l urther
re moval the set.
13) Turn the adjustment nut (2) the measured
height (see point 1) max 5 mm above the 20) Fix the conical element the foundation with
casting .. lor bolts.
14) Lowerthe generating set until rests completely Note! Afte r completion all works the buffer clear-
in itself. ance must be checked, see points 15-18.
04.22 - ES1
Working card
Page ' (4) Edition 24
23/30


Shut-off fuel '
Stopped lub. ' circulation
Descriplion Hand lools
Mounting and adjustment instruction lr new Ring and open-end spanner, 19 mm

GenSet and adjustment instruction for e i st in g Ring and open-end spanner, 24 mm
plants. Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack ( necessary)
Slarling posilion
The foundation should be welded and milled off

shim surfaces.
Relaled procedure
Replacement conicals 519-03.05
Manpower Spare and wearing parls
Working hours : 2 hours Plate Item Qty/

Capacity 2 men
Dala

03.50 ES,
519-03.00 Fitting Instructions for Resilient Mounting of GenSets
Working card
23/30
Mounting and Adjustment Instructions lor 5) Position the jacking bolt with a through-going
New Generating Sets (Method 1) minimum 75 mm.
Make Ready lor Adjustment ConicaI EIe 6) l owerthe generating set until rests completely
ments on the foundation.
1I the conical elements have not been mounted by 7) Check that allthe jacking bolts have ll contact
the lactory, they must be mounted on the prepared with the foundation.
brackets on the base Irame. In case they have been
mounted by the lactory, please start with item 4. 8) Loosen the nut (7).
1) Remove nut (7) and ring (6) Irom the conical 9) Turn all the internal buffers by applying a span-
elemen!. ner th e hexagon (5 = 19) check that they
can move I .
2) Fit the coni cal element th e bracket on th e
suspended equipment by means fi xing the
central buffer (2), the ring (6) and nut (7). 1I all internal buffers Then
3) Tighten the nut (7) by hand and simultane- Can move l conical elements
ously block the central buffe r (2) by appl ying settle min 24 hours.
a spanner th e hexagon (5 = 19) on the
the central buffer (2). Cannot be moved Turn the jacking bolts
l clockwise release the
4) Position the lo r jacking bolts in th e tapped internal bulfer.
holes (8) in the bottom flange.
7 - - --L.P+-I
6 ----Eff~
5
Brackel
4
3
2 _ 1=_=:f
Jacking boll

8 -t=tt---~-
Foundation
Section -
Base casting 5 casting
2 Central buffer (spindle) 6 Ring
3 Synthetic bush 7 !
4 Rubber elemen! 8 Tapped hole 1 2
Jacking boll
Fig 2 Conical element.
MounIing bolt
Fig 1 Conicaf mounting.
03.50 - ESI
DieseII
Working card
Page 3 (4) Fitting Instructions for ResiIient Mounting of GenSets 519-03.00
Edilion 24
L23/30
Adjustment Conical Elements after min 24 l1 Ihe mounling holes Ihe sleel shim according
Hours Settling 10 Ihe conical base casling dimensions.
After Ihe conical elemenls have been dellecled

der slalic load for min 24 hours, Ihe loaded heighl (I) Mounting the Completed Steel Shim
see fig 1, should be measured and compared 10 Ihe
recommended loaded height. 13) Ihe inlernal buffer anliclockwise l l
conlacls Ihe base casting 10 secure Ihe loaded
1 ) Care musl be laken, during levelling Ihe height each conical element.
inslallalion, 10 ensure Ihal individual mounlings
are l overloaded.The varialion lade heighl 14) Lift Ihe generaling sel with crane hydraulic
should l exceed 2 mm and should ideally jack.
be less. The l ade heighl can be measured
belween l and base casling al , 15) Remove all Ihe jacking bolls.
sides (see fig 1).
16) Position each compleled sleel shim.
Ex:Average ; Number conIcal elemenls 17) Lowerlhegenerating sel l l resls complelely

ilself.
Then 18) Number each sleel shim logelher with each

conical element.
Difference exceeds Level Ihe conical elemenl
2mm. by adjusling Ihe jacking
bolls - commencing wilh Adjustment Internal Buffer
Ihe conical elemenl wilh
Ihe largesl devialion. 19) Turn Ihe inlernal bufferclockwise (downwards)
l l makes conlacl wilh Ihe steel shim
Difference does l - The heighl Ihe sleel foundalion.
ceed 2 mm shim can be measured.
20) Ihe inlernal buffer anliclockwise (upwards)
l l oblains contacl wilh Ihe base casling.
The difference belween Ihe sides a conical
mounling should l be more Ihan 0.5 mm. This must be (, (ll turns.
21) the inlernal buffer LULL turn s clockwise

Measuring Steel Shim (downwards) and check wilh a l gauge
belween th e base casting Ihe conical ele-
11) Measure Ihe steel shim several poinls menl and the sleel shim Ihal Ihe inlernal buffer
oblain the highesl possible accuracy during (2), see fig 1, does l louch Ihe sleel shim
preparation. foundalion.
22) Tighten Ihe (7) wilh a lorque 300 Nm

Fabricating Steel Shim and block the cenlral buffer (2) wilh a spanner
(8 ; 19) al Ihe same time.
12) Make sure Ihalthe minimum heightoflhe sleel
shim is 75 mm 10 secure a replacemenl
the sleel shim.
03.50 - ES'
519-03.00 Fitting Instructions for ResiIient Mounting of GenSets
Working card
Page 4 (4)
Edition 24
L23/30
Mounting Conical Elements the Foun-
dation
b) Drill the mounting holes in the foundation by
23) l 1
four mounting holes in th e foundation for means th e drilling pattern from the installa-
each conical element, ei th er tion drawing.
a) Mark the positions the mounting holes on The drilling has to be done on beforeh and and
th e foundation through the conical element. the set must be aligned with the foundation
holes before the work starts to avoid further
(Re)move the set completely so that the mark- removal th e set.
ingscan be reached bydrilling with conventional
tools. 24) Fix the conical elemen t and the steel shim to
the foundation with bolts.
Place the set on its former position by aligning
it wi th the drilled holes. ! After completion all works the buffer clear-
ance must be checked, see points 19, 20, 21 and
22.
03.50 - ES1
Page 1 (4) Fitting Instructions for ResiIient Mounting of GenSets Edition 25
23/30

Slopped engine Plate no Ilem no Nole
Shut-off starling air
Shut-off fuel l
Slopped lub. l circulation
Press button (Blocking - Resel)
Mounling and adjuslmenl inslruclion for new Ring and open-end spanner, 19 mm
GenSel and adjuslmenl inslruction for existing Ring and open-end spanner, 24 mm
planls. Ring and open-end spanner, 41 mm
Measurement 1001
Hydraulic jack ( necessary)
StartIng position
The foundation should be welded and milled off

on shim surfaces.
Related procedure
Replacemenl conicals 519-03.05
Manpower Spare and wearing parts
Worki ng hours : 2 hours Plate no Ilem no Qly/

Capacily 2 men
Data
Dala for pressure and tolerance (Page 500.35)

Dala for torque moment (Page 500.40)
03.50 - ES1
Wrkng card
Page 2 (4)
Edition 25
L23/30
Mounting and Adjustment Instructions for lr l r jacking bolts and mounting holes drilled
New Generating Sets (Method 2) according conical base casting dimensions, is
req uired.
Make Ready for Adjustment of Conical Ele
ments 4) Position the supporting steel shim as per fig
1 and locate the conical element by means !
1I the conical elements have ! been mounted by dowel pins.
the lactory, they must be mounted the prepared
brackets the base Irame. case they have been 5) Position the jacking bolts the tapped holes
mounled by the lactory, please slart with item 4. the supporting steel shim as per lig 1.
1) Remove ! (7) and ring (6) Irom the conical 6) Position the jacking bolts with a through-going
element. minimum 1 mm, see lig 1.
2) Fi t the conical element the bracket the 7) Lowed generating set l ! rests completely
suspended equipment by means lixing the the loundation.
central buffer (2), the ring (6) and ! (7).
8) Check that all jacking bolts have ll contact
3) Tighten the ! (7) by hand and simultane- with the foundation.
ously block the central buffer (2) by applying
a spanner the hexagon (S = 19) the 9) Loosen the ! (7).
! the central buffer (2).
10) all the internal buffers by applying a span-
75 mm supporting steel shim, complete with holes ner the hexagon (S = 19) check that they
can move Ireely.
Brackel
7- - _ - L1DrI
Jacking 6 --_-,!;;~
SupporIing
5
steel shim 4
Steel shim r=d====t====::;:=f:-j 3
Foundation 2 -i=_~~
Section -
8 -:::;.;... _ _ _-""""'
Jacking boll
1 Base casting 5 casting
2 Central buffer (spindle) 6 Ring
3 Synthetic bush 7
4 Rubber element 8 Tapped hole 12
Mounling bolt
Fig 1 ConicaJ mounting. Fig 2 Conicaf efement.
03.50 - ES 1
Working card
Page 3 (4) Fitting Instructions for ResiIient Mounting of GenSets 519-03.00
Edition 25
L23/30
all internal buffers Then Measuring Steel Shim
Can move Ireely Let conical elements 12) Measure th e steel shim several points
settle lor min 24 hours. obtain the highest possible accuracy during
preparation.
Cannot be moved Turn the three jacking
Ireely bolts the supporting
steel shim clockwise, Fabricating Steel Shim
anticlockwise release
the internal bufler. 13) Make sure that the minimum height the steel
shim is 1 mm secure the l replacement
the supporting steel shim .
Adjustment Conical Elements after min 24
Hours Settling ll the mounting holes the steel shim according
the conical base casting dimensions.
After the conical elements have been dellected
der static load lor min 24 hours, the loaded height (1)
see lig 1, should be measured and compared the Mounting the Completed Steel Shim
recommended loaded height.
14) Lilt the generating set 1 mm totally be means
11) Care must be taken, during levelling the the three jacking bolts.
installation, ensure that individual mountings
are overloaded.The variation laden height 15) Position each completed steel shim.
should exceed 2 mm and should ideally
be less. Th e laden height can be measured 16) Relower the generating set by means the
between and base casting at , W three jacking bolts l rests completely
sides (see lig 1). itself.
( + 2 + 3 -----
Ex:Average = Adjustment lnternal Buffer
Number conical elements
17) the internal buflerclockwise (downwards)
Then l
makes con tact with the steel shim
loundation.
Diflerence exceeds Level the conical element
2mm. by adjusting the jacking 18) the internal bufler anticlockwise (upwards)
bolts commencing with l obtains contact with the base casting.
the conical element with
the largest deviation . This must be (, ( trns.
Diflerence does The height the steel 19) the internal bullertwo lll turns clockwise
ceed 2 mm shim can be measured . (downwards) and check with a leeler gauge
between the base casting the conical ele
ment and the steel shim that the internal bufler
Th e diflerence between th e w sides the conical (2), see lig 1, does touch the steel shim
mounting should be more than 0.5 mm. loundation.
20) Ti ghten the (7) with a torque 300 Nm

and block the cen tral bufler (2) with a spanner
(8 = 19) at the same time.
03.50 ES1
'( DieseII
519-03.00 Fitting Instructions for Resilent Mounting of GenSets

Working card
Page 4 (4)
Edilion 25
2330
Mounting Conical Elements the Foun- b) l 1 the mounting holes in th e loundation by

dation means th e drilling patt ern Irom th e insIalla-
tion drawing .
21) Remove th e dowel pins.
Th e dri lling has be done on belorehand and
22) ll 10
mounting holes in the 10undaIion lor the set must be aligned with the 10undaIion
each conical elemen t, either holes belore the work starts avoid further
removal the set.
a) Mark the positions the mounting holes on
the loundation through th e conical element. 23) Fix the conical element and the supporting
sIeel shim/sIeel shim the loundation wi th
(Re)move the set completely so that the mark lour bolts.
ings can be reached bydrillingwith conventional
tools. 24)' Weld th e 10wes sIeel shim the loundati on .
Place the set on iIs lormer position by aligning Note! After completion all works, the bufler clear-

with th e drilled holes. ance must be ch ecked, see points 17, 18, 19
and 20.

03.50 - ES1
',J,i,iHi(MAN Dieserl
Working card
Fitting Instructions for ResiIient Mounting of GenSets
519-03.00
23/30
Safety precautions Special lools

Shut-off startin g air

Shut-off fuel l
Descriplion Hand tools
Mounting and adjustment instru ction for Ring and open-end spanner, 19 mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 24 mm
plants. Ring and open-end spanner, 41 mm
Measurement l
Hydraulic jack (f necessary)
Starling position
The loundation should be welded and milled 011

shim surfaces.
Related procedure
Replacement conicals 519-03.05
Manpower Spare and wearing parls
Working hours : 2 hours Plate Item Qty/

Capacity 2 men
Data

03.50 - ESO
Working card
Page 2 (4)
EdiIion 26
L23/30
Mounting and Adjustment Instructions for 75 mm supporting steel shim, complete with tapped
New Generating Sets (Method 3) holes lorthree jacking bolts, lur mounting holes and
lour tapped holes, drilled according the conical
Make Ready for Adjustment Conical Ele- base casting dimension, is required see lig 1.
ments
4) Position the supporting steel shim as per lig
1I the conical elements have been mounted by 1 and locate the conical element by means
the lactory, Ihey musl be mounled Ihe prepared lour hold-down bolts.
brackels Ihe base Irame. case Ihey have been
mounled by Ihe laclory, please slarl wilh ilem 4. 5) Position the jacking bolts the tapped holes
the supporting steel shim as per lig 1.
1) Remove l (7) and ri ng (6) Irom Ihe conical
element. 6) Position the jacking bolts with a Ihrough-going
minimum 1 mm plus permitted thickness,
2) Fil Ihe conical elemenl 10 Ihe bracket Ihe as specilied Irom the chocklast supplier, see
suspended equipmenl by means lixing Ihe lig 1.
cenlral buffer (2), Ihe ring (6) and (7).
7) Lowed the generating set l rests com-
3) Tighlen Ihe l (7) by hand and simullane- pletely the loundation.
ously block Ihe cenlral buller (2) by applying
a spanner 10 Ihe hexagon (5 = 19) the 8) Check that all jacking bolts have l ull contact
the central buffer (2). with Ihe loundation.
6 ----e~~
Bracket 5
4
3
Jacking bolt~J:!~~~
Supporting
sIeel shim
2 - 1=,,--===r
SIeel shim:E~====t:====1t~
8
Chockfast
Foundalion
1 Base casting 5 casting
2 Central buffer (spindle) 6 Ri ng
3 Synthetic bush 7
4 Rubber element 8 Tapped hole 12

Jacking Fig 2 Conical element.

boll

Mounting bolt
Fig 1 Concal monting.
03.50 - ES1
l' DieseII
Working card
Page 3 (4) Fitting Instructions for Reslient Mounting of GenSets 519-03.00
Editio n 26
23/30
1I all internal buffers Then Measuring Steel Shim and Chocklast
Can move Ireely Let conical elements 1) The steel shim should be at least 1 mm
settle for min 24 hours. heigh .
Cannot be moved n the three jacking Check the minimum permitted thickness ofchock-
freely bolts n the supporting fast for the load and surface of this applcation
steel shim clockwise, or with chockfast supplier.
anticlockwise and
slacken th e lor hold-
down bolts release Fabricating Steel Shim
the internal buffer.
Make sure that the minimum height the steel shim
is 1 mm secure a luture replacement the sup-
Adjustment Conical Element after min 24 porting steel shim.
Hours Settling
11) l 1 the mounting holes the steel shim ac-
After the conical elements have been dellected cording the mounting holes the supporting
der stalic load for min 24 hours, the loaded height ( 1 ) steel shim.
see fig 1, should be measured and compared the
recommended loaded height.
Adjustment Internal Buller
9) Care must be taken, during levelling the
installation , ensure that individual mountings 12) the internal bufferclockwise (downwards)
are overloaded.The variation laden height l makes contact with th e steel shim or
should exceed 2 mm and should ideally loundati on.
be less. The laden height can be measured
between l and base casting at , w 13) the internal buffer anticlockwise (upwards)
sides (see fig 1). l obtains contact with the base casting.
This must be f trns.

Ex:Average = Number conicaI eIements
14) th e internal buffe r w ll l turns clockwise
(downwards) and check with a leeler gauge
1I Then between the base casting the conical ele-
ment and the steel shim that the internal buffer
Difference exceeds Level the conical element (2), see fig 1, does touch the steel shim or
2 mm. by adjusting the jacking foundation.
bolts - commencing with
the conical element with 15) Tighten the (7) with a torque 01300 Nm and
the largest deviati on. blocking the internal buffer (2) with a spanner
at the same time, see fig 1.
Difference does ex- The height ! the steel
ceed 2 mm shim and the chocklast
can be measured. Mounting Conical Elements the Foun-
dation
The difference between the w sides the conical 16) l1 mounting holes the londat on accord-
mounli ng should l be more than 0.5 mm. ing the supporting steel shim/steel shim and
chockfast, either
03.50 - ES1
',"( Dieserl
Working card
Page 4 (4)
Edition 26
23/ 30
a) Mark th e positions the mounting holes b) ll Ihe mounting holes Ihe 10unda1on by
th e 10u nd a1 on Ihrough Ihe supporling sleel means Ihe drilling pattern .
shim .
The drilling has 10 be done beforehand and
(Re)move Ihe sel complelely so Ihal Ihe mark Ihe sel musl be aligned wilh Ihe foundalion
ingscan be reached by drillingwilh convenlional holes before Ihe work slarls 10 avoid fu rlher
1001s. removal ! Ihe set.
Place Ihe sel ils former posilion by aligning Make sure Ihal Ihe mounling bolls are isolaled from
l
wilh Ihe drilled holes. Ihe chockfast.
Note! After complelion ! all works, Ihe buffer clear

ance must be checked, see poinls 13, 14, 15 and
16.
03.50 - ES1
+ .J Dieserl
Working card
RepIacement of ConicaIs
519-03.05
23/30
Safely precaulions: Speciallools :

11
Stopped engine
Plate Item Nole

Shut-off fuel l
Shut-off cooling l
Descriplion:
Replacement of conicals.
Hand lools:
Slarling posilion: Ring and open-end spanner, 22 mm

Ring and open-end spanner, 30 mm
Safety precautions. Hydraulic jack
Relaled procedure:
Fitting instructions for resilient mounting.
Manpower: Spare and wearing parls:
Working hours: hours Plate Item Qty/

Capacity 2 men
Dala:

96.03 - EQOS-G
"I'I,!Ni(MAN Dieserl
519-03.05 WorkIng card
EditIon 01 RepIacement of ConicaIs Page 2 (2)
L23/30
Replacement Conicals
1. Loosen all conicals side. 3. Lift the GenSet l the steel shim can be
removed. This ll give enough space for removing
damaged conical.
2. ! a jack under the base frame. see lig
1.
4. ! !he GenSet conical.
! Conica/s shou/d on/y be re/aced airs, see

lig 2 and /ate 5 1903.
5. Lower the GenSet again.
6. Repeat items 1-5 for the other side.
Steel shim
7. Adjust the conicals, see Working Card 519-
Foundation 03.00 "Fitting /nstructions lor Resilent Mounting
Deck Jack GenSet.
Fig 1 Remova/ ( conicaJs
0

0
One pair
Fig 2 The coIlicals must be pairs
96.03 - ESOS-G
Page 1 (2) Replacement of Conicals Edition 04
L23/30

:J Shut-off starting air
I::J Shut-off cooling water
Shut-off fuel l
Replacement conicals. Hydraulic jack
Starting position
SaIety precautions.
Related procedure
Fitting instructions resilient mounting.
Manpower Spare and wearing parts
Working hours : hours Plate Item Qty/

Capacity 2 men
51903 013 4/
Data

04.22 ESO
', DieseII
519-03.05 Working card
Edilion 04 RepIacement of ConicaIs Page 2 (2)
L23/30
Replacement Conicals
The central buHer is divided in parts and ll be

mentioned as central buffer lower part and central
buffer upper part.
1) Loosen all the conicals in one side the engine

and remove the nut Irom the central buffer.
2) Use the 19mm. spanner and turn the central

buffer an ticlockwise until the buller hits the
base-casting and divides in and remove
the upper part.
6
3) Mount th e hydraulic jack under th e base
Irame.
1. ut
2. Adjustment ul
4) the GenSet until the conical can be remo- 3. Central buffer
ved. 4. Jack-up boll
5. Washer
5) Remove the nut and the upper part the 6. Bottom flange
7. casIing
central buffer, Irom the new conical.
8. Rubber etement
6) Mount the new conical. Add Loctite 243 the

tread connection between upper and lower
part the central buffer. Fig 1 Remova/ concals
7) Lower the Genset Irom the hydraulic jack.
8) Use the 19mm spanner and turn th e central

buller clockwise until hits the loundation and
tighten 300 Nm.
9) Follow the procedure "Loosing central buffer".

Please seethe working card 519-03.1 "Main-
tenance Conical"
10) Repeat items 1-8 lor the other side.
11) Adjust the conicals, please see Working Card

519-03.00 "Fitting Instructions lor Resilient
Mounting GenSet.
04.22 - ESO
',l,l}H'lMAN DieseI!
Page 1 (2) Maintenance ConicaIs EdiIion 02
23/30

D Shut-oll cooling water
D Shut-off luel l
:;:] Press Blocking - Reset
Control and adjustment conicals. Ring and open-end spanner.

Feeler gauge, 2 mm.
Slarling posilion
Relaled procedure
Manpower Replacemenl and wearing parls
Working time 2 hours Plate Item Qty/

Capacity 1 man
Dala

98.41 50
Edition 02 Maintenance of Conicals Page 2 (2)
L23/ 30
Visual Check Result Clearance Check
If h e n
What Check
everylhing is check is cornpleled
1) Check ' l deposits the rubber element.
everylhing is ! adjusl conicals which do !
2) Check ' loose mounting bolts. comply with Ihe clearance
demands acc. 10 iIem 510.
Recheck all conicaJs acc. 10
3) Check ' damage the rubber element. item4.
Result Visual Check everything is 51ll ! replace conical acc. 10

f Then
everything is conlinue 10 nexl conical

Adjustment of Conicals
l deposils rubber clean rubber element
elemenl observed 5) Remove protective cap by loosen the nut (1).
1005e mounting bolts fasten mounting bolIs

6) Turn internal buffer (2) clockwise l makes
damage 10 conicals repIace conical according 10 contact with the steel shim (4).
is observed Working Card 519-03.05
7) Turn internal buffer (2) anti-clockwise l
makes contact wi th the conical base casting
Clearance Check (3). This must be done , l l rotations.
What Check 8) Turn internal buffer (2) ll rotati ons clock-

wise. This ensure ll vertical movement '
4) Check clearance all conicals between steel the buffer.
shim and internal buffer through the slot the
base casting the conical (see fig 1) with a 9) Check aII conicals again.
l ' gauge approx. 2 mm.
1 ) Tighten the (1), see page 500.40 and at
the same tim e block th e intern al buffer (2) with
a spanner.
1.
2. l I buffer
2
3. Conical base caslfng
4. Steel shim
3
Fig 1 Conica/
98.41 - ESOS
Working Card
Maintenance Conicals
519-03.10
23/30

D Shut-off fue l l
Control and adjustment ! conicals. Ring and open-end spanner 19 mm

Ring and open-end spanner 41 mm
Ring and open-end spanner 65 mm
Feeler gauge, 2 mm
Hydraulic jack
Starting position
Related procedure
Manpower
Working time 2 hours Replacement and wearing parts

Capacity t man
Plate no Item no Qty/
Data

04.22 - ESO
Edition 04 Maintenance of Conicals Page 2 (3)
L23/30
Visual Check Result Clearance Check
What Check 1I Then
everyIhing is check is completed

1) Check lor l deposits the rubber element.
everything is adjusl conicals which do
2) Check lor loose mounting bolts. comply wiIh Ihe clearance
demands acc. 10 ilem 5 10.
Recheck all conicals acc.lo
3) Check lor damage the rubber element. item4.
Result Visual Check ee ryl hing is stiJl l replace conical acc. 10

Working Card 5 19-03.05
Then
everyIhing is conIinue 10 l conical

Adjustment of Conicals
ldeposits rubber clean rubber elemenI
elemenl are observed 5) (1) must be loose.
1005e mounting bolts fasten mounling bolls
6) Check that the central bufler can be easily
damage 10 conicals replace conical according 10 turned. 1I see the procedure lor "Loosing
is observed Working Card 519-03.05 Central buffer".
7) Measure the compression at each element min 24

Clearance Check hours after inslallation. Maximum devialion 2
Irom average is acceplable. Devialion 1mm
Whal 10 Check: is perfect.
4) Check clearance all conicals belween sleel 8) 1I devialion is l lolerance adjusl Ihe heighl
shim and inlernal buller Ihrough Ihe slol Ihe wilh Ihe adjustmenl ul (2). Use spanner 65
base casling the conical (see lig 1) wilh a mm. It may be necessary 10 l ft Ihe GenSel
leeler gauge approx. 2 mm. slighlly wilh a hydraulic jack. Make sure Ihal
all Cenlral bullers can be turned Ireely al all
lime.
9) Check compression elemenl again. 1I l

lolerance repeal Irom 8.
1. u
2. Adjuslment ul

3. Rubber elemenl ~
4. Jacking screw ~
~

5. Base casling ~
3
6. Central buffer "
'"

4
'"

Fig 1 Conica/
04.22 ESO
Page 3 (3) Maintenance of Conicals Edition 04
23/30
10) Turn the central buffer anti clockwise without

restriction until slight contact at .
11) Turn the central bufler clockwise and check

that it can be turned freely 3%-4 turns.
12) Turn central buffer anticlockwise 2-2% turns.
13) Tighten nut (1) without turning the central

buffer. Tighten hard ma 300 Nm.
Loosing central buffer
14) Turn the central buffer (6) clockwise until it

makes contact with the loundation and ti ghten
with 300 Nm.
15) Use the jacking screws (4) lift the base casting
until the central buffer can be turned Ireely.
Make sure that there is no contact between
thread central buffer and th e base frame.
16) Turn the central buffer two turns anticlock-

wise.
17) Lovers the base casting by th e Jacking screws

and tighten th e holding bolts.
18) Check that the central buffer can be turned

freely. 1I not go oi nt 14 again.
04.22 - ESO
PIate
Page 1 (2) Flexible External Connections 51902-10
L23/30
Item
Fig. Designation Connection

Fuel l, inlet 1 018
Fuel l , outlet 2 031
Waste l , outlet 3 043
Venting TC bearings C30 138
03.12 - ESO
PIate
51902-10 Flexible External Connections Page 2 (2)
L23/30
Item
Fig. Oesignation Connec tion

Venting to expansion tankl F3/F4 163

fresh water preheating
Ireshwater,inlet G1 222

freshwater, outlet G2 234
Compressed air, inlet 1 271
Exhaust gas, outlet ( 400) 2 329
03.12 - ESO
',Ji$1'MAN DieseII
Plale
Page 1 (2) ConicaI EIement 51903-02
23/30
013
................" .............,.................,.............. ............................
013

025
"

..

Note! When ordering be aware that conical ele- Bemrerk! Ved bestilling al conicals elementer skal
ments always should be replaced in pairs. State conicals elementer altid udskiltes parvis. Opgiv
manulacturing existi ng conical elements. labrkaton s nr. eksisterende conicals elementer.
97.49 ESO
'' DieseI[
Plale
51903-02 Conicai EIement Page 2 (2)
23/30
Item Ile m
aty Designation Bencevnelse a Design ation Ben cevnelse
013 1 / ConlcaI element, Konisk underst0tning,

compIete komplet
025 4/ Screw Skrue
When ordering spa re parts, see a/50 page 500.50. Ved bestfling af reservedeIe, 5e ogsf side 500.50.
= Only ava ilable as part of a spa re parts kit. IilgrongeJig som del af l reservedelsscet.
Qty/M = Qty/Conica l mounting. Qty/M = Qly/ConicaJ montering.
97.49 - ESO
ll DieseII
Plate
Page 1 (2) ConicaI EIement 51903-05
L23/30
013
04.22 - ESO
Plate
51903-05 Con ical Element Page 2 (2)
L23/ 30
Item Item
aty Designation Benmvnelse aty Deslgnation Ben mvne lse
013 1 / Conical element, Konisk u nderSI l n ng,

complete koml el
When orderlng spare parts, see also page 500.50. Ved bestiliing af reservedele, se 09S:' side 500.50.
On ly avaIIable as part of a spare parts klt. Kun tilgrengelig som en del af eI reservedelsscel.
aty/M = Qty/Coni cal mounting. Qty/M = QIy/Conical monIering.
04.22 - ESO
Section 520
Tools
Description
Introduction to Spare Part Plates for Tools 520.01

Working card
Function of the Hydraulic Tools 520-01.05

Application of Hydraulic Tools for Connecting Rod 520-01.06
Application of Hydraulic Toolsfor 520-01.06
Cylinder Head and Main Bearing 520-01.07
Hand Pump 520-01.10
Maintenance of Hydraulic Tools 520-01.15
Tightening with Torque Spanner 520-01.25
Max Pressure Indicator 520-01.25
Plates
Tools for Cylinder Head 52005-04

Tools for Piston, Connecting Rod and Cylinder n 52006-06
Tools for Operating Gear for Inlet Vales,Exhaust 52008-04
Vales and Fuellnjection Pumps
Tools for Control and Safety Systems 52009-02
Automatics and Instruments
Tools for Crankshaft and Main Bearing 52010-04
Tools for Fuel l System and Injection Equipment 52014-03
Tools for Lubricating l System 52015-01
Hydraulic Tools 52021-10
Tools for Oerhaul Height,Piston, 52050-02

Cylinder n and Connecting Rod
Description 520.01
Page 1 (1) Introduction to Spare Part Plates for Tools Edition 01
L23/30
V28/32S
The contents these spare part plates with Iools However, some tools such as l orque spanners, hy-
are a summary STANDARD TOOLS normal draulic tools etc. may also have olher applications.
mainIenance and EXTRA TOOLS recondil ioning, InformaIion about Ihe exacl use the lools appears
which can be supplied by & Diesel A/S, from Ihe relevanI sections the inslruction book.
Holeby. Thus, the list comprises Ihe total extent
Iools available this engine type. Note: The lable the spare parl plates is marked
wilh an S an . S means thal the lools are
For each specific plant Ihe amount lools delivered supplied when ordering .8.landard lools and an
depends the contractual specificalions. means that the tools are supplied when ordering
J;:xtra tools, i.e. Tools Reconditioning (extra l ools
The l ools l sed are assembled sections corres- are slandard delivery)
ponding the chapters the inslrucIion book.
96.03 - ESO
Page 1 (7) Function of the Hydraulic Tools Edition 02
General
D Stopped engine Plate Item Note

D Shut-oll cooling water
D Shut-off luel l
D Press Blocking - Reset
Salety hints and lunction hydraulic tools.
Starting position
Application hydraulic tools 520-01.06
Related procedure
Working time hours Plate Item Qty/

Capacity men
Data

99.43 ESO
,/ DieseI!
Edilion 02 Function of the Hydraulic TooIs Page 2 (7)
GeneraI
Function the l Tensioning Device 8. The operation and handHng the device are
be carried by epert staft only.
order achieve an optimal result with one or
several devices, some ru les have be considered. 9. The given ma. operation pressure is
We epressly that a conscientious handling be eceeded any case and is be walched
the device as well as the accessories is high- at the manometer the pressure generalor
est importance. ignore these rules or separate during the complel e lensioning or loosening
hinls means danger 10 l le or danger injuries! See procedure. When having achieved the given
Safety Hints. pressure, stop th e pressurization immedi-
ately.
SaIety Hints 10. During the pressurization when tensioning or

loosening the bolt connection, always watch
Beside regarding the general accident-prevention Ihe admissible stroke the device. Eceed-
rules, the sale handling ofthe device and the hydraulic ing this slroke is connecled wilh insufficient
accessories demand especially the consideralion generating tensioning lorce because the
the lollowing hints. When disregarding single device is tensioned itselve or the hydraulic
items, you can cause danger Hle and/or danger pressure is bleeded automaticly.
injuries!
11. principle, when connecting high-pressure
1. When leakages occur during the pressuriza- hoses l has 10 be laken care that the connec-
, bleed pressure immedialely and seal the
tions are correcl (see also separate hi nts).
leakage or replace defect parls.
12. The hydraulic hoses have 10 be installed a
2. case repair, use eclusive l y original spare way that th ey are run over by vehicles or
parts. In epert substitution damaged parts unnecessarily walked overby people. Never lay
by non-original spare parts is prohibited. hoses across sharp objecl s (danger cuts)
and never bend or jam them .
3. assembly parls are to be handled corre-
spondence 10 Ihe working cards only. change 13. Never hold or transport the device by using the
the procedure or another operation the high-pressure hoses.
device is allowed.
14. incorrecl working manomeler Ihal doesn
4. Make sure thatthe components be tensioned show the right pressure leads overstressing
do eceed Ihe admissible strain. th e parts and an incorrect bolt connec-
l . Apart from damaged parts an incorrect
5. order 10 use Ihe device, Ihe thread has

boll conneclion can also cause condilions that
be sufticiently eceedi n g order avoid that are danger lile. Therefore take care thal
the turn a th read cracks, see item 4. the manometer shows the right value or the
tensioning force is checked an olher way
6. During the pressurizalion the people involved
have remain an appropriate distance.
(' eampl e by using a master manometer).
Tensioning forces can be checked ' eamp l e
'"

.,.C>
Staying direction towards the bolt a i s is by measuring the Hneardelormati on. Damaged '"

manometers have 10 be echanged immedi- "'

lorbdden. "'

ately.
9
<
7. Tensioning pressures or lensioning forces are

be given orchanged by authorized personnel

<

only while considering Ihe admissible compo-

nent loads, see item 4.
99.43 ESO
Page 3 (7) Function of the Hydraulic Tools Edition 02
General
Working Hints
securing ring
order 10 achieve a boll conneclion high precision,
l is vilal 10 consider Ihe following working hinls:
seal
selling Ihe device, clean all Ihreads and
remove possible damages order 10 avoide
a "freeze on".
The base plale Ihe device musl be plain

disc bol t nippl e
and dir!. Furlher check Ihe squareness
lowards Ihe boll axis order 10 avoid Ihal Ihe
boll has a bending slress during Ihe pressuri-
zalion (Iensioning).
The slroke Ihe device may l al any

be exceeded.
For Iransporling Ihe device l is necessary 10

uncouple all high-pressure hoses. Fig. 1. Trnabfe connection .
After each pressurizalion, bring Ihe device

back 10 , see also Piston Return Stroke. Exchange !he SeaIs
Should leakages show al the connection ,

TurnabIe Connection ! might be necessary exchange the seals.
For doing so, loosen the securing ring and take the
order 10 simplify Ihe conneclion Ihe hydraulic disc Ihe boll l. Having removed the seals,
hose, a turnable conneclion l is mounled clean Ihe components wilh f- cleaning malerial.
some devices. can also appl y compressed air. Having checked
The turnable connection l consists Ihe ll the components damages and oiled them slightly,
ing componenls: apply new seals by help Ihe entry guide and reas-
semble Ihe turnable conneclion !.
boll l
disc : For the cleaning, never use aggressive
seal cleaning liquids.
securing ri ng Foroiling Ihe parls, useexclusively hydraulic
oil .
Furlhermore, an enlry guide is available orcontained For replacemenls, use exclusively new
Ihe scope supply, see (ig. 1. seals.
CoupIing the High-Pressure Hoses
Only couple when Ihe hydraulic syslem iS a

pressureless condition.
produce a high-pressure conneclion,

one coupling and l each olher
while the coupling sockel is pulled back. When
letting th e coupling socket go, Ihere is a form
l barring Ihe conneclion.
99 .43 ESO
Edilion 02 Function of the Hydraulic Tools Pag. 4 (7)
General
drawing the hose with a manual lorce that the max. admissible stroke the device is
about 100 make sure th at the connection is exceeded. Beside that, has be ensured that the
correctly barred. cylinder and th e support sleeve remain centrically
towards each other (consider centering shoulder).
For decoupling the high-pressure hose
a pressureless condition, lirst pull back the Having made all hydraulic connections correctly,
coupling socket and then take off the hose. see lig. 2, start the pressurization lor the tensioning
procedure. 1I the necessary pressure is achieved
stop pressurizati on. The inducted lorce causes the
bolt extend an edging the components
be tensioned so th at the main is lifted Irom the
Screw connectjoo
Ilange. Screw back the flange, see (ig. 3. Check
~~ --3--:-- ---'~ by help a leeler gauge leal whether the main
really lits tight the Ilange. Afterthat, bleed hydraulic
pressure. w the connection is tensioned.
Fig. 2. Cotplng the highpressure hoses. Having brought the piston its zero position, see lig.
4, th e hydraulic hoses can be decoupled. ord er
prevent impurities, is advisable close coupling
Hoses with last-Iock coupling sockets avoid, also sockets and coupling nipples at once by protecting
when uncoupled, that l runs l. When the hoses caps. The device can be unscrewed Irom the boll.
get heated, there can be an inside pressure the
uncoupled condi tion making a coupling impossible. Always consider the salety and working
loosening screw connection (see (ig. 2) the hints!
pressure can be bleeded
avoid a contamination use protecting caps Loosening Procedure

lor the sockets.
order loosen an existing bolt connection, screw
the device the boll. First the support sleeve
Tensioning Procedure the bolt and align centrically th e bolt axis.
When screwing th e device take care that the
the tensioning procedure make sure that support sleeve at the cylinder is correctly centered
th e components be ten sioned are correctly posi- (consider centering shoulder).
tioned towards each other. Then screw th e device
the boll. The piston the device must be at its position.
Having screwed the device down l the support
First the support sleeve the bolt and align sleeve the support cylinder lt s tight th e Ilange,
centrically the bolt axis. When screwing the de- turn back the device by at least the value (slit meas-
vice take care that the support sleeve at the cylinder ure) which the bolt and th e componen ts spring back
is correctly centered (consider centering shoulder). elastically during th e loosening procedure.
Screw the device l the support sleeve the sup- nl: Th e adjusted slit measure may never exceed
port cylinder lits exactl y th e flange. The piston the admissible stroke the device! Furthermore,
the device must be at its zero position. Furthermore, take care th at the window lor the adjusting rod are
take care that th e hydraulic connectorand the window well accessible.
lor the adjustin g rod is we ll accessible. Having made all hydraulic connections correctly, see
1I necessary, turn back the device, but make sure lig.2, start the pressurization.
99.43 - ESO
. I I1 ' .f DieseII
Working Card
Function of the Hydraulic TooIs
520-01.05
GeneraI
During the pressurization, a slightturn-back momen- l:
tum is applied the main nut with the adj usting rod.
th e moment, when the main can be loosened , a) Should be impossible unscrew th e device
interrupt the pressurization. Should be possible after the depressurization , ! has been turned
loosen the main when achieving the original back by a lw measure , the pres-
tensioning pressure, interrupt the pressurization im- surization. Pressurize again l the original
mediately. Find the cause with staft. tensioning pressure is reached, the main
nul and bleed the pressure again (tensioning
Having achieved the loosening pressure, turn back procedure). can turn back the device
the main by the value that the bolt and the com- lurther. (///: consider /he admissible
ponents spring back during the loosening procedure. s/roke of/he device!) repeat the loosening
The slit measure, however, must be lower than the procedure eplained above.
slit measure adjusted at the device belore, see also
hin/ b. b) Should ! be impossible loosen th e main ul
after the depressurization, ! has been turn ed
The main may never be turned back l lts back by a l measure , the pres-
the piston or the cylinder since then th e device surization. Pressurize again and turn the main
can be tensioned itsell. ul lurther back. Bleed the pressure again.
Having turned back the main , the pressure can l: Never screw the main ul back l lits
be bled. The bolt connection is loosened. Belore the piston since the device can be tensioned
unscrewing the device, bring the piston back its itsell.
position, see fig.4. Alterthat, the hydraulic hoses
can be decoupled. order prevent impurities,
is advisable close coupling sockets and coupling Adjustment and Turn Back of the Main
nipples at once by protecting caps. The device can
be unscrewed Irom the bolt. During the pressurization the device, the bolt
is being etended by the tensioning lorce and the
Make sure that operational lorces (e.g. components are being edged. The result is that the
pressure) affect the components be main nut does longer l the Ilange.
loosened since only part the bolts take
these lorces and thu s the bolts, which are Having achieved the necessary pressure, adjust th e
yet loosened, might be overburdened. main - when tensioning - l lts the Ilange
again belore bleeding the pressure, see Tensioning
The pressure when the main can be loos- Procedure. When loosening the bolts, turn back the
ened may nevereceed the tensioning pressure main ! after the pressurization according the
by help ol which the connection was tensioned ! bolt and component delormations, (see Loosening
Should be possible loosen the main Procedure.
when reachi ng the original tensioning pressure
interrupt the pressurization immediately. Find l: During the loosening procedure, never turn
the cause wi th staft. back the main l lits the piston or the
cylinder since the main sticks after th e depres-
Always consider the salety and working surization.
hints!
The main is equipped with several radial bores
where the adjusting rod can be . Th e main !
is accessible through the window the support
sleeve.
99.43 - ESO
''( DieseI!
520-01.05 Function of the HydrauIic TooIs Working Card
GeneraI
During the piston return stroke, considerable back-
pressures can occur in the piston area the device
window device since quite large quantities l have Il back
through the small cross sections the high-pres-
sure connections.
moin nut
odjusting rod
In order noI unnecessarily increase the lorce lor
the piston return stroke turn the piston slowly. On
principle the piston the device has be pushed
back until lits the cylinder again.
Exchange Ihe Seals

Fig. 3 Adjustment and trn back , the n1ain nut.
Should leakages occur at the piston the device,
an exchange the seals might be necessary.
PisIon ReIurn SIroke Driveoutthe piston by carelully beating with a hammer
while using a plastic spacer in order protect the
Al ter each pressurization must be ensured that device Irom unnecessary damages. After removing
the piston the device is brought back its the hydraulic connector, you can also carelully lead
position. On pri nciple, has be considered that compressed air into the piston area.
hydraulic l is being displaced Irom the piston area.
In order enable the l I l back the tank AtIenIion: Sudden input compressed air can lead
the pressure generator, the corresponding hydraulic the piston's uncontrolled outlet.
connections must be done. After re moval ol the piston, the seals and the backup
rings can be removed Irom the piston and the cyl-
The piston return stroke is done by a screw-down at inder.
the bolt itsell belore the device is taken !.
Carelully clean the components wi th Iluff-Iree mate-
n: When using last lock coupling elemen ts, Ihe rial and check them lor damages. 1I necessary, use
oil's runn ing ul and thus a piston retu rn stroke in compressed air lor the cleaning, but never aggres-
an uncoupled condition is impossible! sive cleaning liquids. After that, slightly l these
components with hydraulic l and assemble new
backup rings as well as new seals the piston and
th e cylinder according the drawing.
Fig. 4. Piston (t strake.
Fig. 5. Exchange of the seals.
99.43 - ESO
f,J,lIM DieseI!

Page 7 (71 Function of the HydrauIic TooIs Edition 02
Genera!
As shown the picture, lrst assemble the backup

ring , then the seal the backup ring. Piston
and cylinder can w be assembled again by putting
the components together. slightly hammering
the piston (with plastic spacer), can be driven
l lts tightly the cylinder (piston its zero
position). It is essential that the piston does l
during being driven since this might damage the
seals as well as the components. When assembling
the piston has be taken care that th e air can
come out the piston area.
Maintenance and Storage
Regular maintenance the device is necessary,

but you should consider the lollowing points:
a) SIorage
After each operation, repair possible damages and

clean the device order lor be ready lor the
next operation immediately. In order avoid a cor-
rosion is advisable l th e device and especially
its thread. coupling nipples, coupling sockets and
also loosened screw connections are be closed
by protecting caps.
addition, check the components the device and

its accessories lor completion.
Keep the device the l box also offering protec-
Irom mechanical damages.
The temperature must be between -20 C and +70 C
order exclude a damage th e seals.
b) SIarI-up Ihe device
the deice's operation, repair possible dam-

ages and clean th e device.
~ Check the components the device and its acces-

~ sories for completion.
f)j
i The operating manual has be read by all users.
9
"'g
99.43 ESO
Page 1 (2) Application of Hydraulic Tools for Connecting Rod Edilion 03
23/30

Stopped engine Plate Item
Shut-off cooling water See page 2
Shut-off fuel l
Application hydraulic tools lor connecting

rod.
Slarling posilion
Function hydraulic tools 520-01.05
Relaled procedure
Working time hours Plate Item Otyl

Capacity men
Dala

00.20 - ESO
+J DieseII
520-01.06 AppIication of HydrauIic TooIs for Connecting Rod
Working Card
23/30
This working card gives the information for applica-

tion of hydraulic l ools, be used connection wil h
working card 520-01.05.
Hydraulic l ighlening
52021-633
Hose wilh
52021-513
Distributi on piece
-202
Pump
52021 -0 11
Hose wilh
52021-501
Tools for changing of
Pressure parl
sealing angel connection .
52021-586
52021-621
Allen key
5202 1 -263----
Fig 1 Connecting rod.
00.20 - ESD
Working Card Application of Hydraulic Tools 520-01.06
for Cylinder Head and Main Bearing
23/30
Stopped engine
Plate Item Note

Shut-off cooling water See page 2
Shut-off fuel l
Application hydraulic tools lor cylinder head

and main bearing.
Slarling POSiliOn
Function hydraulic tools 520-01.05
Relaled procedure

Capacity men
Data

00.20 ESO
. DieseII
520-01.06 AppIication of HydrauIic ooIs Working Card

Page 2 (2)
Edition 04 for CyIinder Head and Main Bearing
L23/30
This working card gives Ihe inlormalion lor applica-

lion hydraulic 1001s, 10 be used in conneclion wilh
working card 520-01.05.
Cylinder head Main bearing
Hydraulic jack Hydra ulic jack

52021-358 5202 1-466
High press~~
hose
52021-501
Dislribulion Dislribution
piece piece
5202 1-155 52021-202
High pressure
hose
52021 -5 13
Pressure
pump
52021-608
Please note: driven hydraulic pump

The numbers refer the
plate items section 520.
Fig 1 Hydraulic 100/s.
00.20 - ESO
',ll, MAN DieseI!

Page 1 (4) Hand Lever Pump Edilion
GeneraI

Shut-off cooling water 52000 0 11
Shut-off fuel l
Application hydrau lic tools.
Starting position
Related procedure

Capacity men
Data

00.45 50
520-01.07 Hand Leer Pump
Working Card
Edilion Page 2 (4)
General
Warning: Th e hand lever pump is equipped with Initial Start-up and Venting
a pressure l l valve.
Never use the pump without a mounted manometer. general and venting
Always pay attention the given pressure the
connected pressure consumers. 00 never exceed Please make sure that all parts the pump, espe-
this pressure the max. pressure the hand lever cially the manometer and the pressure , are a
pump. perfect condition. OelecI parts are be exchanged
against W ones immediately.
Important: Except lor hydraulicoil, neveruse different
liquids such as petrol , waIer, diesel l, alcohol brake Turn the carrying handle with counter-clockwise
liquid, since these can lead damages even rotation his lixing. Then turn the hand
desIrucIion the pump and/or the parts connected lever th e pump against th e stopping l ace.
with Choose a place assembling and operation
where the pump can always sIand sale and firm : 1I the carrying handle is srewed-in
a horizontal plain. There should always be sufficienI the hand lever, it can cause injuries wh ile using
space lor operating the pump. th e pump.
Never handle the pump lever with oiled hands and
never use hand lever extensions. Never expose the Open the l l ller cap and check the oil level. 1I nec-
pump great heat, lre extreme coldness, since cessary, l ll the tank with hydraulic l according
this leads damages even destruction. Protect 180 VG 32. Never ll the tank. Close the l
the pump Irom lalling objects and avoid hard blows lller cap.
pushes. Open the tank breaIher with the square wrench
(included the scope supply) by about one turn.
tt Danger 10 lle w loosen the breather screw at the pump th e
Check the manometer the pump lor the needed lel side the pump housing with an allen key 8
hydraulic pressure, given by an auIhorized person , 2,5 by abouI one turn. Close the depressurization
be exceeded. Make sure th at the pressure valve ti ghtly. 8eal the l the pump with a hose
you want generate is also admissible lor all con- and pump at the hand lever l l Ilows out the
necti on parts. breather screw bladder-Iree. Only then are al-
lowed close th e breaIher screw. The pump is w

pressure connections and connecting elemenIs vented and ready lor operation.
have be clean and undamaged. High-pressure
connections Irom the pump th e tools have be Alter each operation and lor the transport, close
established correctly any pressurization. the tank breather order avoid the hydraulic oil's
Oisregard leads danger l . Please see working running
card 520-0 1.06.
- Danger injuries Pressurization

Loads being lfted by the pmp may never be held
by the pmp valves alone. Use additional non - retrn Open the tank breather with the square wrench
valves or safety relief valves and secure the load by approx. turn.
sfficienI spport against falling.
Remark: The pump is only be operated with open
tank breather.
Close th e depressurization valve at the pump

when turning clockwise by handoperation .
00.45 - ESO
Page 3 (4) Hand Lever Pump Edilion
General
Remark: The depressurizati on valve is designed Belowolthe pressure relielvalve is an adjusting screw
lor manual operation . The use any tools at the with hexagon (wrench size 1 mm). Turning
depressurization valve could cause damages the counter-clockwisely the adjusting screw minimizes
valve the valve seat. the change-over pressure, turning clockwise ma-
ximizes the change-over pressure.
Pump at the hand lever until the wanted pres-
sure is achieved. Check the pressurization ": Inside the adjusting screw is another
at the manometer and take care possible grub screwwith innerhexagon (wrench size4 mm)
leakages. limit the stroke the change-over piston inside
the pump block. It is absolutely necessary, screw
Remark: The pump works with w stages. The the grub screw approx. 2 times belore turning
change Irom the lirst stage the second stage the adjusting screw!
happens automatical at a system pressure about
30 bar. The regulation the adjusting screw lollows gra-
dually in approx. 100 - steps. After everv adjusting
: The pump is not equipped with an internal step th e grub screw is screw l lits closely
pressure ll valve. The use a manometer and the and approx. a 1/4 turn loosen.
control the system pressure during pressurizati on
is indispensable. Check by carelully pumping l th e change-over pres-
sure wanted has been reached. 11 necessary, repeat
: Do stand directly V the moving the procedure as described above.
lne the pump lever. Under arising circumstances
the lever can "hit back". avoid accidents stand
sideways the pump.
- High-pressure hydraulic
principle, tihen leakages occurduring the pressu-
rization, immediately release the hydraulic pressure
and seal the leakage renew delect parts.
Depressurizalion
Open the depressurization valve slowly by a

turn the lelt.
Make sure that the hydraulic pressure at the

manometer has been completely released.
Consider the returning time the hydraulic
~ l.
...~
a
~ Adjuslmenl of change-over pressure from
'"
~ slage 1 10 slage 2
'?
g
"' exeptional case, can be uselul adjust the
change-over pressure Irom stage 1 stage 2 (Iactory
adjusted at approx. 30 bar).
00.45 - ESO
", Dieserl
520-01 .07 Working Card
Edition Hand Lever Pump Page 4 (4)
Genera!
Analysis and Correction of Malfunction Pressure Port
Correclion maIfunclions The pressure the pump is produced accor-

ding our customers' wishes. ln addi ti on, there is a
In case malfunctions at the pump, the following variety possibilities connect the pump with one
points are help you with the analysis ofthe problem or more pressure consumers.
and correcting yourself.
For this, uncouple unscrew all consumer and Attention Danger 10 Iife
highpressure hoses from the pump. the pump' s start-up please make sure thaI,
no matter which pressure you chose, aII con
nection elements are in a peiect condition. Convince
yourself the fact that these are correcIIy connecIed
MalfuncIion CorrecIion
and suitable the necessary pressure.
ressu rization 1. Check Ihe il l l and, l
necesS8ry, lll l 85 n High-pressure hy draulic
described chapter On principle, when leakages occurduring the pressu-
maintenance and storage.
2. Close depressurization valve. rizaIion, immediately release the hydraulic pressure
3. Visual inspectio n whelher and seal the leakane renew defect parts.
there are leakages. 1I 50,
seal them.
4. Vent the pump as described
chapter inilial slart-up and Maintenance and Storage
venting.
Th e pump should be lu br caed frequentIy at the
Insufficient pressurizalion 1. Check the l el and, l
movable parts. Protect itfrom contamination because
necessary, ll l up, as
described i chapter dirt in th e l in the pressure can lead the
( 10 any correcIions, maInteance and storage. pump' s fail ure. dry storage avoids th e steel parts'
de-pressurizaIion 2. CloSe depressurization l. getting rusty.
valve and release hydrauJic 3. Visual inspection whether Ihe
The storage and transpo rt oft he pump should always
pressure completely) are leakages. 11 so, seal lhem.
4. Venl the pump as described be done in a horizontal position. Thus, you avoid a
chapter I start-up and possibly necessary venting the pump during iIs
venting. start-up.
Pressure drop 1. Visual inspection whether
there are leakages. If so, For checking the l level, please open the depres-
(
any corrections, seal them. surization valve and l e the l completely f w back
depressurization 2. Close depressurization valve. into the tank. Open the l fi ller cap and ll hydraulic
valve and release hydraulic
l according 180 VG 32, neccessary. not
pressure completely).
overcharge the Iank. Close the l fill er
If the problem cannot be solved, please contact cap.
Diesel.
Th e use ofthe pump in a di rty area requiresa regular
l change. Fill the pump with clean hydraulic l and
lu br cae all moving parts (hinges) regulary.
00.45 - ESO
',Ji$'MAN Dieserl
Page 1 (2) Maintenance of HydrauIic TooIs Edition 01
L23/30
D Slopped engine Plale Ilem Nole

D Shut-off slarling air
D Shut-off cooling waler
D Shul-off luel l
D Shul-off cooling l
D Slopped lub. l circul.
Descriplion:
Mainlenance hydraulic lools and pressure

lesling hoses. Hand 10015:
Al len key, 6 mm.

Clean lub. l .
Slarling posilion :
Relaled procedure:
Plale Ilem Qly/

Man pow er:
52021 430 Hydraulic 1001.
Working lime 1/2 hour 52021 442 Hydrau lic 1001.
Capacil y 1 man 52021 299 Hydraulic 1001.
52021 309 Hydraulic 1001.
Dala:
Dala lor pressure and lolerance (Page 500.35)

Dala lor l orque momenl (Page 500.40)
96.03 - ESOS-G
EdiIion 01 Maintenance of Hydraulic Tools Page 2 (2)
23/30
----- --------
1) The hydraulic jacks require mainlenance
excepl replacemenl deleclive sealing rings, each
which consisls an oring and a back-up ring
liIIed ring grooves Ihe pislon and cylinder.
The pislon and cylinder are easily separaled bylaking

l Ihe bleed screw and pressing Ihe parls aparl by
means working air.
Compression 1001
Fig2.
Fil Ihe sealing rings and l ub r cale wilh clean lub.

Fig 1. l.
The pislon and cylinder are pressed logelher by
means Ihe 1001 supplied. See Ihal Ihe rings do l
gel sluck belween Ihe pislon and cylinder.
Make sure Ihal Ihere are marks scralches
Ihe sliding surfaces Ihe parls. The presence
melal parlicles ll damage Ihe sealing rings. Pressure Tesling Hoses
2) The sealing rings are 10 be liIIed wilh Ihe 0- avoid working accidenls caused by emission
rings nearesl 10 Ihe pressure chamber and wilh Ihe pressure l Irom Ihe hydraulic hoses, Ihe hoses
back-up rings away Irom Ihe pressure chamber. should be pressure lesled al 1200 bar once a
year.
: During Ihe pressure lesling Ihe hoses musl

be covered carelully.
96.03 - ESOS-G
f,l+6H'fMAN DieseI!
Page 1 (2) Tghtening with Torque Spanner Edition 0 1
23/30
Safely precautions: Special lools:
D Slopped engine Plale no Ilem no Nole

D Shut-off slarli ng air
D Shul-off cooling waler
D Shut-off fu el l
D Shul-off cooling l
D Slopped lub. l circul .
Descriplion:
Hand lools:
Starling position :
Related procedure:
Working lime hour Plale no Ilem no Qly/

Capacily man
Dala:
Dala for pressure and lolerance (Page 500.35)

Dala fo r lorque momenl (Page 500.40)
96.03 - ESOS-G
EdiIion 01 Tightening with Torque Spanner Page 2 (2)
23/30
1) Belore the nuts are screwed on, the threads and 7) For setting the spanner at the torque required,
the contact laces should be greased with copaslip there is a ball a small arm at the end the
similar, the tightening torques being based a handle.
coefficient l cton the threads.
8) When pulling the ball with the arm outwards,
2) The nuts should l easily the thread, and a small crank handle is formed.
should be checked that they bear the
contact lace. spring-Ioaded slide the handle provided with a
mark which, when turning the crank handle, can be
3) the case new nuts and studs, tighten and set at the required torque the scale.
loosen the nuts 2 3 times so that the thread may
assume its dilinite shape, thus obviating the risk The torque spanner lnctons are as lollows:
loose nuts.
9) The above-mentioned spring activates a pawl
4) Nuts secured with asplit are tightened the system the handle, and when using the spanner,
stated torque and then the split-pin hole. this pawl system ll be released when the pre-
set torque has been reached, at which moment a
5) The lollowing instructi ons apply the use and small jerk is l elt the spanner and a small click is
maintenance the torqu e spanner. heard.
1 ) The torque spannermust be used lortorque

Torque Spanner higher than those stamped , and must be
damaged by hammering the like.
6) The handle the torque spanner is provided
with a scale indicating the torque at which the span-
ner can be se!.
Scale for Iorque moment Key for adjusling

Iorque moment
Fig 1. Torque spanner.
96.03 - ESOS-G
DieseII

Page 1 (2) Max Pressure Indicator Edition Q1H
23/30
V28/32S
Safely precaulion5 Special 10015

Shut-off cooling water 52005 109 Ma. press.
Shut-off fu el l indicator
Shut-off cooling l
De5criplion
Operation.
Overhaul intervals.
Dismantling, overhaul and assembly. Hand 10015
Allen key, 3 and 6 mm.

Copaslip or similar.
Slarling 05n
Related procedure
Manpower
Working time 1/2 hour

Capacity 1 man
Replacement and wearing parl5
Data Plate no Item no Qtyl
Data for pressure and tolerance See Plate 52005

Data for torque moment
Declaration of weight
96.03 - ESO
Edition 01 Max. Pressure Indicator Page 2 (2)
23/30
V28/32S
General
Measuring Procedure ------

For mountng and dismantling the indicator use exclusIvely
the provided hollow spanner.
1. Before screwing the peak~ pressue indica to, open the indIcator
l cock. blow any dirt, and dose 1 again.
... DANGER! The indicator ole ejects hot 9as under high
~ pressu re. Danger of sparks and burning.
2. Close the venting screw the MSI5 and mount the peak-pressure
indica tr the indicator ole using the connecto Tighten
the connector t (15) using the spanner included the scope of
3.
supply.
the indIcator valve as far as l ll 90.

. "
After a measuring period of . 10 seconds, you ( take a
peak-p ressure reading and enter the log diagram.
4. C10se the indicator valve. ~--- "
. WARNfNG: Suitable gloves should be worn as the lower

~ section (13) ll get very hot during .
5. After the measuring procedure is complete, detach the MSI 5

fmmediately from the indicator valve to prevent any unnecessary
Fg 1 Pressure IndicaIor.
buildup of heat the instrument. Actuation the venting screw
resets the device to its zero position and termJnates measurement.
Parts List
l\
CAUTION: Whenever the indicator le is open, the enti ng
~ screw must remain i closed position and be opened.
Item Description
6. After the measuring procedure is com pleted, open the venting 1 Handle
screw (8) revolutions order let the condensed humfdity
2 Bracket for handle
.sc'p . PROCEDURE co OF HOURS. P.,k-
pressure indicators which are used should be stored with open 3 Manometer, 0- 250 bar
venting screw. 4 Profile washer for G1/4"
5 Adapter
For further measurements start again with the l rst step.
6 Pressure spring
7 Valve
Safety Instructions
8 Venti ng screw
9 Indicator valve
CATIQN: Before using indicalor, open indicalor l cock,
10 Valve guide
blow l any dusl, and close l again. ~
11 Valve baseplate
DANGER! l gas and par1icles may be ejecled.WEAR GLQVES
SAFETY GLASSES!
12
13
Cu-seaI24 1 81,0
Lower section
"'"
~
~
~

~
14 Holding ring
Connecting nut, chromeplated

15 9ro
16 Heagonal screw 5 10 DIN 6912

ro

17 lw spanner
18 Ball-point pen
19 Leather bag
20 Wooden bo
21 Set of spare parts, valve complete
22 Pad of log diagrams
96.03 - ESO
Plale
Page 1 (4) Tools for Cylinder Head 52005-04
23/30
Illustration Tool s Designation f--. , e.no;-s_io,n.s----' Item

D_im
C (;j
Lifting tool cylinder head,

complete. 139 113 68 S 014
1>-, '
D
U u :

Mounting tool valves,

complete. 248 65 072 S 051
11
95
Max. pressure indicator. S 109
S = Slandard = Extra
01.17-ESO
Plale
52005-04 Tools for Cylinder Head Page 2 (4)
L23/30
Illustration ofTools Designation I----;:.

D.::.
im
,:.e:;n;,:s::.:io;.:.n:.:;s----i
C ~
It em

Extractor for valve seat ring
(complete). ,, 137 290 504
lIll
F
'=

::; -

Grinding table for cylinder head ,
with bracket for wall mounting ,
complete. 846 426 648 254

Grinding table for cylinder head,

with frame for fl oor mounting,
complete. 833 1050 744 301
S = Standard = Extra
01.17-ESO
Plate
Page 3 (4) Tools for Cylinder Head 52005-04
23/30
Dimensions w Item
Illustration of Tools Designation
C
Grinding machine for valve seat

ring , complete. 350
Spare Parts:
------ 362 Stone 362

----- 374 Guide 374
~ Grinding machi ne fo r valve
~ 408
spindle, complete. 408
Spare Parts:
11 ~
Stone 421

Mounting tool for valve seat rings,
complete. 078 315 457
01. 16-ESO
Plale
52005-04 Tools for Cylinder Head Page 4 (4)
23/30
Dimensions w lIem
Illustration Tools Designation
C U5
Grinding tool lor cylinder head

and cylinder liner. 470 S 205
~
~6 ~
'\ Tools lor grinding valves. ,, 110 95 S 553

((
);
Oi*-t

Hand wheel lor indicator valve. 107 110 NV1' S 673

v------- ~

ll
<~
01.17 ESO
f,l,I'M L DieseII
Plate
Page 1 (6)
TooIs for Piston , Connecting Rod and CyIinder Liner 52006-06
23/30
Illustration Tools Designati on

Dimensions
C -
w Item
( fJ

Eye screw lor lilting piston. 1 2 030 20.5 S 021

C
~.
/
'\

/
"'--
Shackle lor lifting piston. 28 60 S 033
/ ~
-U
I~ Eye bolt lor piston lift at check
I~Q
connecting rod big-end 1 2 54 410 S 070
bearing.
C
:~
--' L
~ .-
08.01 - ESO
Plate
52006-06 Tools for Piston , Connecting Rod and Cylinder Liner Page 2 (6)
23/30
Illustration ! Tools Designation

Dimensions
C -
w Item
( f)

Back stop for cylinder liner,
~
2 pieces. 280 060.3 75 S 094
;1
~
(IC

Guide ring for mounting ! - 0298 110 S 116
ston.
Only for 900 rpm and
~ ~
-- 720 50 rpm Stati onary
t----
j
Guide ri ng for mounting ! - 0275 85 S 11 7
ston .
i'" - -

Only for 72050 rpm Marine
-- ~~
S = Standard = Exlra
08.01 - ESO
Plale
Page 3 (6) Tools for Piston , Connecting Rod and Cylnder Lner 52006-06
23/30
Dimensions w Item
Illustration Tools Designation
h A" "'B-r--:C;;-l Jj
Piston ring opener. 105 260 S 141
)J
,-
~~ .1
Testing mandrel lor piston ring

and scraper ring grooves.
[D=1~i_ _ _j~J Grooves lor piston ring. 4.43 S 153
Grooves lor scraper ring. 7.43 S 165
Plier lor piston pin lock ring. 550 25 03.5 S 200
BqL=
C
~
~v
~
~
~ Torque spanner 20- 120 Nm 463 2 " S 261

~
~ J
:; Torque spanner 80-360 Nm 718 3,4 " S 273
2 -c-:-
f B
08.01 - ESO
'}2' / DieseII
Plate
52006-06 TooIs for Piston , Connecting Rod and CyIinder Liner Page 4 (6)
23/30
Dimensions w Ilem
Illuslralion ! Tools Designalion
C

Socket. 24 55 :.. " S 381
Pneumalic impact spanner 3/4" 415
Lifting tool for cylinder l . 370 930 S 452

l. 'L
S = SIandard = Extra
08.01 - ESO
Plate
Page 5 (6) Tools for Piston , Connecting Rod and Cylinder Lner 52006-06
23/30
Dimensions w Item
IIlustration ofTools Designation
C {;j
Honing brush incl. woodenbox 0 228 850 S 488
Funnel lor honing cylinder

liner. 111258 1615 S 51 1
Magnil ier (30 ) . 140 50 S 559

.i
S = Standard =
08.01 ESO
',J,t@' Desel
Plale
52006-06 TooIs for Piston , Connecting Rod and CyIinder Liner Page 6 (6)
L23/30
Illustration ofTools Designati on

Dimensions
C -
w Item
( f)

Inside micrometer:
Measuring range
--- _.- 225-250 mm 618
1 . IJ~--~~
Grinding tool fo r cylinder liner 350 503 S 655

UO l
08.01 . ESO
Plale Tools for Operating Gear for Inlet Valves, 52008-04
Page 1 (1)
Exhaust Valves and Fuellniection Pumps
23/30
Dimensions w Item
IIlustration ofTool s DesignaIion (fj
C no
Feeler gauge for inlet valves. 0.5 0.6 S 0 10
,~
""- Feeler gauge for exhaust val
ves .
0.9 1.0 S 022
....!;.. (2 sets ! each)

.'S<
~~c,
ExIractor for IhrusI piece on

r:-c=:::2'r- roll er guide for fuel pump. 49 1329.5 24 S 058
1 .5

-
C
Distance piece 98.5 1330 1324.5 S 071
98.51 ESOS
'/ DieseII
Plate TooIs for Contro! and Safety Systems
52009-02
Page 1 (1) Automatics and Instruments
L23/30
Dimensions w lIem
Illustration Tools Designati on
C ()j
C Spanner lor adjusting

overspeed stop. 125 020 100 S 016
s = Standard = ExIra
01 .17 ESO
,,'( DieseII
PJaIe
Page 1 (2) TooIs for Crankshaft and Main Bearing 52010-04
23/30
Illustration ofTools Designati on

Dimensions
C -
w lIem
( f)

Turning rod. 925 ~42.4 S 011
Crankshaft alignment gauge
-e- f!
(autolog). 210 150 S 059
cO
!~!~I~~

.1
Dismantling 1001 for main

C bearing, 2 pieces. 060 125 12 S 106
1. b" ~
D1.17 ESD
',l,HHi(MAN DieseI!
Plale
52010-04 TooIs for Crankshaft and Main Bearing Page 2 (2)
23/30
Illustration Tools Designation w Item

~
C (f)

1
Lilting straps lor main and guide
bearing cap, 2 pieces. 1000 16 15 S 155
(j
C ~~
~

Dismantling toollorguide bearing

shells. 250 32 S 202
l lor upper main bearing. 050 51.5 S 214

r O-ring. 07.9 02.6 S 226
214 -------
~
226 -------
01.17 - ESO
Plale
Page 1 (2)
TooIs for FueI System and Injection EqUpment 52014-03
23/30
Ill ustration Tools Designation

Dimensions
C -
w Item
U)
.
Pressure testing pump, compl. S 013
o~ ,,~
~~ .~
~~ ~~
O~~
"- /~ V

Cleaning l for luel injector

consists 01: 84 022.5 S 108

' L
1 pc. needles.
1 pc. holder.
~J_.,,_ . Ta~~ 61 -
1 pc. box.
Spanner for fuel injectio 184 S 204

pump.
(~~
.. -

98.35 ESOS
PIale
52014-03 TooIs for FueI System and Injection EqUpment Page 2 (2)
23/30
Illustration ofTools Designation

Dimensions
C -
w
rn
Ilem
.
Grinding 1001 fo r fuel injection

~ Fuel Nozzle
valve. 25 018 055 300
A[rt.=::.:'"
~
Grinding 1001 for seat for fuel
= injeclion valve. 018 533 ",70 S 361
-

'
c "
.= =
Exlraclor for fuel injector valve. 150 185 240 S 407
"
m c
r

-'-- -
~"

J
S = Slandard =ExIra
98.35 - ESOS
PIale
Page 1 (1) Tools for Lubricating l System 52015-01
L23/30
Dimensions w Ilem
Illuslralion ofTools Designalion ~
C (j)

Guide bar lor dismantling
r- lubricating l cooler. 030 305 20 S 019
[]-

8-c
S = Slandard = Exlra
96.03 - ESOS
PJate
Page 1 (5) Hydraulic Tools 52021-10
L23/30
IIlustration ofTools Designati on f---,~

D_ imre,",n,",s--;
io_n-;s~ w Item
C U5
Pressure pump, complete, wi th

steel box S 011
Manometer 023
Pressure testing pump 059
/
059
Distributing piece for cyli nder

head, complete. S 155
1 55
Gasket 167
Quick coupling 179
011
W = 350 450 250 mm

06.25 ESO
Plale
52021-10 Hydraulic Tools Page 2 (5)
23/30
Illuslralion ofTools Designalion

Dimensions
C -
w 11em
( f)

Quick coupling 179
Venling screw 275
Ball 645
645
Adapler 657
704 669
Slroke indicalor band
716
Hydraulic 100ls lor connecling
741 ----I;i;I~,II!
rod wilh steel box, com- S
plete 633
716
Pislon lr hydraulic jack 704
753
Sel O-rings wil h back-up
ring 716
790 Adjusting rod 728
Cylinder lr hydraulic jack 741
Spacer piece 753
Angle piece complele, incl . ilem

765, 777, 789, 790 621
728 O-ring 765
777
$) $)
Adapter

Coupling socket 789
~ ~ Hydraulic jack as ilem nos. 179, ~

275, 645, 657, 669, 704, 716 , ..
,,;

@1 @ 728,741, 753
Quick coupling
586
790
'"

~

~
'!
Q
9
'"

'"

633
W = 350 450 250 mm
s = Standard = Extra
06.25 - ESO
f,I,,'( DieseI[
PlaIe
Page 3 (5) HydrauIic TooIs 52021-10
23/30
Illustrati on of Tools Designation

Dimensions
C -

( fJ
Item

0'334 t--
,
263
Quick coupl ing
Hydraulic tools for cylinder head

179
179
-A~ with steel box, complete S 251
657 a55 AIIen key, 7 mm 263

275
~ ~
812

~i'
-- 645
~
~
Venting screw 275
,
299 --
287
Piston for hydraulic jack 287

299 , ~ 310
~

Set of O-rings w ith back-up
309 / ~ ring 299
, ~
~
~

, -
~ - 800
O-ring 309
~
~ Cylinder for hydraulic jack 310
m
/
167 179
Spacer piece
Tommy bar
800
334
.... ~ r- Hyd raulicjackas Item Nos. 179,
1
11 ; 275, 287, 299, 309, 3 10, 645,
.... .. U; 657, 812 358
~
Ball 645
~
~ ~
Adapter 657

Stroke indicator band 812
~:;;?; Distributing piece for main S 202

bearing, complete
~ @ Gasket
Quick coupling
167
179
W
2t
= 350 450 250 mm
s = Standard = Etra
06.25 ESO
lI,t,tH'lMAN DieseI!
Plate
52021-10 HydrauIic TooIs Page 4 (5)
23/30
Dimensions w lIem
Illustration ofTools Designation
C ()j
586 Quick coupling 179
Allen key, 7 mm 263
334
Venting screw 275
Tommy bar 334
Ball 645
Adapter 657
824 Hydraulic tools lor main

bearings wi th steel bo,
430' complete S 405
430 Spacer piece 417
Cylinder lor hydraulic jack 429
Set O-rings with back-up

405
ring 430
Piston lor hydraulic jack 454
Hydraulic jack as Item 179,275,

429,430,454,645, 657,824 466
Stroke indicator band 824
Disc 586
Guide 574
4s
W = 350 450 150 mm
05.25 ESO
Plate
Page 5 (5) Hydraulic Tools 52021-10
L23/30
Dimensions w Item
Illustration Tools Designation ~
C (f)

~ 549
Hose for hydraulic tools, 4 -
ces compl ete 600 027 S 501
Hose lor hydraulic tools, 1 -

~ 836 ces complete 3000 027 S 5 13
~ ~,
Hose 1 3000 537
Quick coupling with protecting

cap 549
<{
'1V 525
~
Hose 600 525
.=, Adapter 836
i--
'=f
836
r-'"
Air-dri ven high pressure pump
for hydraulic tool s 367 256 326 608
~ ~
J r==:.. 9"
""
C Q)@)0
~1'0 00
;'~ ~ ...
.-
06.25 ESO
PJate Tools for Overhaul Height,
Page 1 (2) 52050-02
Piston, Cylinder Liner and Connecting Rod
23/30
021 021
033
057
01.1 7 - ESO-G
Tools for Overhaul Height, Plale
52050-02
Piston, Cylinder Lner and Connecting Rod Page 2 (2)
23/30
Item Item
aty Designation Bencevnelse aty Oesignation Bencevnelse
021 21 Pulllift Pult-lift
033 1 / Litting l for cylin- L0ftevrerktoj ! cylin-

der IIner, complete der1oring, komplet
045 1 / Collar ' connecting Halsjern for plejlslang,

rod , complete komplet
057 2/ Shackle Sjcekel
When ordering spare parts, see also page 500.50. Ved bestll i ng af reservedele, 5 og s ~ side 500.50.
= On ly avai lable as part of a spare parts klt. lilgrengelig som del reservedelssret.
Qty/E = Qty/Englne. aty.lE = Qly./Molor.
01 .17 - ESOG
Volume 2
Descriptions
DOOSAN - Diesel
5 23/30 720 RPM
ll 3071
Engine Type 5 L23/30 720 RPM
Project Name: SETA3071-1,2&3
Project . DMM1-5182/5183/5184
NICE Service
~ Necessary /nformation for Customers' Exectation
Access to NICE Service via website, by e-mail
http://nice.doosanengine.com
e-mail: nice.service@doosan.com
DOOSAN ENGINE CO., LTD. 69-3, Sinchon-dong, Seongsan-gu Technical Serice : +82552606996
CUSTOMER SATlSFACTlON Changwon-si, Gyeongnam, Korea 642-370 Parts Sales : +82 55 260 6260
T e l e f a x : +82 55 260 6772
Doosan Engine
Doosan Engine
23/30 Vol. 2
Index for Description
CHAPTER 1L--~T1=TL~E_ __ _ _ _ _ _ __ _ _----.J
02
DRAWING5
5 5 REPORT (Plan History)
! Doosan EngJne 23/30 Vol. 2
DRAWINGS
1-1. SPECIFICATlON OF DIESEL GENERATOR ENGINE
2-1. ARRANGEMENT OF CONNECTlON

2-2. OVERHAUL AREAS OF ENGINE
2-3. T/C POSITlON INCLUDING EXPANSION JOINT
2-4. EXHAUST GAS SILENCER
3-1. ARRANGEMENT OF HOLDING DOWN TS

3-2. SUPPORTlNG OF RESILIENT MOUNTlNG
3-3. CALCULA 10 OF RESILIENT MOUNTlNG
3-4. CALCULATlON OF TORSIONAL VIBRATlON
4-1. PIPING DIAGRAMS

4-2. FLEXIBLE HOSE LIST FOR EXTERNAL CONNECTlON
4-3. SYMBOL & LEGEND FOR PIPING DIAGRAMS
5-1. FUEL I SPECIFICATlON

5-2. LUBRICATlNG I SPECIFICATlON
5-3. LUBRICATlNG I QUANTlTlES BASE FRAME
5-4. FRESHWATER TREATMENT SYSTEM
6-1. PRE-LUBRICATlNG PUMP l MOTOR

6-2. JACKET WATER PREHEATlNG I
7-1. LIST OF SPARE PARTS

7-2. LIST OF TOOLS
8-1. ENGINE AUTOMATlC SYSTEM

8-2. LOCAL STARTER
8-3. GENERATOR
Doosan Englne
5 23/30 720 RPM

1-1. SPECIFICATlON OF DIESEL GENERATOR ENGINE
DOOSAN-MAN DIESEL Page 1/ 18
Client : Yangzhou Dayang Shipbuilding Co.,Ltd.
Engine Type : 5L23/30
Tier 1 ll . : DY139/DY3071
Tier 2 ll . : -
Subject:
SPECIFICATlON OF DIESEL GENERATOR

ENGINE
Note:
Attachments : Refer the con tent s for drawing i st
2010111 5 ~ ~ ?dEH ~ ?dEH ~ First Issued.
Date Drawn Chk' d App'd Description Rev.
~
Doc.
Doosan Engfne 1-5179-0
.
-
DOOSAN DIESEL age 1/ 18- '
REVISION HISTORY
REV DESCR IPTlON
201011 15 First Issued .
ENGINE

5L23/30 PART Machinery
Doc,
DESCR IP- ,
1-5179-0

SPECIF ICAT ION OF DIESEL GENERATOR ENGINE

Ooosan Engine CO. ,Ltd.
Page 2/ 18
Engine Specification
CONTENTS
1. General 3/18
2. Principal Particulars 4/18
,, 3. Scope of Supply 5/18
4. Shop trial 11/18
5. Overhaul Inspection 13/18
6. Description of Engine 14/18
7. Alternator 17/18
~ Doosan Enln. Doc

.
1-5179-0
Page 3/18
1. General
1-1 .
DOOSAN - DIESEL 123/30 diesel engine is be built by Doosan
Engine Co., Ltd. under Iicense Irom DIESEL & TURBo.
Model 5 123/30H(GEN)
1-2. Engine Design and Manulacturing

Some practical modilication Irom DIESEL SE drawings shall be incorporated
at the engine builder lor rea sons adoption Japanese Industrial Standard(JIS)
and/or Korean Industrial Standard(KS) , dillerence the manulacturing lacilities
and improvement based the builder' s eperiences etc.
The main parts (wear parts & maintenance parts) engine shall have
interchangeability with DIESEL & TURBO designed parts.
1-3. Standard Manulacture

The engine shall be manulactured according the engine builder's standard and
practices. Materials and littings such as valves, cocks , gauges, bolts, nuts, steel
plate, pipes and so which are used engine are Japanese Industrial
Standard(JIS) and/or Korean Industrial Standard(KS) and the engine builder's
standard. The industrial units accordance with metric system.
1-4. Rules and Regulations

The engine shall be designed and manulactured accordance with the
requirements the Classilication Society, Bureau Venitas (BV).
1-5. Scope Supply

1) Engine complete
2) Accessories, spare parts and tools
Details accessories are described Chapter 3.
1-6. Standard Manufacture

Details specilication which are ! described this specilication are
accordance with the engine builde~s practice.
~ Doosan Engfne
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2. Principal Particulars
Vertical, lour cycle, direct injection , single

acting , trunk piston with exhaust
turbocharger and air cooler
Model L23/30H
Number cylinders 5
Cylinder bore mm 225
Stroke mm 300
kw 650
Maximum continuous
Revolution rpm 720
rating (MCR)
Mean ellective
MPa 1.82
pressure
Maximum continuous Mean piston
mls 7.2
rating (MCR) speed
Direction rotation(Ahead) Clockwise , seen Irom Ilywheel side
Specilic luel l consumption g/kwh 193.6 g/kWh + 5% tolerance
Cylinder jacket Fresh water
Cylinder head Fresh water
Cooling medium cooler Fresh water
lub. l cooler Fresh water
Piston lub. Oil
Starting air Compressed air(Max. press. 1.0 MPa)

1) The ! is valid at tropical condition lollowings :
- Blower l temperature 45 "C
- Blower l! pressure 1,000 mbar
- Charge air coolant temperature 36 "C
2) The stated luel il consumption is valid under lollowing conditions.
- Blower l ! temperature 25 "C
- Blower l! pressure 1,000 mbar
- Charge air coolant temperature 25 "C
- calorilic value luel l 42,700 kJ/kg
- With engine driven . and pumps
~ Doosan Engfn.
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3. 5cope of 5upply
3- 1. Basic Diesel Engine

1) Standard diesel engine
2) Calculation torsional vibration
3) Engine rotation clockwise seen from flywheel
4) Preservation for long term storage and ocean transpor1ation
3-2. Foundation, Damping, Pipings

1) Common base frame for engine and alternator
2) Resi lient rubber mounting
3) Rigid coupling
4) Torsional vibration damper
5) Gangway with railing
6) Ete rna l flanges sealed ecept ehaust gas outlet
7) Manual bar for turning device
8) Fleible hose between engine and shipyard
9) Epansion joint after T/C without counter flange
10) Etema l flange standard : DIN/ISO
11 ) Protection cover for flywheel
3-3 . Fuel l System

1) Injection pump for each cylinder
2) Thermal insulation F.O inlet and outlet
3) Leakage alarm b o for waste l ( 42)
4) l filter (50 micron)

5) Protecting cover connection where fl ange joint
3-4. Lub. l System

1) Lubri cating l pump engine dri ven
- Gear type
- Capacity: 16 m3/h 0.3 - 0.5 MPa
2) Level switch in l sump(LAUH 28)
3) Lubricating l cooler(plate type)
4) Pre-Iubricating pump, electric driven including statue :
~ Doosan Englne
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- Capacity: 2.5 m3/h, Max 0.25 MPa

- Motor: AC 440V 3 phase 0.75 kW, 3,420 rpm
- Protection : 55
- Start current () : 9.6
- Full load cunent () : 1.6
- Starter included local control panel
5) l filter with diff. pressure switch
6) Thermostatic 3-way valve
- Setting ! : 60 "C
7) Specification lubricating l viscosity(SA E 30)
8) Connection for lubricating l to/from purifier
9) . connection with cock for fresh water auto shut va lve
1) Protecting cover pipe connection where flange joint
3-5. Cooling Water System

1) One(1) string system
2) Engine driven pump
- Capacity 36 m3/h 0.1 - 0.25 MPa
3) Thermostatic 3-way valve water outlet
- Setting ! : 82 "C
4) Connection for venting
5) Electric type external preheating module including starter
Electric heater : 10.0 kW, 1 100%/module
Electric pump : 1.0 m3/h 0.2 MPa 1 set
One(1) starter for one(1) preheating module
3-6. Compressed System

1) starter motor (0.7 0.9 MPa)
2) Solenoid valve for remote start (24 DC)
3) Pressure reduction !
- Specification : 3.0 MPa --> 0.07 - 1.75 MPa
3-7. Combustion System

1) Turbocharger with dry air filter
- Type : NR15/R
Doc
Doosan Englne .
1-5179-0
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2) One(1) stage ai r cooler

- : Fin-tube
3) drain from charge air receiver
4) Water cleaning provision for turbocharger compressor including
- One(1) injector ship
5) Lambda controller including fuel limiting device, jet assist
3-8. Exhaust Gas System

1) Water cleaning provision for turbocharger turbine including
- F.W pressure reducing valve with pressure gauge, quick coupling
and 20m fleible hose (Ioose supply, one(1) setlship)
- Yard connection : 42 2 male
2) Gas outlet for connection
3) Turbocharger placing front end side
4) Ehaust gas silencer (absorption )
- Damping 25 dB(A) ,without insulation
- Vertical ND350mm, Without spark arrestor
3-9. Speed Control System

1) Hydraulic woodward governor
- : UG 8D
Synchronizing governor motor
l : DC 24 from controller
Power consumption : 25
- controller (One(1) EA/engine, loose supply)
l voltage : 100-220 VACIVDC
voltage : 0-24VDC adjustable
Shutdown solenoid : DC 24
2) Local thermometers
- F. . engine l! ( 40)
- . cooler l ( 20)
- . engine l ( 22)
- engine l ( 1)
- each cylinder l ( 11)
- air cooler l ( 01)
I~
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Doosan Engfne .
1-5179-0
Page 8/18
- air cooler l ( 02)

- . cooler outlet ( 03)
- Charging air cooler inlet ( 30)
- Charging air cooler outlet ( 31)
- Exh. gas each cylinder l ( 60)
- Exh. gas T/C outlet ( 61)
3) Pressure gauge panel
- F.O engine inlet ( 40)
- . turbocharger l ( 23)
- . engine inelt, before/after filter (I21/22)
- engine inlet ( 01)
- engine l (110)
- Charging air engine inlet ( 31)
3-10. Safety and Alarm System

1) Shut down funcIion
Pressure switch and temperature switch for fol lowing shut-down functions are
be supplied by maker and cabling work between sensor and junction box
is be carried by maker.
- l ub. l , l pressure ri (PSL 22)
- Fresh waIer, high temperature (TSH 12)
- Engine overspeed stop with alarm (ZS 81, SSH81)
2) Alarms
- Pressure switch transmitter
F. engine inlet pressure transmitter for alarm & indication ( 40)
Fuel l filter differential pressure switch for alarm (D 43-40)
lub. l pressure transmitter for alarm & indication ( 22)
lub. l filter differential pressure switch for alarm (D 21-22)
pressure transmitter for alarm & indication ( 1)
Starting air inleI pressure l switch for alarm ( 70)
Level switch
Fuel oilleakage tank, leval high ( 42)
Pre-Iubrication l engine l, non-flow ( 25)
lub. l sump levellow (LAUH 28)
- TemperaUre elements
~ Doosan EngIne
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Lub. l engine l temp. transmitter for alarm indication(TE 22)

engine l ! temp. transmitter from alarm indication(TE 12)
Eh . gas T/C l temperature high(TE 62)
Switches and transmitter above listed are attached the engine and cabling
work the terminal box l l be carried by engine maker.
3) Starting SafeIy Devices
Devices for engine stand-by start signal for starting interlock
- Turning safety switch
- Lub. l prming
4) Terminal and Local Starting
3-11 . Test Running

1) Tested running with altemator
3-12. Painting Name plate Documentation

1) Painting color MUNSELL 7.5 BG 7/2
2) Name plate & Documentation ENGLlSH
3-13. Following Documentation shall be submitted.
1) Appro val drawing 8 setsI project
2) Working drawing 8 setsI project
3) Final drawing 6 setsl ship
4) CD-ROM manual 3 setsl ship
5) Class . certifi cation 4 sets/engine (1 original & 3 copies)
3-14. Spare parts

1) Standard spare parts complying with the requirements Classification
society and DOOSAN's standard (1 seship)
3- 15. Tools
1) Standard tools according DOOSA N's standard (1 seship)
~ Doosan EngIne
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4. Shop Trial
The diesel engine shall be applied coupling test in combination with alternator
on the common bed plate as lollowing schedule.
4-1 . Load test

This test sha ll be carried ! in the state the engine coupled with altemator
under rated speed. Load test is be carried ! based on engine power and
testing order and duration for each load are as follows .
Load Engine output A lternator at shop test Duration
RPM
(%) (kW) =
PF 1.0, kWe (min)
load - - - -
10' 65 55 720 30
25 162.5 152 720 30
50 325 312 720 30
75 487.5 467 720 30
100 650 620 720 60
110 715 680 720 30
'* Note
1) In case measurement is required by class only.
The measurements lor each load range are performed and recorded on
DOOSAN ' s test record sheets.
4-2 . Governor Test
Instant and permanent speed variation and voltage variation shall be measured
respectively by rapidly changing the load the engine as following method.
When full load is sudden ly taken off --> 50% --> 100% load, the speed is
control within 10% momentary variation and 5% permanent variation of rated
speed.
Speed variations with load changes in accordance with aboves are return and
remain within 1 % of final steady state speed in no more than 5 seconds.
Govemor load 100% is based on 610 kWe on board conditions .
4-3. Load Characteristic Test
After setting frequency(speed & voltage) at the rated value , change the load as
Doc
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lollows .
100% - 75% - 50% - 25% - 0% - 25% - 50% - 75% - 100% - 110% - 100%
During the each load condition , Irequency and voltage value shall be recorded
without regulation.
4-4. Parallel running test
condition 75% load alternator, the Irequency and voltage are regulated
the rated values. After regulation, parallel running test shall be applied lor three
gensets at once.
Load variation parallel running test is as lollows.

75% - 100% - 75% - 50% - 20% - 50% - 75% - 100% - 75%
For any load between 20% and 100% the sum the rated all
generators, the load any generator is ! diller more than 15% the rated
kilowatt the largest generator.
4-5. Starting Test
1) Local start / stop

2) Emergency start / stop
4-6. Salety Function Test
Th is test shall be carried ! the state the engine being load lor lollowing
items.
1) Shut down test
- Over speed
- Lub. l engine l, l pressure
- Fresh water engine outlet, high temperature
2) Alarrn test
be omitted because AMS is supplied by yard.
emission measurement lor exh. Gas and certilicate according requirement, l
4-7.
requested by class.
4-8. Measurement
1) Crankshalt dellection
~ Doosan Enfno Doc

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1-5179-0
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2) Torsional vibration One(1) engine project
~ Doosan Engfne
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5. Oerhaul Inspection
After the shop test, the overhaul inspection shal l be carried ! lor the lollowing
items at shop.
. Name plates Descriptions

1 Crankshalt journal Visual inspection, remained engine
2 Crankshalt Visual inspection, remained engine
Visual inspection, bearing shell is dismantled Irom
3 Main bearng shell
crankshalt journal
Crank bearng Visual inspection, bearing shell is dismantled Irom
4
shell crankshalt
Visual inspection l surface remained
5 Cylinder l
engine
Visual inspection combustion surface dismantled
6 Cylinder cover
Irom engine Irame
7 Connecting rod Visual inspection machined surface
Visual inspection combustion surface and piston
8 Piston
rings , dismantled Irom cylinder l
9 Camshaft Visual inspection remained engine
'* Remark
1) The scope overhaul inspection is cylinder per engine.
2) The cylinder ! lor overhaul inspection l l be determined by attendances after
the shop tesI.
~
Doc
Doosan Englne .
1-5179-0
Page 14/ 18
6. Description of Engine
6-1 . General
The engine is a turbocharger, single-acting lour-stroke diesel engine the trunk
piston with a cylinder bore 225mm and a stroke 300mm. The crankshalt
speed is 720rm.
6-2 . Base Frame

The engine Irame which is made cast iron is a monoblock design incorporating
the cylinder block, the crankcase and the supporting Ilanges.
6-3. Base Frame
The engine and altemator are mounted on a rigid base Irame.
The rigid base Irame construction can be Ilexible mounted on the engine seating.
6-4. Cylinder Liner
The cylinder liner is made fine-grained, pearlite cast iron and litted in a bore in
the engine Irame. The lner is clamped by the cylinder head and is guided by a
bore at the bottom the cooling water space the engine Irame.
6-5. Cylinder Head
The cylinder head is cast iron , made in one piece. ! has a central bore lor the
luel injection ale and bores lor two exhaust ales, two inlet ales , indicator
ale and cooling water.
6-6. inlet and Exhaust Vale
The ale spindles are made heat-resistant material and the spindle sets are
armoured with welded on hard metal.
6-7. Val e Actuating Gear
The rocker arms are actuated through roller guides and push rods. The roller
guide lor luel pump and lor inlet and exhaust al es are mounted in one common
housing lor each cylinder. This housing is bolted the engine Irame.
6-8. Fuel injection system
The engine is proided with one luel injection pump unit, an injection ale, and a
high pressure lor each cylinder.
The injection pump is mounted on the ale gear housing by means lour screws.
The pump consist a pump housing, a centrally placed pump barel and a plunger.
~ Doosan EnIno Doc

.
1-5179-0
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The pump is activated by the fuel cam, and the volume injected is controlled by
turning the plunger.
6-9. Piston
The piston , which is oil-cooled and the monoblock type made nodular cast-
iron , is equipped with 3 compression rings and 1 l scraper rin g. The piston has
a cooling l space close the piston crown and the piston ring zone.
6-10. Connecting Rod
The connecting rod is die-forged . The big-end has an inclined joint in order
facilitate the piston and connecting rod assembly be withdrawn through the
cylinder liner. The joint face s on connecting rod and bearing cap are serrated
ensure precise location and prevent relative movement the parts.

6-11 . Crankshaft and Main Bearings
The crankshaft, which is a one-piece forging, is suspended in underslung bearings.
The main bearings are the trimetal type, which are coated with a running layer.
attain a suitable bearing pressure and vibration ll the crankshaft is provided
with counterweights, which are attached the crankshaft by means two screws.
6-12. Camshaft and Camshaft ri
The inlet and e hau st va lves as well as the fuel pumps the engine are actuated
bya camshaft. The camshaft is placed in the engine frame at the control side.
The camshaft is driven by a gear wheel on the crankshaft through an intermediate
wheel, and rotates a speed which is half the crankshaft.
6-1 3. Governor
The engine speed is controlled by a Hydraulic woodward governor
6-14. Monitoring and Control System
media systems are equipped with thermometers and manometers local
reading and for the essential pressure the manometers are together with
tachometers centralized in an engine-mounted instrument panel .
6-15. Turbocharger System
The turbocharger system the engine , which is a constant pressure system,
consists an ehaust gas receiver, a turbocharger, a charging air cooler.
6-16. Compressed System
The engine is started by means a built-on air starter.
I~
Doc
Doosan Engfne .
1-5179-0
Page 16/18
The compressed air system comprises a main starting valve , an air strainer, a
remote controlled starting valve and an emergency starti ng valve which ll make
! possible start the engine in case of a power failure.
6-17. Fuel l System
The built-on fuel il system consists of the fue l l fi lter and fuel injection system.
6-18. Lubricating l System
moving parts of the engine are lubricated with l circulating under pressure.
The lubricating l pump is of the gear wheel type with built-in pressure control
valve. The pump draws the l from the sump in the base frame , and on the
pressure side the il passes through the lubricating l cooler(plate type) and the
fi lter which both are mounted on the engine.
6-19. Cooling water System
The cooling water system consists of a lw temperature system and a high
temperature system.
The water in the l temperature system is passed through the charge air cooler
and the lubricating l cooler, and the alternator if the latter is water cooled.
6-20. Turning
The engine is equipped with a manual tuming device.
~ Doosan Engfne
Doc
.
1-5179-0
Page 17/18
7. Alternator
7-1 . General specification

1) Generator type Three phase synchronous generator
2) Required quantity One(1) set / engine
3) Application Marine generator for diesel engine
4) Ambient air temp. 45 "C
5) Paint color MUNSELL 7.5 BG 7/2
6) Rotation Anticlockwise
(Viewed from prime mover)
7-2. Technical specification

1) Rating Continuous at fullload
Rated 762.5 /6 10
Rated voltage AC450V / 3 ph / 60
Rated speed 720 rpm

- Connection Star(y) , Damper winding
- Power factory 0.8 Lagging
2) Type
- Excitation type Brushless self excited wi th AVR
- Insulation class F CLASS
- Temperature ri se F CLASS
- Protection degree I23 ( be approved for fixed water
mist fighting system)
- Cool ng type Self-air cooling (Wth air filter)
- Lubricating type Self-Iubricating
- Coupli ng type Rigid coupling
- Bearing type Single sleeve bearing
3) Reauirements
- Operation condition Single operation and parallel operation
- Voltage regulation W ithin2.5% from no load ull rated
load
- Voltage adjustment 5 % the rated voltage
- Overload capacity 110% ll rated load for 1 hour
12 hours
- current 150% the rated curent for 2 min .
~ Doosan Enan Doc

.
1-5179-0
Page 18/18
- speed 120% of the rated speed for 2 min.

4) Accessori es
- Stator IMnding temperature 100 6 (2 phase)
- Bearing temperature ROD type thermometer
- Anti-condensation heater AC220V 1 ph 60
- Automatic oltage regulator Mounted on each generator(IP44)
- Manual ol tage adjuster Mounted on separate panel
- Terminal box Mounted on each generator(IP44)
- Foundation bolts, jack bolts and adjust shims
5) Spare parts
Spare parts be supplied in accordance with the requirements of
classification society and maker's standard.
6) Tools
- Maker' s standard
~ Doosan EngIne
Doc
.
1-5179-0
"!= D005an l
5 23/30 720 RPM

2-1. ARRANGEMENT OF CONNECTlON
2-2. OVERHAUL AREAS OF ENGINE
2-3. T/C POSITlON INCLUDING EXPANSION JOINT
2-4. EXHAUST GAS SILENCER

Engine Type : 5L23/ 30
1 Hull . : DY139/DY3071
2 Hull . : -
Subject :
ARRANGEMENT OF CONNECTlON
Note:
Attachments : Re f er the con t ent s drawing ist
x~ ~
20101112 ~o ~ t12 t1 2 First Issued.
Date Drawn Chk'd App'd Descripti on Rev.
~
Doc.
Doosan Engine .
2-5179-0
DOOSAN - DIESEL aae 1/ 4- #
,
REVISION HISTORY
REV DESCRIPTlON
201011 12 First Issued.

ENGINE

5L23/30 PAR T Mach inery
Doc.
DESCR IP- .
2-5179-0
1 0
ARRANGEMENT OF CONNECT ION

Doosan Engi ne CO . ,Ltd.
DOOSAN - DIESEL aae 2/4
CONTENTS
Rev. DESCRIPTION DWG. . SHEET

GENERAL ARRANGEMENT 40-0 1507 1-0 1
GENERAL ARRANGEMENT 40-0 15072- 0 1

ENG INE

5L23 / 30 PART Machinery
Doc.
DESCRIP- .
2-5179-0

ARRANGEMENT OF CONNECTI ON
Doosan Engine Co. ,Ltd .

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DOOSAN-MAN DIESEL Page 1/6
Client : Vangzhou Oayang Shipbuilding Co.,Ltd.
1 Hull . : 139/ 03071

Tier 2 Hull . :-
Subject:
OVERHAUL AREAS OF ENGINE
Note:
Attachments : Re!er the cont ent s ! or dr awing
201011 16 =E:J~~ ~~~ ~ 5~ First Issued.
Date Drawn Chk'd App'd Description Rev.
~
Doc.
Doosan Engine .
MR01-5179-0
DOOSAN - DIESEL aQe 1/6- #' .
REVISION HISTORY
REV DESCRIPTlON
20101116 First Jssued.

ENGINE

Doc.
DESCRIP- .
MR01-5179-0


Doosan Engine CO. ,Ltd .
-
DOOSAN DIESEL aae 2/ 6
CONTENTS
Rev . DESCRIPT ION DWG. . SHEET

AREAS OF ENGINE 44-0 12748-0 4
ENGINE

5L23 /30 1 1 PART Machinery
Doc.
DESCR IP- .
MR01-5179-0

Doosan Engine Co. ,Ltd.

Page 3/6
Overhaul Areas of Engine
Note:
2
1
20071120 iJEH ~ td ~~ O~ 'C'J First issued.

Type L23/30 MS/MG COMMON
~
Drawing
Doosan Englne .
44-012748
Doc. . : MR01 - 5179- 0

Page : 4/6
CONTENT
1.0 Dismantling Height for Piston
2.0 Dismantling Space for Various Components
~ Doosan Elne o~:;"g 44-012748
Doc. . : MR01 - 5179- 0

Page 5/6
1.0 Dismantling Height for Piston
1 : For dismanlling pislon and connecling rod al Ihe camshaft side
2 : For dismanlling piston and connecting rod passing Ihe alternator

(Remaining cover l removed) .
3: For dismanlling piston and connecting rod passing Ihe turbocharger
El1gil1e " Frame (H1j Cylil100r Head ( 2) Tlr bocl1arger ( 3)
56L2330 [720;750 l) 1919 2:)gB 2453
7 L2 330 (720;750 l) 1919 2398 2453
67BL2:>"30H (900 l) 1919 239 2553
1I lower dismanlling height is req uired, special too ls can be delivered as l .
~ Doosan Englne
Drawing
.
44-012748
Doc. . MR01 - 5179- 0

Page 6/6
Oerhaul Areas of Engine
2.0 Dismantling Space for Various Components

must be considered that there is sufficient space for pul ling the charge air
coo ler element, air l on the turbocharger, lubricating l cooler, lubricating
l l cartridge and bracing bolt.
,\ \1' ' l
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C h tgCll'
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S 72(\'750 1270 2288 585
6 72(\'750 1270 2288 58.5
6 joo 1]:>111 1270 2388 226
7 72750 1270 2388 226
7 900 1].'111 1420 2388 226
8 72750 1270 2:388 226
8 900 1]J1i1 11)20 2388 226
~ Doosan Englne
Drawing
.
44-012748
DOG. . MR01 - 5179- 0

Engine : 5L23/30
1 ll . : 139/ 03071
Tier 2 ll . :-
Subject:
T/C 5110 INCLUDING 510

JOINT
Note:
Attachments : Ref er the cont ent s f or dr aw ing ist
20101 11 9 E!2I~ ! .2 ! .2 First Issued.
~
Doc.
Doosan Engine 10-5179-0
.
DOOSAN - DIESEL age 1/ 5- # ,
REVISION HISTORY
REV DE SCR IPTlON
20 10111 9 First Issued .

ENGINE

5 L23 /30 PART Machiner y
Doc.
DESCRIP- .
10-5179-0
10
T/C POSIT ION INCLUDING EXPANS ION JOINT

Doosan Engine Co. ,L td .

DOOSAN - DIESEL aQe 2/5
CONTENTS
Rev. DESCRIPT ION DWG. . SHEET

POSI TI ON OF GAS U L TUABOCHARGER 44- 1 283 1 -0 2
COMPENSATOR 42- 1 2441 - 1 1

ENGINE

5 L 23/30 PART Machiner y
Doc.
DESCRIP- .
10-5179-0

T/C POSI TI ON INCUDI NG EXPANSION JOI NT
Doosan Eng ine Co. ,Ltd.

Page : 3/ 5
Position Gas outlet Turbocharger
Note:
3
2
2007 11 28 ~~~ fd;::;~ ol~ ~ First issued.

Type L23/30 MS/MG COMMON
~
Drawing
Doosan Englne .
44-012831
Doc. . : 10-5179-0
Page 4/5
Position Gas outlet Turbocharger
5 -6 L23/3 0 ( 72 0- 750 rpm)
At t.. _ _

-
,
7-8L23/30H (720-750 rpm )-6-7 -8 L23/30 (9 00 rpm)
~-
' --
_ " ._ ---1. ...... _
Flange
Exhausl flange 1). malirlQ dirnensions

EngJne type 00 PCD Hole No.ofholes
56123i30H 350 rrrn 490mm 16mm 445mm 22 mm 12
7-8L2313OH
6L23/30H-900 rpnl ;00 rrrn 540mrn 16mm 4QSmm 22 rnm 16
PCO 1'4---.-
7-8l23130H-900 rpm 450 rrr 595 n1m 16mm 55Dmm 22mm ,6
~ Doosan Englne
Drawing
.
44-012831
Doc , . 10-5 1 79-0

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Min .movement c . spr irg ro te Be ll ows
t(nm) LaI etQ I!( r.nl l Lol e ro l i n.no.o f ..l
BC D Ln ,d Ilolero)=OI ( =0) ( N/rrm) IN/nn) ye s Convo l ul M:'.JSS (kg) t .
200 320 280 222 244 205 490 8,18 16 50 75 75 15 3 2,(5-12) 21 1627934-3
250 375 335 276 294 255 350 12 ,18 16 68 28 54 37 3 2,(5-12) 18 1673441-7
250 375 335 276 298 259 545 12,18 16 50 75 75 20 3 2, ( 5 - 12) 28 1627935 - 5
&(
300 440 395 327 344 306 350 12,22 16 68 28 62 60 3 2, ( 5-12) 22 1670058-0
300 440 3 95 327 353 305 560 12 ,22 16 50 75 75 20 3 2, ( 5 - 12) 38 1627936 - 7
-
350 490 445 359 384 337 490 12,22 16 100 50 75 30 3 2, (5 - 12) 40 1627937 - 9
- 400 540 495 410 435 388 495 16,22 16 100 50 75 40 3 2, ( 5-12) 43 1627938-0
450 595 550 461 486 439 500 16,22 16 100 50 75 50 3 2, ( 5-12) 48 1627939-2
500 645 600 512 537 490 520 20,22 16 100 50 75 60 3 2, ( 5-12) 54 1627940-2
550 703 650 563 587 540 520 20,22 20 100 50 75 70 3 2, ( 5-12) 65 162794 1 4
600 754 700 614 639 592 535 20,22 20 100 50 75 80 3 2, ( 5-12) 79 1627942 6
650 805 750 665 689 64 3 535 20,22 20 100 50 75 100 3 2, ( 5-12) 88 1646653
700 856 800 716 740 693 555 24,22 20 100 50 75 1 1 3 2 ( 5 - 12) 98 1627943 8
750 907 860 767 791 736 635 2422 20 100 50 90 140 3 2, ( 5 - 12) 1 14 1644984 - 9
800 958 900 818 842 787 635 2422 20 100 50 100 180 3 2 ( 5-12) 133 1644985
-
lillJ be s Iamped. . WORK ING COND ITI ONS

Nx0d ("C) : 500
-
- 0 0___ =-'0- PRESSURE (8AR): 2.5
"l~
c MATERIAL
<ra5 a - 0f -'- \\0 FLANGE : DIN- 17100 W. NR.l.0038
" " 0~ i 1)0 MEMBRANE : DIN-1744Q W.NR. 1 . 4541
L T 0
'--
- R I NG : DIN-17440 W.NR.l .454 1
1. 1
CONNECTING : DIN- 17440 W. NR . 1.4541
Flanqes occ lrdina 86044.
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D.. I .. ted 1
rn i~~ OOOSAII ~~o!" " '.' I ~i'

f r s t s Ivc d
Type Doubl e
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lor combined
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bore: 200mm -
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trode- "',,'''<1'
J!ffi "...Doosan
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'
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42 -01 2441 ' -
~
1,

, Ooc. . : Wl1o-S179-0
1 Hull . : 139/ 03071
2 Hull . :_
Subject:
EXHAUST GAS SILENCER
Note:
Attachments : Ref er the cont ent s f or dr awing i st
20101119 ~ 2J"~ {;! .Q {;! .Q First Issued.
~
Doc.
Doosan Engine .
13-5179-0
DOOSAN - DIESEL Page 1/ 4- #
REVISION HISTORY
REV DE SCR IPTlON
20101119 Fi rst Issued .

ENGINE

5L23/30 PART Machiner y
Doc.
DESCR IP- .
13-5179-0


Doosan Eng ine Co . ,Ltd .
DOOSAN - DIESEL age 2/4
CONTENTS
Rev. DESCRI PT IDN DWG . . SHEET

SILENCER 34-0 16839- 1 2

ENG INE

5L23/3D PART Machinery
Doc.
DESCR IP- .
13-5179-0

Doosan Engine CO. ,Lt d.

Page 3/4
Exhaust Gas Silencer
Note:
Exhaust gas silencer(absorption type)
Damping 25dB(A), without insulation

Vertical, 350mm
Without spark arrestor
Flange(DIN Standard)
Without counter flanges, bolts, nuts, gaskets
Without mounting bolts, nuts
20100722 tI .z Ol~ ~ O I~ eJ Changed drawi ng format. 1

20080229 ~~ ~ ~~ ~ ol ~eJ First issued.

Type COMMON MS/MG 0096
~
Drawing
Doosan Englne .
34-016839
Doc. . 1 3-5179-0
1- 8 7 6 5 ;. 4 3 2
Page . 4 / 4
,

'f-:: o.D.720 ~
490
500
P.C.D 445
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SUPPORT BRACKET & [
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8 7 5 5 111' 4 3 2
Doc. . 13-5179-0_
DOQsan EngIne
5 23/30 720 RPM

3-1. ARRANGEMENT OF HOLDING DOWN TS
3-2. SUPPORTlNG OF RESILIENT MOUNTlNG
3-3. CALCULA 10 OF RESILIENT MOUNTlNG
3-4. CALCULA 10 OF TORSIONAL VIBRA 10

Cient : Yangzhou Oayang Shipbuilding Co.,Ltd.
Tier 1 ll . : 139/03071
Tier 2 ll . :-
Subject:
ARRANGEMENT OF HOLDING
BOLTS
Note:
Attachments : Re f er the cont ent s for dr awi ng i st
2010111 2 ~2J* ~~ ~ ~ First Issued.
~
Doc.
Doosan Engfne .
MR03-5179-0
DOOSAN - DIESEL aae 1/ 3- #
,
REVISION HISTORY
REV DESCRIPTlON
20 101 11 2 F irst Issued.

ENGINE

Doc.
DESCRIP- .
MR03-5179-0

ARRANGEMENT OF HOLDING D BOLTS

Doosan Eng ine CO . ,Ltd .
DOOSAN - DIESEL aae 2/ 3
CONTENTS

AARANG E blNT OF LD NG OO\~N L TS 40-0 13248-5 1

ENG INE

523/30 PART Machi ner y
Doc.
DESCRIP- .
MR03-5179-0

ARRANGEMENT OF HOLDING D BOLTS
Ooosan Eng ine CO. ,Ltd.

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Client : Vangzhou Dayang Shipbuilding Co.,Ltd.
Tier 1 ll . : 139/3071
Tier 2 ll . : -
Subject:
SUPPORTING OF RESILIENT MOUNTlNG
Note:
Attachments : Refer the con t ents for dr awing ist
2
Corrected dimension between common bed and resilient
2011 0614 deJ* ~5~ ~ ~~
mounling (80->95) in lig.2
1
201011 12 ~eJ* ~~ ~~ First Issued.
Date Draw n Chk'd App'd Description Rev.
Doc.
Doosan Engine .
MR04-5179-1
DOOSAN - DIESEL age 1/ 12-"
REVISION HISTORY
DATE REV DESCR IPTlON
2010 111 2 First Issued .
201 10614 1 Co rrected dimensio n betwee n common bed and resilie nt mounting (8 0->95) fig.2
ENG INE

5 L23 /30 PART Machiner y
Doc,
DESCRIP- ,
MR04-5179-1
1 0
SUPPORT ING OF RESI LIENT MOUNT ING

Doosan Engi ne CO"Ltd,
DOOSAN - DIESEL Page 2/ 12
CONTENTS
Rev . DESCR IPT ION DWG. . SHEET

1 SUPPORT ING OF RES ILIENT MOUNTING 34-017765-2 10
ENGINE

Doc.
DESCRIP- .
MR04-5179-1
10
SUPPORTING OF RESILIENT MOUNTING
Doosan Eng ine CO .. Ltd.

Page 3/12
Supporting of Resilient Mounting
Note : For Generating Sets l
Resilient Mounting Type : RD314 or Equalent
3
Corrected dimension between common bed and
201 1061 3 ~~~ ~ o l ~~ .. m n "nHn n (RO _ Qfi\ ; ?
2
20091208 fd~ 4- :d~~ o l ~~ Added procedure for engine leveIing 1
20080429 ~ EH ~ o l ~~ o l ~~ Firsl issued.

Type 2 3/3 0 MS/M G COMMON
~
Drawing
Doosan Engfne .
34-017765
Doc. . MR04- 5179- 1

Page 4/12
CONTENT
1.0 Foundation Recommendations
2.0 Resilient Mounting of Generating Sets
3.0 Resilient Support
4.0 Adjustment of Engine and Generator Base Frame
5.0 Genset Leveling Procedure with Fitting lnstruction of Resilient

Mounting
34-017765
Ooc. . MR04- 5179- 1

Page 5/12
Supporting of ResiIient Mounting
1.0 Foundation Recommendations
When Ihe generaling sel s are insl alled on a Iransverse sliffened deck slructure, l is
generally recommended 10 slrenglhen Ihe deck by a longitudinal sliffener inline wilh
Ihe resilienl supporls, see Fig 1.

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For longitudinal sliffened decks l

is recommended 10
Iransverse sliffening below Ihe
add

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resilienl supports.
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line wilh bolh Ihe supporting

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slructure , Fig 2, 10 oblain
SCREW 635
sufficienl sliffness in Ihe support
Ihe resIIIenl mounled Fig.2 Transverse slill deck slructure
generaling sels.
The slrenglh and Ihe slillness Ihe deck slructure has 10 be based on Ihe actual
deck load, . . weighl machinery, lanks elc. and lurthermore, resonance wilh Ihe
Iree lorces and momenls Irom especial ly Ihe propulsion syslem have 10 be avoided .
[ ~ Doosan Elne Drawing

.
34-017765
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Page 6/12
2.0 ResiIient Mounting Generating 5ets
resilienl mounled generaling sel, Ihe diesef engine and Ihe generalor are pIaced
a common rigid base Irame mounled Ihe ship's/erection haII's loundalion by
means conicaI Iype resilienl supports.
connections Irom the generating sel 10 the exlernal systems shaII be equipped
with flexibIe connections, and pipes, gangway elc. musl be weIded 10 Ihe exlernaI
part Ihe instaiIation.
resiIient mounling Ihe

generaling sel is made wilh a
number conicaf mountings.
The number and Ihe dislance

belween Ihem depend Ihe size
Ihe pIant.
These conicaf mounlings are

bolted 10 brackels Ihe base
Irame, see Fig 3.
The setting Irom unIoaded . NECESSARY DIS IANCE

Ioaded condition is normaIIy " OF C"OCK ) 5 m
j rXNESS
between 511 mm lor the conicaI
mounting. Fig.3 Resilient mounting generating set
The exact setting can be lound Ihe caIcu lalion Ihe conicaI mounlings lor Ihe
pIant question.
3.0 Resilient 5upport
The support the individual conicaI mounling can be made the 10IIowing
Ihree ways:
Method 1.
The support between the bottom flange and the loundation the con icaI mounling is
made with a Ioose steef sh im. This steef shim is adjusted an exact measurement
(min. 75mm) lor each conicaI mounting.
~ Doosan Englne
Drawing
.
34-017765
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MeIhod 1
Sleel shim .
FoundaIion
Melhod 2

i!.'
Supporllng
51eel shim
Foundation
Supporling
51eel SI11m
Sleel shim
ChockIasl
Foundation
Fig.4 Support Con icals
~ Doosan Englne 34-017765
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Page 8/12
Method 2.
The support can also be made by means steel shims, at the a loose steel
shim at least 75 mm and below a steel shim at least 1 mm which are adjusted
lor each con ical mounting and then welded the loundation.
Method 3.
Finally, the support can be made by means chocklast. is necessary use

steel shims, the steel shim should be loose and have a minimum thickness 75
mm , the bottom steel shim should be cast chocklast with a thickness at least 1
mm .
Irrespective the method support, the 75mm steel shim is necessary laciltate
a possible luture replacement the conical mountings, which are always replaced
pairs.
4.0 Adjustment Engine and Generator Base Frame
The resilient mounted generating set is normally delivered Irom the lactory with
engine and generator mounted the common base Irame. Eventhough engine and
generator have been adjusted the lactory with the generator rotor correctly placed
the stator, and the crankshaft bend the engine within the prescribed tolerances.
5.0 Genset Leveling Procedure with Fitting lnstruction Resitient Mounting
General
This procedure ll describe the leveling with the litting instruction conical
mounting the basis Method 1., which is common use at the shipyard. For other
methods, please contact us separately.
Make ready lor adjustment conical elements.

1I the conical mountings have ! been mounted by the lactory, they must be
mounted the prepared brackets the base Irame. case they have been
mounted by the lactory (Doosan's standard) , please start with item number 4.
I~ Drawing
Doosan Englne .
34-017765
Doc. . MR04- 5179- 1

Page 9/12
--...
..
_.~ ~""1Co'I'. _..... ... .-"'
2 3 5
,

"

.. . ~
'-r--I'i--~~
.
. .....
: :
, .'~A clng
2
3
Ccnl'llJbulk:fIIIrdlc)
Synttotic W$M
S Topca$lii'lg
6
7
"Iin

Fig. 5 Arrangement Conical Mounting Hut:ber lmenl 8 0018 12
1) Remove nut (7) and ring (6) from the conical

mounting.
2) Fit the conical element the bracket on the
suspended equipment by means fixing the
cen tral (2), the ring (6) and (7) .
3) Tighten the (7) by hand and simultaneously
~
~.
the central buffer (2) by applying a spanner 1
hexagon (5=19) the the central buffer
(2).
4) Position the jacking bolts the tapped
hole (8).
5) Position the jacking bolts with a through-going
minimum 75mm. , ""

6) Lower the generating set until rests LU .1 1

completely the foundation. Fig. 6 Jacking Bolts
7) Check that all jacking bolts have ull contact
with the foundation , and then loosen the nut (7) .
8) Turn all the internal buffers by applying a spanner (5=19) check that they can
move freely.
~ Doosan Englne
Drawing
.
34-017765
Doc. . MR04- 5179- 1

Page 10 /12
1I all internal buflers Then
Can move Ireely Let conical elements settle lor . 24 hours
Turn the lour jacking bolts clockwise anti-clockwise

Can move Ireely
release internal buffe
AdjusImenI Conical ElemenIs afIer SiIIing

After the conical mountings have been deflected
under static load lor min. 24 hours , the loaded
height (I) , should be measured and compared
the recommended loaded height.
Hrackct
'<
~=1 9) Care must be taken, during leveling the
Jacking boll , installation , ensure that individual mountings
/- 1- , are ! overloaded. The variation laden

height should eceed 2 mm and should
Founda1.on /
SecIronA-A
, Ii ideally be less. The laden heighl can be
measured between and base casting
Eample:
Average = I + 2 + 3 + ------- +
Number conical elements
The difference between the sides a conical
Fig. 7 Sitting Conical Mounting mounting should l be more than 0.5 mm.
1I Then
Level the conical element by adjusting the jacking

Dillerence eceeds 2 mm bolts commenci ng wi th the conical element with
Ihe largest deviation
Difference does l eceed

The height Ihe steel shim can be measu red .
2 mm
Measuring Steel Shim

1) Measure Ihe steel shim several points 10 oblain the highest possible accuracy
during preparalion .
~ Doosan Enlne
Drawing
.
34-017765
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Page 11/12
Fabricating SteeI Shim

11 ) Make su re that the minimum height the steei shim is 75 mm to secure a future
repIacement the con icai mounting.
D the mounting hoies the steeI sh im accord ing the conicaI base casting
dimension.
Mounting the Completed SteeI Shim

12) Turn the internaI buffer anti-cIockwise contacts the base casting secure the
Iaden height each conicai mounting.
13) LI generating set with crane hydrauIic jack.

14) Remove aII the jacking boits.
15) Position each compIeted steeI shim .
16) Lower the generating set rests compIeteIy itseIf.
17) Number each steei shim together with each conicai mounting.
Adjustment InternaI Buffer

18) Turn the internaI buffer ciockwise (downwards) makes contact with the steei
shim foundation.
19) Turn the internaI buffer anticIockwise (upwards) obtains contact with base
casting. This must be ( (ll turns.
20) Turn the internai buffer turns ciockwise (downwards) and check with a feeIer
gauge between the base casting the conicaI mounting and the steeI shim that the
internai buffer (2), see Fig . 5, does ! touch the steei shim foundation . (Mark the
position each centraI buffer.)
21) Turn the (7) with a torque 300 Nm and bIock the centrai buffer (2) with a
spanner (S=19) at the same time. (Check the marking position.)
.1.
Fig.8 Adjustment Internai Buffer
~ Doosan Englne
Drawing
.
34-017765
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Page 12/ 12
Mounting Conica l Elements the Foundation

22) Drill lour mounting holes the lo und at o n lor each conical mounting, either.
a) Mark the positions the mounting holes the lo und at on through the conical
(Re)move the set completely so that markings can be reached by drillin g with
conventional tools.
b) Drill the mounting holes the lo undat o n by means the drill ing pattern Irom the
installation drawing.
The drilling has to be done bel orehand and the set must be aligned with the
loundation holes belore the work starts avoid lurther removal the se!.
23) Fi all the conical mountings and steel shims the lo un dato n with lour bolts. (Fig.
6)
Note!
After completion all works the buffer clearance must be checked again , see item
18)-2 1).
Fig. 9 Installation GenSet U Structure
Doc. . MR04- 5179- 1

Tier 1 U . : 139/ 3071
Tier 2 Hull . :-
Subject:
CALCULATlON OF RESILIENT MOUNTlNG
Note :
Attachments : Re ! er the cont ent s !or drawi ng ist
201011 12 ~~* ~ ;; ~ ~;;~ First Issued.
~
Doc.
Doosan Engine .
MR05-5179-0
-
DOOSAN DIESEL age 1/ 26- '
REVISION HISTORY
20 10 111 2 First Iss ued.

ENG INE

5 L 23/30 PART Machi ner y
Doc.
DESCR IP- .
MR05-5179-0

CALCULATION OF RES ILI ENT MOUNTING

Doosan Engine CO. ,Ltd .
-
DOOSAN DIESEL aae 2/ 26
CONTENTS
Rev. DESCRIPTI ON DWG. . SHEET

CALCULAT ON OF RES ILl ENT MOUNT ING 34-030909-0 24

ENG INE

Doc.
DESCR IP- .
MR05-5179-0

CALCULATION OF RESIL IENT MOUNTING
Doosan Engine CO. ,Ltd.

Page 3/26
CaIcuIation ResiIient Mounting
Note:
1. Engine Type : 5L23/30
2. Engine Powerl Speed : 650 kW at 720 rpm
3. Mounting Type : 8 RD314 in 45 Q Shore
4. Mounting Position : 1016-1756-2606-4170
5. Main Engine
71) Engine Type : 6S50MC-C (2 stroke)
2) MCR : 9480 kW a1127 RPM
3) NCR : 7395 kW at 11 3.7 RP M
4) Propeller blades : 4(FPP)
3
2
1
20 101024 t!~9 id~ t!~~ First issued.
Dale Drawn Chk'd App'd Descriplion Rev.

Type 5 L23/30 MS/MG 0000
~
Drawing
Doosan Englne .
34-030909
Doc. . MR05- 5179- 0

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HPRRPTO : Calculations the reslllently mounted system Page: 1 J
Doosan /1125/1 l~,...,1Rubber Design

, Yfbrati on iltJd noi,s .. c:ontro'
Rubb<r Doslgn ,.
Indu$lrIowog 21
General data cllent and project .. 15
2995 ZG HoorJensdam
the Nethe1an ds
Mainproject Doosan Engine t. +31 (0)786778778
f. +31 (0)786771 036
Description Doosan Engine Co Ltd . !ofQ@0ibbordoog
w. wwwn '!thm1m!gn
Customer 5732
Company Doosan Engine Co. Ltd.
Address 69-3, Sincheon-Dong, Changwon
Zipcode ow 641-370 Kyungnam
Country South Korea
Application 4 3 sets 5 23/30 Generatorsets
Note:
Mountingtype 8 RD 314 - 45 Shore
Perfonance 650 kW at 720 RPM
Bellows 1 250
Centre of Gravity 2345 [Front baseframe], = , = 81 [Bottom baseframe]

JC=
X-Coordinates 1016; 1756 ; 2606; 4170 [Front baseframe]
Free forces and moments

1.0 Order YawM 6600 Nm
2.0 Order Pitch 18600 Nm
2.5 Order RolI M 20500 Nm
5.0 Order RolIM 6400 Nm
Main engine
MAN-B&W 6S50MC6-C7
Number of cylinders 6
wo stroke engine
Engine output MCR 9480 kW at 127 RPM
Engine output NCR 7395 kW at 113,7 RPM
Propeller blades 4 [FPP]
Calculation based mounting parameters detenined at a frequency range 5 ll 30 with an

amplitude of ,1 mm and an environmental temperature 40C.
Date: 18-10-2010 User: TIme: 13:13:08 j
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HPRRP1 : Calculations the lI mounted system Page: 2 1
Doosan ,/1125/1
Basic data of the resiliently mounted system
Mass WeighI 18654,00 [Kg]
Mass moments Inertia Inertia -: 5845,42 [Kgm'] Inertia -: 0,00 [Kgm']

Inema - : 35005,98 [Kgm'] Inertia - : -1668,01 [Kgm']
Inema - : 31991,07 [Kgm'] Inertia - : 0,00 [Kgm' ]
+1 1
Legend
Axis Frequency
= Longitudinal f1 = Longitudinal
= Lateral f2 = Lateral
= Vertical =
f3 Vertical
Rotation =
f4 Rolling
f5 = Pitching
Delta = rotation f6 = Yawing
Sigma = rotation
Date: 18-10-2010 User: Tlme: 13:13:08 J
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HPRRPT2+3 : Calculatons the resiliently mounted system Page: 31
Doosan Englne/1125/1 I~ . . IRubber Design
'ftbr,illtion ilRd no I s~ cnt
Mounting rees
Mounting C IkN/mJ Cy [kN/mJ Cz [kN/mJ DynlStat Ratio Oyn. Magnifier

314'25'45'[40] 4580,00 4580,00 3040,00 1,28 19,00
NW250-TST 140,00 140,00 60,00 1,00 50,00
Mounting parameters
Positions of mo nl ings [mmJ Rotations ( ] Calculated static stiffnesss [kN/mJ
. t}' '"
Mounting
31425"45(401
'"
-1329,00 635,00 -610,00
Sigma
0,00
Defta
0,00 4580,00 4580,00 3040,00 0,00 0,00

"'"
0,00
2 3142545(40J -1329,00 -635.00 -6 10,00 0,00 0,00 4580,00 4560,00 3040,00 0,00 0,00 0,00
3 314 2S 4540]
0 0
-589.00 635,00 -6 10,00 0,00 0,00 4560,00 4580,00 3040,00 0,00 0,00 0,00
4 3142545(40J ..s89.00 -635,00 -610,00 0,00 0,00 4580,00 4580,00 3040,00 0,00 0,00 0,00
3 1 4 0 25 4540]
0
5 281,00 635.00 -610,00 0,00 0,00 4560,00 4580,00 3040,00 0,00 0 ,00 0,00
6 3142so4S0140j 261,00 -835.00 -6 10,00 0,00 0,00 4580,00 4580,00 3040,00 0,00 0,00 0,00
7 314"25"45"[40J 1825,00 635,00 -6 10,00 0,00 0,00 4580,00 4580,00 3040,00 0,00 0,00 0,00
6 3 14"2545"[401 1825,00 -635,00 -610,00 0,00 0,00 4580,00 4580,00 3040,00 0,00 0,00 0,00
9 NW250-TST -2033,00 -8 10,00 1575,00 0,00 0,00 140,00 140,00 60,00 0,00 0,00 0,00
Date: 18 102010 User: Time: 13:13:07 1
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HPRRPT4 : Calculations of the reslllently mounted system Page: 4 j
Doosan I/1125/1 r;;: Rubber Design ~

~ "ibr.aHofl and 110 "oJ!
Calculated natural frequencies
11 Loogitudinal f2 Lateral f3 Ve1ical f4 RoIling f5 Pitching f6 YWng
[] 9,19 4,60 6,54 13,27 4,93 8,19
[1/min] 551,47 276, 12 392,17 796,02 295,74 491 ,41
Elgenvectors of the system
[mm] [mm] [mmJ <> [rads] pitch (rads) yaw (rads]
Mode 1 1,000+00 - 1 ,482-03 2,011-02 -8,134-07 -5,175-04 7,833-0 7
Mode 2 - 1,632-2 1 , 000+00 -4,782-03 -1,112-03 - 1 ,814 -05 2 , 572-
Mode 3 -4 , 384-02 2,709-03 1 ,000+00 - 1 ,507- -2,444-05 2 , 377-08
Mode 4 2, 18 -04 3,484-01 -4,882-04 1,-03 -5,583 -07 1,638-05
Mooe 5 9,94-0 1 3,708-02 8 , 824-0 2 -3 , 794-05 1,000-03 -5,335-
Mode 6 2,287-03 -2, 558-02 2,741-04 - ,122-05 3,799- 1,000-03
Date: 18102010 . User: TlrTJe: 13:13:q7 !

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Page 8/26
HPRRPT5 : CaIcuIations of the resIIientIy mounted system Page: 51
Doosan Englne/1125/2 ,..- RubberDeSgn
- ' - 'tI b r.jf.H~JI itnd nol :!.,f 1:0" t l Qt
Calculated deflection: Mountings
Moments & Forces ] {] [] a [Nm] b [Nm] c [Nm]
,+ ,+ -1,830+05 ,+ ,+ , +
Cordinates (mm] {mm] [mm]
,+ ,+ ,+
Calculated static deflections [mm]
Mounting number 2 3 4 5 6 7 8
Forcd defl. 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Forced defl. 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Forced defI. -8,876 -8,876 -8 ,683 -8,683 -8,462 -8,462 -8,056 -8,056
Date: 18102010 User:MEP T1me: ,13:13:23 1
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HPRRPT5 : Calculations the resilently mounted system Page: 6 1
Doosan Engine/1125/3
Calculated deflection: Due to starting stopping
Moments & Forcs [) [) [) [Nm) b [Nm) c [Nm)
,+ ,+ ,+ 8,621+03 ,+ ,+
Coord inates [mm) [mm] [mm)
,+ ,+ ,+
Calculated static deflections [mm]
Mounling number 2 3 5 6 7 8 9
Fced defl. 0,005 -0,005 0,005 0,005 -0,005 0,005 -0,005 -0 ,001
Forced defl. 0,018 0,018 0,012 0,005 0,005 -0,007 -0,007 -1,770
Forced defl. 0,526 -0,516 0,524 0,522 -0,520 0,518 -0,524 -0,658
Date: 18-10-201 User: . TIme: 13:13:36 1

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HPRRPT6 : Calculations of the reslllently mounted system Page: 71
Doosan Englne/1125/4 ly" .JRubber Design
Yfbr.afion ilnd nol s.:t o " _ ~
Displacements caused by ship movements : Roll
DispIacements {mm]
D eg fBs 5" 10" 15" 20" 25" 30" 35" 40"
monting number
1: 0,000 -0,001 0,000 -0,002 -0,002 -Q,002 -0,002 -0,002
1: 0,426 0,647 1,263 1,669 2,063 2,440 2,799 3,137
1: -0,556 -1,048 -1,472 -1,826 -2,107 -2,313 -2,441 -2,492
mounting number
2: 0,000 0,001 0,002 0,000 0,001 0,002 0,002 0,002

2: 0,426 0,647 1,263 1,669 2,063 2,440 2,799 3,137
2: 0,604 1,262 1,969 2,721 3,511 4,333 5,181 6,049
mounting number
3: 0,000 -0,001 0,000 -0,002 -0,002 -0,002 -0,002 -0,002

3: 0,426 0,648 1,264 1,671 2,064 2,442 2,802 3,140
3: -0,554 -1,046 -1,471 -1,827 -2,111 -2,321 -2,454 -2,511
mounting number
5: 0,000 -0,001 0,000 -0,002 -0,002 -Q,002 -0,002 -0,002

5: 0,426 0,649 1,266 1,672 2,066 2,445 2,805 3,143
5: -0,552 -1,044 -1,470 -1,828 -2,116 -2,330 -2,470 -2,534
mounting number
6: 0,000 0,001 0,002 0,000 0,001 0,002 0,002 0,002
6: 0,426 0,649 1,266 1,672 2,066 2,445 2,805 3,143
6: 0,607 1,266 1,971 2,719 3,502 4,316 5,153 6.007
monting number
7: 0,000 -0,001 0,000 -0,002 -0,002 -0,002 -0,002 -0,002

7: 0,426 0,851 1,268 1,675 2,070 2,449 2,810 3,149
7: -0,549 -1,040 -1,468 -1,831 -2,124 -2,347 -2,498 -2,575
mounting number
8: 0,000 0,001 0,002 0,000 0,001 0,002 0,002 0,002

8: 0,426 0,851 1,268 1,675 2,070 2,449 2,810 3,149
8: 0,610 1,269 1,973 2,717 3,494 4,298 5,125 5,966
monting number
9: -0,004 -0,004 -0,001 0,004 0,014 0,026 0,042 0,060

9: 2,421 4,820 7,183 9,491 11,727 13,872 15,911 17,829
9; 0,762 1,579 2,443 3,349 4,289 5,256 6,244 7,244
Date: 18102010 User: Tlme: 13:13:39 1

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Page 11 /26
HPRRPT7 : CaIculations of the resillentIy mounted system Page: 8 J
Doosan Engine/1125/4 &",~I RubberDesign

- - " br.{i'.1 and "O!j. .. -c (
Displacements cased by ship movements : Pitch
Dlsplacements (mm}
Degfees 5 6 7 8 9 10 11 12
mounling number
1: 0,432 0,519 0,605 0,691 0,776 0,862 0,947 1,032

1: 0,003 0,003 0,004 0,004 0,005 0,005 0,006 0,006
1: 0,413 0,502 0,594 0,687 0,783 0,88 1 0,982 1,084
mountlng number
2: 0,430 0,516 0,601 0,687 0,772 0,857 0,942 1,026
2: 0,003 0,003 0,004 0,004 0,005 0,005 0,006 0,006
2: 0,409 0,497 0,588 0,681 0,776 0,874 0,973 1,074
mounting number
3: 0,432 0,519 0,605 0,691 0,776 0,862 0,947 1,032
3: 0,001 0,001 0,002 0,002 0,002 0,002 0,003 0,003
3: 0,206 0,254 0,304 0,356 0,411 0,468 0,527 0,588
mounting number
5: 0,432 0,519 0,605 0,691 0,776 0,862 0,947 1,032

5: 0,000 0,000 -0,001 -0,001 -0,001 -0,001 -0,001 -0,001
5: -0,032 -0,032 -0,029 -0,024 -0,017 -0,007 0,004 0,019
mounting number
6: 0,430 0,516 0,601 0,687 0,772 0,857 0,942 1,026

6: 0,000 0,000 -0,001 -0,001 -0,001 -0,001 -0,001 -0,001
6: -0,036 -0,036 -0,034 -0,030 -0,024 -,015 -0 ,004 0,009
mounting number
7: 0,432 0,519 0,605 0,691 0,776 0,862 0,947 1,032

7: -0,003 -0,004 -0,005 -0,005 -0,006 -,006 -0,007 -0,008
7: -0,470 -0,557 -0,642 -0,724 -0,804 -0,882 -0,957 -1,029
mounting number
8: 0,430 0,516 0,601 0,687 0,772 0,857 0,942 1,026

8: -0,003 -0,004 -0,005 -0,005 -0,006 -0,006 -0,007 -0,008
: -0,474 -0,561 -0 ,647 -0,730 -0,811 -,889 -0,965 -1,039
mountlng number
9: 1,041 1,249 1,457 1,664 1,871 2,078 2,284 2,489

9: -0,003 -0,003 -0,004 -0,004 -0,005 -0,006 -0,006 -0,007
9: 0,605 0,733 0,863 0,995 1,1 30 1,266 1,404 1,545
Date: 18-102010 User: Tme: 13:13:39 1

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HPRRPT8 ; Calculations of the resillentiy mounted system Page; 9 j
Doosan Englne/1125/5 ..
I ,~1 Rubber Design
f br .tin ilnd flOIS't i;o"t fQ_ ~
Dynamic amplitudes caused by free moments and forces

INPUT [) [) [) a (Nm) b (Nm) c (Nm)
F1 ,+ ,+ ,+ ,+ ,+ ,+
F2 ,+ ,+ ,+ ,+ ,+ 6,600+03
F(begln) = 12,00 () F(end) = 12,50 ( ) F(step) = 1,00 () F(F2) = 12,00 ( ]
Calculated output: Due to 1st order excitation

Amplitudes (mm]
Frequency ( ] 12
mounting number
1: 3,849-02
1: 1,450-01
1: 3,882-02
mounting number
2: 3,849-02
2: 1,450-01
2: 3,917-02
mounting number
3: 3,849-02
3: 1 , 06-01
3: 3,890-02
mounting number
5: 3,849-02
5: 5,063-02
5: 3,899-02
mounting number
6: 3,849-02
6: 5,063-02
6: 3,90 1 -02
mounting number
7: 3,849-02
7: 5,027-02
7: 3,915-02
mounting number
8: 3,849-02
8: 5,027-02
8: 3,884-02
monting number
9: 4,933-02
9: 6,249-02
9: 5 , -02
Date: 18-10-2010 User; Time: 13:13:44 1
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HPRRPT9 : Calculations of the reslllently mounted system Page: 10
Doosan Englne/1125/5 . r,:J. Rubber Design

!::J v fbr.aHo r ilnd n011$ cContl~(
Transmitted moments and forces caused by free moments and forces

INPUT [] [] [] [Nm] b [Nm] c (Nm]
F1 ,. ,. ,' ,' ,' ,'
F2 ,. ,' ,' ,' , 6,600'03
F(begln) = 12,00 ( ] F(end) = 12.so (] F(step) = 1,00 (] F(F2) = 12,00 (]
Calculated output: Due to 1st order excitation

OUTPUT Fraq (] (] ( ] (] (Nm) (Nm] , (Nm)
12,00 6,838 3,00203 3,986.00 2,596'03 2,15401 5,007'03
Date: 18102010 User: Tlme: 13:13:44 1
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HPRRP8 : Calculations of the ll leI mounted system Page: 11 )
Doosan Engine/1125/6 I,. Rubber Design

. - ' 'ffbr.aHoJl .nd nu ls-:t contfQ'

INPUT [] [] [] [Nm] b [Nm] c [Nm]
F1 ,+ ,+ O,OQOE+OO O,OQOE+OO ,+ ,+
F2 ,+ ,+ ,+ , + 1,860+04 ,+
F(begin) = 24,00 [] F(e nd) = 24,50 [] F(st.p) = 1,00 [] F(F2) = 24,00 []
Calculated output: Due to 2nd order excitation

Amplitds [mm]
Frequency [] 24
moonting number
1: 1,742 -02
1: ,+
1: 3, 366-02
mountlng number
2: 1,742-02
2: , +
2: 3,369-02
mounting number
3: 1 , 742-02
3: ,+
3: 1 ,467-02
mounting number
5: 1,742-02
5: , +
5: 6,720-03
mounting number
6: 1, 742-02
6: ,+
6: 6,69 1 -03
mounting number
7: 1,742-02
7: , +
7: 4,644-02
mounting number
8: 1 , 742-02
6: ,+
8: 4,641-02
mounting number
9: 3,807-02
9: , +
9: 5, 157 -02
, DaIe:16102010 User: . Time: 13:13;47 1
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HPRRPT9 : CaIcuIations of the resiIientIy mounted system Page: 12 J
Doosan Englne/1125/6 W..-I Rubber Design

. . y~ br .ltion and nV:IH ,:l "

INPUT ] ] ] a INm] b [Nm] c [Nm]
F1 ,> , ,> ,> ,> ,>
F2 ,> , ,> ,> 1,860>04 ,>
F(begin) = 24,00 [] F(end) = 24,50 [] F(step) = 1,00 [] F(F2) = 24,00 []
Calculated output: Due to 2nd order excitation

OUTPUT Freq [] [] [] [] [Nm] [Nm] r [Nm]
24,00 8,191>02 ,> 3,277+ 1 3,043> 1.617+3 8,684-01
Date: 18-10-2010 User: Tlme: 13:13:47 j

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HPRRPT8 : CaIcuIations the resDlenlIy mounted system Page: 13 i
Doosan Englne/1125/7 . . " Rubber DesigR
I~
":r.tin iilnd l ~" <.
Dynamic ampltudes caused by free moments and forces

INPUT [] [] [] a [Nm] b [Nm] c [Nm]
F1 ,+ ,+ ,+ ,+ ,+ ,+
F2 ,+ ,+ ,+ 2,050+04 ,+ ,+
F(begin) = 30,00 [ ] F(end) = 30,50 [] F(step) = 1,00 [] F(F2) = 30.00 []
Calculated output: Due to 2,5th order excitation

Amplitudes [mm]
Frequency [] 30
mounting number
1: 4,34-03
1: 6, 99-02
1: 7,559-02
At mountrng number
2: 4,34-03
2: 6,99-02
2: 7,559-02
mounting number
3: 4,34-03
3: 7,410-02
3: 7,559-02
monting number
5: 4,34-03
5: 7,997-02
5: 7,559-02
At mounting number
6: 4,34-03
6: 7,997-02
6: 7,559-02
! mounting number
7: 4,34-03
7: 9,077-02
7: 7,559-02
mounting number
8: 4,34-03
: 9,077-02
: 7,559-02
monting number
9: 5,592-03
9: 1,960 -01
9: 9,642-02
Date; 18-10-2010 Jser; Time: 13;14;08 1

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HPRRP9 : Calculations the resiliently mounted system Page: 14 1
Doosan I!1/112517 rp Rubber Design

,t!.::) ~O"tfQ~
"fbril-tion a"d

INPUT [] [] [] [Nm] b [Nm] c [Nm]
F1 , + ,+ ,+ ,+ ,+ ,+
F2 ,+ ,+ ,+ 2, 0 50+04 ,+ ,+
F(begin) = 30,00 [ ] F(end) = 30,50 [] F(step) = 1,00 [] F(F2) = 30,00 []
Calculated output: Due to 2,5th order excitation

OUTPUT Freq [ ) [] [ ] [) [N m) [Nm) [Nm)
30,00 ,+ 3, 666 +0 3 ,+ 3, 62 1+0 3 , + 7, 936 +0 2
Date: 18102010 User: Time: 13:14:08 1

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HPRRPT8 : CaIcula~ons the reslllenlIy mounted syslem Page: 15 ,
Doosan Englne/1125/8 (.- Rubber Design

. yib f.iIti~n and noJ:H ntvf

INPUT [ [ [ [Nml b [Nml c [Nml
F1 ,+ ,+ ,+ ,+ ,+ ,+
F2 ,+ ,+ ,+ 6,400+03 ,+ ,+
F[begln) = 60,00 [HzI F(end) = 60,50 [HzI F(step) = 1,00 [HzI F(F2) = 60,00 [HzI
Calculated output: Due to 5th order excitation

Amplitudes (mm]
Frequency [] 60
mounting number
1: ,+
1: 4,472-03
1: 5,164-03
At mounting number
2: ,+
2: 4,472-03
2: 5,164-03
mounting number
3: ,+
3: 4,794-03
3: 5,164-03
monting number
5: ,+
5: 5,163-03
5: 5,164-03
mounting number
6: ,+
6: 5,163-03
6: 5,164-03
At monting number
7: , +
7: 5,844-03
7: 5, 1 64-03
At mounting number
8: ,+
8: 5,844-03
8: 5,164-03
At mounting number
9: ,+
9: 1 ,360 -02
9: 6,587-03
[ Dale: 18102010 Use,: Time; 13:14:11 J
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HPRRPT9 : CaIcuIalions the resilienlIy mounted system Page: 16 j
Doosan Englne/1125/8 !..-", 'fibr.aHon

Rubber Design
o l ~." ~ontIQ:t
iilnd

INPUT ] [ [ a [Nml b [Nml c [Nml
F1 ,+ , + ,+ ,+ ,+ ,+
F2 Q,OOOE+OO ,+ ,+ 6,400+03 ,+ , +
F(begln) = 60,00 [HzI F(ond) = 60 ,50 [HzI F(st. p) = 1,00 [HzI F(F2) = 60,00 []
Calculated output: Due to 5th order excitation

OUTPUT Freq [ ] [ [ [ [Nml [Nml [Nml
60,00 ,+ 2, 376+02 ,+ 2, 52 7+0 2 , + 5,072Et01
Date: 18102010 User: Time:13:14:11 j

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MMORP: CaIcuIatlons the (combined) mass moments inertla Page: 1
Doosan Engine/1125/1
Calculations of the (combined) mass moments of inertia
Combinning ffias SBS

Masss Coordinetes of ind. C. of G. Blook dimensions
Posnr. Description [kgJ [mmJ [mmJ [mmJ [mm] [mmJ [mm]
Engine [5 23/30] 10600,00 1590,00 0,00 940,00 2200 900 1800
2 Flywhoel 1249,00 3041,00 0,00 800,00 225 1200 1200
3 Baseframe 1670,00 3560,00 0,00 250,00 2263 900 550
4 Generator 4000,00 4046,00 0,00 800,00 1610 1040 1040
5 CooIlng water 325,00 1740,00 0,00 940,00 1800 900 1000
6 Lub. oil 340,00 1740,00 0,00 140,00 1800 900 300
7 Lub. cooler 360,00 -425,00 0,00 250,00 300 900 300
8 Lub. oil f1fter 110,00 -425,00 0,00 1090,00 200 900 200
al mass : 18654,00
IndiVd ual mass moments of iner1ia
Posnr. Description l x (kgm:l] [kgm'] [k9m~ l y [kgm~ l [kgm~ [kgm']

Engine [5 23/30] 3577,50 7137,33 4990,83 0,00 0,00 0,00
2 FlywheeI 299,76 155,15 155,15 0,00 0,00 0,00
3 Baseframe 154,82 754,79 825,42 0,00 0,00 0,00
4 Generator 721,07 1224,57 1224,57 0,00 0,00 0,00
5 CooIing water 49,02 114,83 109,69 0,00 0,00 0,00
6 Lub.oll 25,50 94,35 114,75 0,00 0,00 0,00
7 Lub. oil cooler 27,00 5,40 27,00 0,00 0,00 0,00
8 Lub. 011 (I 7,79 0,73 7,79 0,00 0,00 0,00
COOrdinates total center of gravity relatie data orig in
2344,74 [mmJ
0,00 [mmJ
811,82 [mmJ
aI moment inertia about secified xes directions but through total center of OiY
5845,42 [kgm~
35005,98 [kgm~
31991,07 [kgm~
dal prooucts inertia
ly 0,00 [kgm~
l -1668,01 [kgm~
0,00 [kgm~
Date: 18-10-2010 User: TIme: 13:01:49 1
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GPRKRT: Calculations of the liI mounted system (graphics) Page: 1
Doosan Englnel1125 "",! RubberDesign

J _ .. ~br.at on on d nolsl' cn: f
Velocity leels (rms) caused by free moments and forces
Position at mounting number 1 direction
- -- --",,---,
!
:::===tt~=-~ ===
11 ,41 -----j----' ----"-~------ - - -'--""-1--
9,78 ,-,- -t--- '" ,-, -- ~--'-'--;--------' -- -------- -------: '---'-'1--'--- _ 1st order
8,15 .. ~ ...~. .. .... .. .. .... l_, .... " .. _ .. .. "" .. - -t ......._,...."; ..'''..........,,... 2nd order
! 2,5th order
6,52 !-----\
, --;--- :::::J 5th order
! Nn , speed 720 1/mln
4,89 - - ~- -+:---1
'---.'"; -----+! . _---

, ,-
!
..
------i-
!
616 704 792 880
Speed [1/min]
Date: 18-10-201 User: Tme: 13:15:39 j

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! GPRKRT: Calculations of the lI mounted system (graphics) Page: 1YV !
Doosan Englnef1125 lA{l Rubber Design

~ yibr.tfon ilnd noI,." t:onIrof
70,3 ----'''--'--1---- --"----' -- -----1 --'-1--'-
-t=i -=
: . . ;
:::: - - ~ - - - - -- j-
----------------- +F L! - - -
, --------------
4921

------.j----- --1
-+--- -------------- - ----+ -----,-----

: ::=~~=-- ~=:--~~
j;
. , :
- ---~~-~ =~-~:--=:=~-~~~=~~-~~=-
_ 1st order
-t,:
.a 2nd order

;
!
lIIIIiII 2,5111 order
28,12 ----- ---- - ----~--- -- ' ----j -----
c:::J 5th order
----
i lIIIIiII Norn _ seed 720 11mln
i , j
~:::: ---------------- ----[-= = ~~ '---+---

7,03 -- --~---
_________ !. -----~--------
:
- -"-"--"1-- *
---::::::- --
u
----8~-;16 2~4-3~-40__s2atjt- 704 "-792 880
Speed [1/min]
Date: 18102010 User: Time: 13:16:18 1
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GPRKRT: CaIcuIations of the resilientIy mounted system (graphics) Page: 1 !
Doosan Englne/1125 !~.,. Rubber Design

. ' r fbr.a-tion il nd ro &1, i:ont rll t
~~--Lt~,t= =tCj- _ 1st order
27 ,5 -----1-----~------~--
, i ;
-II------J----------
\1 i
.-----!----~-------
i
~

2nd order
2,5th d
1 : i ; i [::::J 5th order

22 -----T---i------j- -.- ---.-----t----- ------+---- --':---
i ;
Nom .seed 720 1/mln
-
16,51---!, --i---+- ;\ ! --
;...!
i i '" ! '
11 -- r : -~:1--
!~:
j '~
~
,- , "'--- ,.--~.L-=-t -"~~
!
~-=

5,5 ---'--!.1!-~ \ ,--- '\:::.-- ---;-----------r----- -...+:::::
! \ -l, ~_--_:_~--....,__- -"-V "
_ .... ""'" '" , .... . --;-
88 176 264 352 440 528 616 704 792 880
Speed [1/min]
Date: 18-10-2010 , User: Tme: 13:16:51 1

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GPRKRT: CaIcuIations of the resiIienUy mounted system (graphics) Page: 9XV I
Doosan Engine/1125 . ry: RubberDesign

.:r:::J Yibra-tion ond !.. c:nrJ
21 r--------~3
!,
:
:'
--------
!
!
j
!j
:
18,9 "'"1 t - ._- ..1 i ......"..."'.....1"'...

16,8 ___ ----- --- . ;------ . . -----;-- . --j-----I---i--+--
14,71 - - - + - - + + - - + - - - 1 - - - + -1'-\- !
i
j-----tl---j-
! i : ;
,
12,6 : ~ ----+----
-+-----J------ ------f---- -I-------~------t---+-----
_ 1st order
. . 2nd order
1 '5 ------ ---- . _ 2,5111 order
i ! 1 . . 11
! i j! CJ 5111 orner
8.41---1-1-+\-+--+-------t,-/--+--,---+,--+_,----
_ Nom.speed 720 1/min
6,3 - - . J.; . ~ -/i - i. .f --- 1 -- :--- -- -f - -

1 t 'f \ ; !, j
\\ .-+., ..~.~ ----,

2,1 ----- -
__ .._~
, J\
,
--~
:
"
! \:" :
...v _
_....---
i

...:c= >r- - - i
l
7-~1'--~-,----t---"'" ---",--~-
j " . _

, ---'- : ___ '!
-t---..
88 176 264 352 440 528 616 704 792 880
Speed [1/min]
[ DaIe: 18-10-2010 User: Tlme: 13:17:28 1
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! GPRKRT: CaIcuIatons of the resilienfly mounted system (graphics) Page: 9YV !
Doosan Englne/1125
"'' -+t--,l-~~+=
100.16 -- .... -.-+ . --.-.-..-..--.-.. -.-I-t-._--i_._.---I. _---_-i.f-- - - -- - - ~ .--:- - .- -.
87.64 ___ ~Ii
. ---. ---- _ _ _ ....
, !
'::+=+H=H=ft=
50.08
1 ---J--- -
i
--+--- --- ' --+--.. -+.--+--t
i; . i !
_
_
_
c::::::J
_
1st order
2nd order
2,5th order
5th order
Nom.speed 720 1/mln
37,56 ~~,_L
.; --- - -+ ._-~ _. +--4-----+! - ! ! !
'-t-+=T=
! ; 1 !
::+r-,. ,-~--~
" ..... _ ~"
-' - '88 - 176 264
~352_.--.
440
,. .__. ___616
__. . .,..528 ..J....._ _ _.L
704
..--1",,---:-"
792 880
Speed [1/min]
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GPRKRT: CaIcuIations the resiIiently mounted system (graphics) Page: 9ZV I
Doosan Engl"e11125 1\1." 1Yfbr.ation

:. and n!!t "o"t rnf
RubberDesign
Velocity leels (rms) caused by moments and forces

--- -----,--_.,,.---,-----,
~ -
::: -== -i---~--=::::T
i
49 ,28 --+---j---1!--II-Hj_-+-~f----+--H--'-,!
i ! !
__
42,24 ----- '.---.-- ._--+_.~. -; -- -----+--+--.--j+--~--- _ 1st order
~::=~-t--- -~_t-
_ 2nd order
_ 2,5th order
c:J 5thorder
i --1\ - '
_ Nom.speed 720 11min
21,12 - - - ___ .--.;--
14,08 -- ,j I N ~, ....==_:....:-.:::; .- -1+\ -'

7,04
u
----JN
. .---~\ j -_ .:J---.'I! -- -+---_.. ------.,::::----'----::::1='::7' _~=-L
----........
. h
-..J
i
C ''' '
!
: , <, i
,.-;..----
-- :
i
!
88 176 264 352 440 528 616 704 792 880
Speed [1/min]
Date: 18102010 User: Tlme: 13:18:33 [
Doc. . MRD5- 5179- 0

. DOOSAN-MAN DIESEL Page 1/24
Tier 1 Hull . : 139/ 03071
Tier 2 Hull . :-
Subject:
CALCULATlON OF TORSIONAL
VIBRATlON
Note:
Attachments : Re f er the cont ent s f or drawing i st
20101118 e 2i .2. ~ ~ ~ ~ First Issued.
~
Doc.
Doosan Engfne .
MR06-5179-0
DOOSAN - DIESEL aae 1/24- i'~
REVISION HISTORY
REV DESCRIPTlON
20101118 First Iss ued.

ENGINE

Doc.
DESCRIP- .
MR06-5179-0
10
CALCULATI ON OF TORSIONAL VI8RATI ON

Doosan Eng ine CO. ,Ltd.
CONTENTS

CALCULATION OF TORSIONAL V 34-{) 172 14- 4 22

ENG INE

5 L23/30 PART Machinery
Doc.
DESCRIP- .
MR06-5179-0

CALCULATI ON OF TORS IONAL VI BRATI ON
Ooosan Eng ine CO . ,Ltd .

Page 3/24
Calculation Torsional Vibration
Note :
1. Engine Type : 5 L23/30
2. Engine Powerl Speed : 650kW at 720 rpm
3. Application
1) Fly wheel with Gear rim : 273.5 kgm2
2) Generator ( ) rotor : 61 .1 kgm2
3) damper : Viscous damper 6017/1
\ .
Added V damper drawing

20090216 e~.2 ~~~ ol~~ & Deleted name 4
20090121 e ~ .Q ~ ~~~ Added natural f requ ency data. 3

20080519 ~ * H ~~ ol~~ Change the lore Ilange 2
20080509 ~*H
/ ~ ~Tt
Change the engine power & speed and
lore Ilange
1
20080326 ~*H ~~Tt ol~~ Fi rst issued.

Type 5 L23/30 MS/MG 0055
~
Drawing
Doosan Englne .
34-017214
Doc. . MR06- 5 179- 0

Page 4/24
Torsional
Vibration CalcuIation
Customer & Doosan 18-Jan-2009
Engine 5L23/30 GR 3212
!mportant Notice
The enclosed calculations made with adanced computer programs.
Geislinger has rely data furnished by technical documentation of the engine builder and
cannot guarantee the correctness of these data and therefore ecludes any warranty. liability
responsibility whateer as damage. failure malfunction of the installation due incorrect
torsional data.
n receipt of this documentation is strongly recommended check the torsional data for
correctness. Geisl inger also recommends erify these calculations. especially if they for frst
installations. by torsional ibration measurements under correct operating conditions and after
temperatures hae stabilized.
Copyright GEISLlNGER 2008
- 5L23/30 with Geislinger Vdamp 60/7/1 @ 720 rpm (Alpha counterweight)

Flywheel 273.5 kgm 2
. 2-20
Calculations based 80' C ambient temperature with l mist condition.
Geislinger GmbH
Hallwanger Landesstrasse 3
-5300 Hallwang/Salzburg. Austria
Tel +43 662 66 999 30 -l lange@geislinger.com
Fa +43 662 66 999 40 Internet www.geislinger.com
GEISLINGER ::
Doc. . : MR06- 5179- 0
Page 5/24
Eng lne 5L23/30H Generator-curve c n stan t GR 3212
18-Jan-2009
V 19.3-0
Torsional system 8532 (08)
Engine MCR 650kW 4-cycle Number of Cylinders 5 18.16bar

8peed al MCR 720rpm Bore 225mm Connecting rod rat10 0.25 19.96bar
Torque al MCR 8.621 kNm 81roke 300mm Reciprocating mass 46kg
Firing sequence [j] :? 11] $] 1;j]
Firing interval 1440 1440 1440 1440 144'
GSLJG ON~1 Casing ::fIiia Ring Inertia Total Mass Ambient Temperature .
kg kgrrr kg 'C
6017/1 2.5 2.91 96.6 80
. Inertia Stiffness Abs .Damp. Re l.Damp. Eq. Dia. E ~I

speed Tel Firing angle
kgm2 MNmlrad Nms/rad Nms/rad mm Realspeed
2.9 1 Vt) t;.urn1
dynamic data acc. C/D-diagram D
2 2.5
infinite
3 2. 039 F1ange+Flyw.+Gear
35.3
4 5.84 1.8 Cyllnder [j] '
27.3 1200 185
5 5.84 1.8 Cyllnder [~] 1440
27.3 1200 185
6 5.84 1.8 Cylin,Jer [~) 5760
27.3 1200 185
7 5.84 1.8 Cyll nder [41 2880
27.3 1200 185
8 5.84 1.8 Cyllnder [~) 432'
40.4 185
9 1.67 Camdrive
185
10 0.45 Flange
infinite
11 273.5 FIywheel
25.66 21 0
12 61. 1 Rotor
E c itation per Cylinder - tangential pressure components (EXC1)

L23/30H
En gine speed 720 rpm 18.16bar 19.96bar
Ideal firing Corpression
l ~ Gas M ass 10lal r-_- Ga. ...............
order k JpC,k2+ (Ps,k+ m k)2 sine Ps,k cosine Pc,k sine m k Ps,k+mk sine Ps,k cosine Pc,k
bar bar bar bar bar bar bar
0.5 7.31 4.93 5.4 2.37 2.37
1 10.8 9.71 3.19 0.627 6.03 5.4
1.5 8.7 8.63 1.06 4.46 4.46
2 3. 09 8.01 -0.205 -4. 93 0.384 4.55
2.5 6.61 6.57 -0. 767 3. 91 3.91
3 3.7 5.43 -1.09 -1.89 1.38 3.28
3.5 4.57 4.37 -1 .33 2.76 2 .76
4 3.52 3.38 -1.43 -0.159 2.08 2.24
4.5 2.89 2.55 -1.36 1.86 1.86
5 2.31 1.92 -1.25 0.0255 1. 52 1.49
5.5 1.82 1.4 -1.16 1.23 1.23
6 1.42 0.957 -1.04 0.00384 0.972 0 .968
6.5 1.07 0.609 -0.883 0.796 0 .796
7 0 .816 0.367 -0.729 0.619 0 .619
1 bar I> 0.5964kNm
7.5 0 .634 0.1 85 -0 .606 0.511 0.511
8 0 .49 0.0351 -0.489 0.39 0.39
8.5 0. 373 -0 .0688 -0.366 0.322 0.322
9 0.286 -0 .122 -0. 258 0.24 0.24
9.5 0.233 -0.148 -0.18 0.204 0 .204
10 0. 205 -0.17 -0 .1 14 0.1 42 0 .142
10.5 0 .181 -0.174 -0 .0492 0.121 0.121
11 0.157 -0 .157 0 .00169 0.0726 0.0726
11.5 0.137 -0.133 0.0298 0.0641 0.0641
12 0 .125 -0 .116 0.0481 0.00258 -0.00258
-WARNING- 19.96 ;< 18. 74bar due 10 9as ecrtalion accordil1g G8 445
2
GEISLINGER-~
(O~' l rfrlG S ~1) OAI.!PEII . ~,,;T ) -S
Ooc. . : MR06- 5179- 0

Page : 6/24
Eng lne 523/30 GR 3212

18-Jan-2009
V 19.3-0
Crank angIe & sum Engine torque excitation frequency-domain (CRANK)
rCTiiideij
L...:Y_._ .........

clockwise rotation viewed from Flywheel Flywheel
F r n9
t
Cylinder angle interal
'
1440
[?] 1440
1440
:<\1 2880
1440 2.0
[} 4320
144'
i~1 5760
1440
1.5
1.0
0.5
2 4 6 8 10 120rderk
,~------~
, ------~,--------
50 100
- - Ideal firing
.. Sum Engine torqu e excitation at MCR

CR Torque at MCR 8.621 kNm
3
G~ISJING~R'~
co~ It."GS !'> I)AM'<.IIi. .,,~ 1:) ,~}T
Doc. . : MR06- 5179- 0

Page : 7/24
EngIne 5L23/30H Generator-curve constant GR 3212
18-Jan-2009
V 19.3-0
Ecitation per Cylinder in time- & frequency-domain (EXC2)

23 /30
Engine speed720rm 18.16bar 19.96bar () =MIPMCR
> 576rpm
'2
TangentiaI gas pressu re [P,.k cos(ka) + P'.k sin(ka)] Torque
k=O
bar kNm
60 \
\
30
40
20
20
10

\. " ....-
'""
-10
-20
2 2
jpc/+ (Ps,k+ mk )2
jPC.k + Ps,k
bar kNm bar kNm
10 6
6
8
4 4
6
2 2
2
246 8 10 12 Order k 6 8 10 12 Order k

, , , , , ,
50 100 50 100
mkl
bar kNm Ideal firing - Gas
10 6
Excitation due to reciprocating mass 46kg
8
4 Ideal firing - Gas & Mass
6
4 -WAHNING MIF' 19.96* 18.74 bar due gas excitation

2 according to GS 445
2
2 4 6 8 10 12 Order k
~,------~,------~,------
50 100
4
GE!SLING~R< :?
(OU9l IG~ D A ~IPf~S _~~lt ~~T
Doc . . : MR06- 5179- 0

Page : 8/24
Englne 5L23/30H GR 3212
18-Jan-2009
19.3-0
Graphic torsional system (GRAPH)
291
VS t:(j(7!1
OAMPER ;1,
2.5 2

~
c
~
2.039 .<
Flange+Flyw.+Gear 3

~

5.84
\1} 4 -":::r"J~
:
~
-
5.84
fgj 5 ._.s:>-j ~
~
~ ~ ~
-
[~!
5 .84
~
6 . . "";. 1:'
: -
4]
5.84
~
7 -,,,>1:'
5.84
~ f!!~
-
[ 8 :;:)I~
~
1.67
~
.
~
Camdrive 9
~
:"
0.45
Flange 10
.~
c
273.5 ~
Flywheel
61.1
~

..

~

11
Aotor 12
Inertla kgf
SIiffness MNmlrad
Damplng NmSrad
1(:: '
Eq.Oa. mm
5
GISGf2R'';
CuuI'tIH;S 4Jilt
l ;! {IAIt,c ,.s . :: l~1
Doc. . : MRD6- 5179- 0

Page : 9/24
EngIne 5L23/30H GR 3212
18-Jan-2009
19.3-0
Natural frequencies - Holzer tabu lation - Without Damping ( )
1 Frequency
Node 1 543 radls 86.42 5185niri'
. Rel.AngIe Ek1n Rel.rorque

1 1.48 0.136 0 .473 0.637
2 1.06 0 .4 13 1.42
3 1.06 0.0597 0 .337 2.05
4 1 0 .261 0.861 3.77
5 0.862 0.506 0 .639 5.26
6 0.669 0.753 0 .385 6.41
7 0 .434 0 .939 0.162 7.16
8 0 .172 0 .688 0 .0255 7.45
9 -0 .0125 0.15 0 . 383 -4 7.45
10 -0.0527 0 .000185 7.44
11 -0.0527 0 .198 0 .112 3. 19 Resttorque
12 -0.177 0.282 -0 .000298
Modeshape 11,"
ReI.AngIe 1~'~~:~=~~-----~=-~:--:--~'=~'~--~"'--1------i-~~~--~_~=~
[] [?] lJ.l [1] [~1
Energy dIstrIbutIon
6
Page : 10/24
Eng lne 5 23/30 GR 32 12
18-Jan-2009
V 19.3-0
Natural frequencies - Holzer l abulalion - Wilh oul Damping ( )
(1)1 Frequency
1
Node2 723.2rad/.< 1 1 5. 1 6906Inin-
. Rel.Angle ," Rel .Torque

1 2 .06 0.738 1.62 1.57
2 1.12 0 .82 3.03
3 1.12 0 .253 0 .669 4.23
4 1 0.97 1 1.53 7.28
5 0 .733 1.66 0 .821 9.52
6 0 .385 2.1 0 .226 10.7
-0.00729 2.09 . 811 4 10. 7
8 -0.398 1.11 0 .242 9.46
9 -0 .632 0 .214 0 .175 8.9
10 -0 .68 0 .0545 8. 74
11 0.68 153 33 .1 88.6 Resttorque
12 2 .77 123 -0 . 38 - 5
Rel.Angle
Energy dlstrlbut lon
pot ,--11 -
1 2
- -8- - -
3
8-
4
- .... - -
5
_ - __ - -
6 7
_ -_
8
--
9
-_ -_
10
--
11
- _ 12
7
Page ; 11 /24
Englne 523/30 GR 3212
18-Jan-2009
19.3-0
Natural frequencies - Holzer tabulation - Without Damping ( )
3 Frequency
Node3 1182 radls 188.2 I1 11290,n/n"
. Rel.Angle pot Ekin Re1.r orque

1 15. 1 234 232 30.7
2 0.159 0 .044 30.1
3 0.159 12.5 0 .0359 29.7
4 1 8.49 4 .08 21.5
5 1.79 0 .88 13.1 6.93
6 2.04 1.74 17 9.74
7 1.69 10. 1 11.6 23.5
8 0.825 11 .3 2.78 30.2
9 0.0766 2.5 0.00684 30.4
10 -0.0878 0.00243 30.4
11 -0 .0878 0 .202 1.47 3.22 Resttorque
12 0.0377 0 .0607 -0.0317
ModesIlape
Re l.Angle
Energy distribLltIon
pot
1
-----~---.---~--- ___ -__ ---~- ______
2 3 4 5 6 "{ 8 9
8 - _______ 8-_
10 11 12
}- --,- -- -t- --,- -- -t- ---1---- ~ ----! -- --- ---~-- -1t ---~
8
GEI~ur\jG~~':?
(iill~tfH'S AN ~ Q"M'<~S. (;Ji,T!~ (
Doc. . ; MR06- 5179- 0

Page : 12/24
Englne 523/30 G R 3212
18-Jan-2009
19.3-0
Natural frequencies - Holzer tabulation - With out Damping ( )
. Frequency
Node4 1722 'C!.' 274"'2 16440tnir(
. Rel.Angle Epot Ek1n Rel.Torque

1 -1.54 9.43 5.08 6.62
2 1.31 6.39 3 .11
3 1.31 1.73 5.21 11
4 1 14.7 8 .66 28.4
5 -0.0388 14 0 .013 27.7
6 -1 .05 1.64 9.6 9.46
7 -1.4 4 17 14.8
8 -0.858 10.9 6.38 29.6
9 -0.125 2.47 0.0386 30.2
10 0.0387 0 .000997 30.2
11 0.0387 0.026 0.606 1.16 Resttorque
12 -0.00637 0.00368 -0.0665
Modeshape
.... .;a.---- .....
Rel.Angle ----------
23
ft]
4 ----_--;7--
[~)
6
@
7
]
8 9
--~--_ro--_;'t- --K
12
'-., ._-.
Energ y distrlbution
_1___ -----1--1--... ---'--1---'----_---_-

1 2 3 4 5 6 7 8 9 10 11 12
L_..J ___ L _-.J____ -~--l--!--_--.--

1 2 3 m 4 '5' 6 7 8 '9'
___ --.
11 12
9
Page : 13/24
Englne 5L23/30H Generator-curve constant GR 3212

Ideal firing 18-Jan-2009
V 19.3-0
(P-C)
IPower-curel
kW
800
600
400
200
200 300 400 500 600 700 800 900 rpm

Engine speed
(-)
Power & Mean effective pressure & Static tarque

_ .......... Engine & no ...1.1.::.R
Engine speed 200 300 400 500 576 600 700 ~ 800 900 rpm
Power 520 541 .7 631.9 lj@ 722.2 812.5 kW
18.16 18.16 18.16 18.16 18. 16 18. 16 bar
T(Engine) 8.621 8 .621 8 .621 8 .621 8.621 8 .621 kNm
(11-12) 8.621 8.621 8.621 8.621 8.621 8.621 kNm
10
(~tIS~G
' ,)
c:. ll ~S ~~'" n~_~\, ,; ~s. ~ ((~
;r(.q:
\$ 1
Doc. . : MR06-5179- 0
Page 14 /24
Englne 5L23f30H Geeratcurve constant GR 3212
V 19.3-0
( LL )
IThermaJ loadl of whole torsio nal system
kW
1.4
1.2
1.0
0.8
0.6
SlJm aII
...!:1..
1< !! [);.,r. .
-";.,rr ["';:!
(ANG)
Vibratory angle Free end at inertia . .2..
mrad deg synthesls ""ad syn4 .66mrad900rm deg

5 2.0
0. 10
1.5
0.25
1 .0
0.05
4
l
0.5
,.
0 .20
2 4 6 10 12 Order k
50 100 150
3
mmd sYI13 .5I/1Iad 720rprn deg
2 .0
0.10
2 1.5
1.0
0 .05
0.5
0 .05 2 4 6 10 12 Order k
50 100
200 300 400 500 600 700 800 900 m

Engine speed
11
Page : 15/24
Englne 523/3 0 Generatr-cure constant GR 32 12
Ideal firi ng 18-Jan-2009
V 19,3-0
(ACC)
Vibratory lacceleration Camdrive at inertia . 3!.
synthesis radI!l !>yr1 127(;!(w 865
1400 --,----------------'- - -----

40
1200 20
1000 2 4 6 8 10 12 Order k
50
800 rad/f! S 81.4radls" 720m
600 40
20
400
2 4 6 8 10 12 Qrder k
200
50 100
5.
9.5
200 300 400 500 600 700 800 900 rpm

Eng ine speed
( )
IThermalloadl due Abso lute Damping
kW sum kW sum O.00309kW900rpnJ

Engine 0 .0020
0 .00 15
0.0030
0.0010
0.0005
0.0025
4 8 12 16 20 24 Ordef'*2
,
0,0020 6 200 300
kW sum O .00125kW720pnI
0.0020
0,00 15
0 .0015
0.0010
0,0010
0 ,0005
4 8 12 16 20 24 OrdCf. 2
0.0005
100 200
200 300 400 500 600 700 800 900 rpm

Engine speed
12
Page 16/24
Englne 523/30 Generator-curve cnstant GR 3212
V 19.3-0
()
!ThermalloadJ due 10 Relalive Damping
kW sum kW HJnIO.187kW900IfJff'
~:)I~!:~ ~,,'
0.20 Engine 0.10

0.08
0.06
0.04
0 .02
0.15

100
8 12
200
16 20
300
2. Ordcrt"2

kW slJm O . 0854 k~v720rm
0.10 0
0 .06
0 .06
0.04
0.05 0.02

100
8 12 16
2<)0
20 2. Ordcr*2

200 300 400 500 600 700 800 900 rpm

Engine speed
(MSC)
IMaximum stressl Crankshaft between inertia . 2-11
N/mmZ synthesis N/mf sYI132.3 N!trHr( 900 rpIn
15
60
10
50 5
40
,

2
,
50
6
100
8 10
150
12 Order k

N/mf syn 25. 9 Nrr? 720
30 15
10
20
5
10

2
5'0
6 8
100
10 12 Orderk

200 300 400 500 600 700 800 900 rpm

Engine speed
13
Page : 17 /24
Englne 523/30 Generator-curve constant GR 3212

V 19.3-0
(VISDA)
Vibratory Ito rque l 6017/1 between inertia . 1-2
kNm synttlesls kNm syn 2 . 54 kNrI 900JpI
1.5
1.0
3 0.5

2
50

100
8 10
150
12 Order k

kNm S 2.591<m 7 20rpm

2
1.5
1.0
0.5
7 5.
.

2
.
50
8
100
10 12 Order k

200 300 400 500 600 700 800 900 rpm

Engine speed
(TLGVD)
IThermal loadl due to Relative Damping 601 between inertia . 1-2
kW sum kW s,m 1.09kW900rpm
.
2.0
0.4
0 .2
1.5

,00 8 12
200
l 20
300
2' Order-2
kW sumO.436kW720rm
1.0
0.6
.
0 .2
0.5

8
100
12 l
200
20 24 Ordcr. 2
-
200 300 400 500 600 700 800 900 rpm

Engine speed
14
Page : 18/24
EngIne 5 23/3 0 Generator-curve constant G R 32 12
IdeaI firing 18.Jan-2009
V 19.3-0
(ROTOR)
Vibratory Istressl & to rque Rotor shaft 021 mm between inertia . J.1:1l.
2
N/mm kNm synthesls Nlmm' syn 13.1 N/Y!f 865 kNm
~)~~!:~ i:', ~I~
14 8 15
25
6
10
12 4
5
20 2
10
2 4 6 8 10 12 ()(der k
8 ,
5'0 ,00 150
8 15
N/mri' SI5. 991l' 720 kNm
8 15
6 6
10 10
~-~- -- --- 4
4 5
2
5 5
2 4 6 8 10 12 Orderk
2
sO 1(~X)
200 300 400 500 600 700 800 900 rpm

Engine speed
15
Page : 19/24
Englne 523/30 Generator~ curve constant GR 3212

Misfiring marked Cylinders according oompression 18-Jan-2009
19.3-0
(P-C)
IPower-curvel
kW
800
600
400
200
200 300 400 500 600 700 800 900 rpm

Engine speed
(-)
Power & Mean effective pressure & Static torque

- .- Engine & no.1.1.:..:!...6..
Engine speed 200 300 400 500 576 600 700 IUQ] 800 900 rpm
Power 520 541 .7 631 .9 ~ 722 .2 812.5 kW
18.16 18.16 18.16 18.16 18.16 18.16 bar
T(Engine) 8.621 8.621 8.621 8.621 8.621 8 .62 1 kNm
( 1 1-12) 8.621 8.621 8.621 8.621 8.621 8.621 kNm
16
Page : 20/24
EngIne 5L23/30H Generator-cure constant GR 3212
Misfiring marked Cylinders according compression 18-Jan-2009
V 19.3-0
HIGHEST EFFECT OF [!;::.;!'iifi] l DIFFERENT FIRING (HEFOC)

Vibratory ~ Free end at inertia . 2..
mrad deg sy nthes ls Inrad syrl1 1 .9IIJIfld 578 deg

10 0.6
12 8
\ 6
0.4
0.6 4 0.2
10 2
2 4 6 8 10 12 Order k
8 2'0 4'0 6'0 io 100
mrad syn 8.34mrad7 20rm deg

10 0.6
6
8
0.4
6
4 4 0.2
0.2 2
2 2 4 6 8 10 12 Orderk
50
200 300 400 500 600 700 800 900 rpm

Engine seed
HIGHEST EFFECT OF [!;,\:.: l DIFFERENT FIRING (HEFOC)

Vibratory acceleration Camdrive at inertia . ~
synthesls radl~ syn 136rar's" 865

60
1400
40
1200 20
1000 2 4 6 8 10 12 Order k
,
50
800 radIfI syn 83.8 radl~ 720rr

60
800 40
20
400
2 4 6 8 10 12 Orderk
200

200 300 400 500 600 700 800 900 rpm

Engine speed
17
Page : 21/24
Engln e 5L23/30H Generator-curve constant GR 3212
V 19.3-0
HIGHEST EFFECT OF f9Y'ii l DIFFERENT FIRING (HEFOC)

IThermalloadl due to Absolute Damping Engine
kW sum kW Iiurn O . 00329kW900Irr
0.0015
0 .0010
0 .003
,:
0.0005
.,
., 4 12 16 20 24 Orde.... 2

100 200 300
0.002 kW SUIT10.00153kW720rpn
0.0015
0.0010
0.001 0.0005
, 12 16 20 2' Ordcr*2
100 200
200 300 400 500 600 700 800 900 rpm

Engine speed
HIGHEST EFFECT OF 19.YhlijIi.gj'n l DIFFERENT FIRING (HEFOC)

IThermalloadl de to Relative Oamping Engine
kW sum kW srm O.187kW900rpnJ
0.10
0. 20
0.08
.,, 0 .06
0.04
0.02
0.15
4 8 12 16 20 24 Order*2

kW SrIrrt O.0848kW720rpIn
0.10 0.10
0.08
0.06
0.04
0.05 0.02
.

4 8 12 16
.
200
20 24 Orde ....2

"".,:, ....
1
800 900 rpm

Engine speed
18
J"
{'I~tt:I "' ;:.J.::
,,~K" .. " r" '" '"
(OVOtrN<iS / iJAM~H S. ~uitr ~;"
::r
Doc. . : MR06- 5179- 0
Page : 22/24
Englne 5L23/ 30 Generator-curve constant GR 3212
Misfiring marked Cylinders accord ing co mpression 18-Jan2009
V 19.3-0
HIGHEST EFFECT OF [i?'!.)}:\'] l DIFFERENT FIRING (HEFOC)
IMaximum stressl Crankshaft between inertia no. 2-11
synthesIs N/fnf1r sy r~ 32. 5N1f/'lni 900fl

15
60
10
5
50
2 4 6 8 10 12 Or'der k
40 50 100 150
Nlmd syn 26. 1N/mm 720 rpm

15
30
10
20 5
10 2 4 6 8 10 12 Orderk
, ,
50 100
200 300 400 500 600 700 800 900 rpm

Eng ine speed
HIGHEST EFFECT OF [!5.Y!;Iij.qg:RJ l DIFFERENT FIR ING (HEFOC)

Vibratory Itorguel D 6017/1 between inertia .
kNm synthesls kNm syn3.51 kNrlJ 900rfJJ

1.5
,/ 1.0
3 . .-,--i'-f' ! 0.5
:/
..,...r! . 2 4 6 8 10 12 Orderk
5'0 160 150
kNm syn 2.62kNIII 720

2
{ 1.5
./ 1.0
~
0 .5
2 4 6 8 10 12 Order k
, ,
50 100
; :
.... ~! ::~:::_~L~j~[?i~:~I!6.~~~~:~~!!~f[j~~i[~~j~~jr.f.ij![f.J~~J~i_~fj~
200 300 400 500 600 700 800 900 rpm
Engine speed
19 (5':' <'" ! G'~ ~ .Jb

.?",,;jl1.H" ~.. o::r
(OU~L , r.G~ ') DA .l prts t\HI1~ u:
Doc. . : MR06- 5179- 0

Page : 23/24
Englne 523/30 Generator-curve constant GR 3212
19.3-0
HIGHEST EFFECT OF [f";!'!.'j' VH DIFFERENT FIRING (HEFOC)

IThermaIIoadl due to ReIative Damping D 6017/1 between inertia no.1i1.
kW s um kW surn 1.11 kw900rprll
.
2.0
0 .4
0.2
1.5 4 8 12 1. 20 24 O'dep2
160 200 360
kW sumO.43kW720 fplll
1.0 .
0.4
0.2
0.5
4 8 12 1. 20 24 Ordcr*2
,
100 200
200 300 400 500 600 700 800 900 rpm

Engine speed
HIG HEST EFFECT OF [q')'J)'?:] V H DIFFERENT FIRING (HEFOC)
Vibratory Istress & torque Rotor shaft 021 mm between ea no. 1..1.:...!.R.
N/mrr kNm synthesIs N/mrrf syn 14.2N!n/Irf 865rl kNIn
8 15
14 25 10
4
12 5
2
20
10 2 4 6 8 10 12 Orderk
,
5'0
15 N/mrrl :syn 6A wmf' 72.) kNm

8
8 15
6
10
4
10
5
4 2
5 2 4 6 8 10 12 Order k
2
50
200 300 400 500 600 700 800 900 rpm

Engine speed
20
G~15Ir.;~,:~
COV" U'GS " DAM or~s ~;:;!O ~>r.
r
Doc. . : MR06- 5179- 0
. "~ """ ..
""
...
J'tNma Doosan Engln.
5 23/30 720 RPM

4-1. PIPING DIAGRAMS
4-2. FLEXIBLE HOSE LIST FOR EXTERNAL CONNECTlON
4-3. SYMBOL & LEGEND FOR PIPING DIAGRAMS

1 Hull . : DY139/DY3071
2 Hull . :-
Subject:
PIPING DIAGRAMS
Note:
Attachments : Refer the content s f or drawing ist
20110117 [!~~ t12 t12 Corrected sensor fuel l system (de leIed 40) 1
20101112 [!~C.! t12 t1 2 Firs! Issued.
Date D raw n Chk'd App'd Description Re.
~
Doc.
Doosan Engine .
4-5179-1
DOOSAN - DIESEL aae 1/ 7- #<
REVISION HISTORY
D REV DESCRIPTlON
20101112 First Issued.
20110117 1 Co rre cted senso r fuel l system (de leted 40)

ENGINE

Doc.
DESCRIP- .
4-5179-1
10
PIPING DIAGRAMS

Doosan Eng ine Co .. Ltd.
CONTENTS
Rev . DESCRI PT ION DWG . . SHEET

1 FUEL OIL DIAGAAM 42-010644- 1 1
LUB . OIL DIAGAAM 42-0 12993- 1 1
COO I NG DIAGAAM 42-012994- 1 1
COMPRESSED DIAGRAM 42-0 14510- 0 1
COMBUST ION DIAGRAM 42-0 129 17- 1 1
ENGINE

Doc.
DESCRIP- .
4-5179-1

PIPING DIAGRAMS
Doosan Eng ine CO . . Ltd.

,
De.cr ip t , " "
$; !

- CYl .
Leak from
fue l vc l ve
'~~

, gh _ ,
~
,,
Yr.'l......-- F ue l pump
Fue

~FueI
i n l et
1111 111 return---j- Ff
~ L eak from

fue l o i lpump
J ~ ~ ~ ~ ,~, ~
l eck f rom
fuelo i lpump
l eakage a l a rm
50.
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2 1 --~
0 0 '0
cn c:n o~

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Ooc. :-': !4-5179-1
3
C3/C16 Lubricating l from seporalor'

Lubricoting supp l y
~ F l onge connec ti on
_ __ _ _ _-"--_ _ --=;- DN25 , PN1Q , D 250 1
< -

Droin 110m (
discharge .
t5ee Combust d i ogromJ
C13 vapour
Flange connection
d i sc~arge
, DN50,PN 10 , DIN2501
Governor
V rocker
dr ve
(;J
Engine dri wen

lub. .::
c
C4 Lubricot i ng l
10 to seporoto r
Flange conn e ction:
a shul ! , ,
!10 Copper [ ON25,PN10,DIN2501
~
1
Jj! :
m"
;n
!
: "i'
10: , Doosan EgIne

ih
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t~!! f
!.;f

~
f.!'!~ ~
F F
Qoc. . VJ)4-5179-1
, 5 6 Paoo 5/7
F3
Non-ReIurn Valve wi Ih
ResIricIion (03 m)
=:sl Vent ing 10 expans ion iank
F l ange connection:
DN1 5, 1 0 , DIN2501
- -
F
j
..-t---O
CHARGE AIR
COOLER .
r--
i \ . )
F
li

".~ ~
:~
11
Q!

PUMP
enginedri ven
G2 . . fresh a !I.!

Flonge cannec!
DN80. 0, DIN250 1

~
c
L_
f
I - - - - - _ _ _
8 . I L COOLER
~- MJ ]" ", """
Flange connect lon
DN80, FN10, DIN2501
~", ,""
~
,!
' OOOSA~ 'I~r 01\,''(.'
~
It' ! Co"ec!ed Flonge si le (ON100- >DN80J
20080410
KA~AW ;:. ,Ir~ I t:~
OOOSAN ~~'!- -I jjr ol 'l;t'
'i! 20080225
KA RA W ~ I ~i' ~~\l 1 ~ 'o';
Firt ;nucd
i!i ()~\. ,_. O,o",n C,CT,'d D. ,ctip( i on ' Rc , .on jR

~;:
~i~
ift . . " '<' ..".."
fEB'" "<.,"Doosan EgIne .-_''''.0 :
; :1
. speci f icat
i!~i
components . 23/30
\\lor '< i ng pressure:
! preS$ure :
4 bor
6 bar
'.<""
G -+ 1 ~t ""
COO l lNG WA ER DI AGRAM
Dicmeter
DN80
the
excet
l ipes
wher e otherwise sIa I ed
i~i!
3.~
:!
"$<.,".-

~
NIS
.. ...
.,..,.... ( , I S TRING )
1"" '- 10; 1'~
~!~.: 0000 42- 01 299 4
F F
Doc. -:- 4-5179-1
2 3 5 P2Qe
. Desc, ipt ;on We , ," S i le

~
'
- r=-+---rn : 1 1 ~
COMPRESSED A!R I
Max. working pressure :7 bor
Flange connection:
DN40, 40. DIN250'
--l
-
C- supp ly must ! be
i nlerrupted whe n eng ine
.-< is u
.-00"
F '
<
'-0

(2) Ai r Storter Comp l eIe. F
Overspeed
'
device with bulIon
emergency ond Iest stop .

C) Cy l inder for Lomdo control l er

ond Overspeed slop.
8
-!
vc l ve jeI syslem
(2) AIR START ER COMPLETE
el
Ov
Yl.,
e

L
- FOR 7
-~
bor(kgf/cm~
0 . 7 MPa
,
j:,
Olt'1 I "I t'! I Fif II i IHIed
...
li
.,
c~;. o,c.,. CI'I1 d I~'d
~ Doosan EngIne
tI.,., i , i ~ R i ;o~
.. .., "'-'....
D
~1~ ..... '..' " ~ 167 1666-0. Ol~
r
!
"".
=10
.,. j..... ,
~;!~ < 1" ","
....
.. 1 ~'
.. .. ,, '" ''
............
l23/3DH
"''"'C'C'C''''"'"' .,,.., !
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. ",..., ..",,,
>.
2
kf
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N/S
~A , ," ' ,,, ,.
!!~; ODOD 42- 4:>l
F F
Ooc . . : 1rU.(}4-5179-1
1 2 3 1 4 5 5 ;! : 717
. ::> Oro", ; ng . Desctption I '1 w.ate, ;a t l We , ght S i ze
Water WOSh Ir1 g,
tu rb i ne s id e-j nle!
Iobec?nnecIed"'!iih ExhoustgC$ Chorgeair . _
1/2" qulck couIIngCfemoleJ l i nlet C wash I n9 .
comp r essor $lde wIth
,-_____ __________ _ 7 2 1 8 qulc' coupl 109 - I-" I-'e-'.I_ _ _--,
~~
]]
,,-
~g
Q).-

\1
60

60
~I) 60

60
i~
~
-
Compressed olr-In l el .
(see Compressed l d I ogrornJ
-

bO
_ ~ \ -/ ~ f-
--g
"" _ \r - - - " -- ~
~ ___ )~\; _ _ __ '. f-
c~ EXHAUST GAS .C. _~~
8~! ,.:----~.:--- l r'c.:- --- X- - ] \ . . .

-g~ ~ lh ~ ~
'\
'-{).
~.~ fPI\. ~ .1 CHARG NG R FROM . C ""
-
~~--~
~ r

~~
~ 31 62
' l(
- _: 1'- d roin trcp
n
c
G)
1 .
CYIInder for L cmbd contro l l er 6 : . " .
Qnd Overspeed stop ,,~ 1 . C l eon!n~ Hose set f or ~7 (1/2 -4 2 20m) 1 $ be
D f r om " ~I su pp lI ea by DOOSAN cs tool .
(1) l discorge orr. turbochorger- 2 . Press. reducl i on unit ond press. gouge are be
See l ub . l d i ogram. 0l:lt l et / 6 included C l eon i ng hose set.
222.5 Droin from chorge
- . coo e r ,
engIne bottom c h orge recei ver ond i;~
r-------------------------------------------, vopour d i scho rge ~~= OOOSAN ' 'I~ I t'! 'I '' Chcnged 7 M~ due 10
EXHAUST FLANGE 2, DIMENS I ONS (Acc. 10 I 86044) - out l et :i: 2009070! chcnge wo shI n g loo l 1
Open dro i n 2xzj8 p i pe !; OOOSAN 1;:,'t ' '1 'I'C.' . .
ENG . 00 THICKNESS PCO SIZE NO .OF HOLES end !
~,
200801 KARAM "I~o ~'I : o' 'I~ FII st , llue~ Q
5-6 L23/30H .350 m. 490 m . 16 rrm. 445 rrm . 22 rrrn. 12 e n g i ne bottom i~~ Dat. c_ . O,a... n CM"" ~'d De,<r;p\;onaIRe"" on R
6 23130 - 900 r pm 400 m. 540 m. 16 rrm. 495 m . 22 rrm . 16 ~i~ ~ DoosanEngine ]

D 7- 23/30 400 m. 540 rrm. 16 rrm . 495 nn . 22 rrrn. 16 ! .; ~ ~
7- 23/30 - 900 m
IDr
450 rrm. 595 rrm. 16 rrm . 550 rrm. 22 rrm. 16
ii~:~
"i ... " '''''' .." .".,.' ""

' ''''.0' ., .. ,..... .
~
5 28/32 400 rrm. 540 m . 16 rrm . 495 rrm. 22 rrm . 16 ~!i~ .,.j",,, ..., ',.. 23/30, 2 8/32 :
6 28 !32 450 m. 595 rrm . 16 rn. 550 m . 22 rrm . 16 ~:~~ ...': ~ .~,.~t ",.. COMBUST. AIR DIAGRAM ;
7 - 28!32 500 m. 645 rrm. 16 nm. 600 rrm . 22 rrm. 20 f~1g N/ S 2 <) ~
9 28/32 550 mn. 70.3 nn . 20 rrrn. 650 rrm. 22 m. 20 ~~ij
!!.!':
... ,..,....
0000
' .. ',,.,.,
42 - 012917
I"~. -'"
1/1
:
~
'---- , ,
,
OOC. . : 04-517!
1 Hull . : 139/ 3071
2 Hull . :_
Subject:
FLEXIBLE HOSE LlST FOR EXTERNAL

CONNECTlON
Note:
Attachments : Refer t o the content s f or drawing i st
20101 112 ~~~ C! Q C! Q Fi rst Issued.
Date Drawn Chk'd App'd Descri ption Rev.
~
Doc.
Doosan Engine .
3-5179-0
DOOSAN - DIESEL aae 1/9 - #'
REVISION HISTORY
D REV DESCR IPTlON

ENGINE

5 L23 /30 PART Machinery
Doc.
DESCRIP- .
3-5179-0

FLEXIBLE HOSE LI ST FOR EXTERNAL CONNECTI ON

Ooosan Engine CO. ,Ltd .
Page 2/ 9
FLEXIBLE HOSE LlST

FOR CONNECT
- Li st For F l e. Eterna l Connections

Connection Medium Type spec Drawing
1 Fuel l l expans ion DN20. 16, D I 2501 43-013831-0

2 Fue l l expal1siol1 joi l1 l DN20. 16. D I 2501 43-01383 1-0
3 Was le Flex ible 110se DN I5. I 6, DI 2501 42-012930-0
C3/C 16 lub FromSeparalor Flex ible 1,0se D25 , l, DI 2501 42-012933-0

lub Supply
C4 l ub Separa lol F b e 110se D25 , l, D I 250 1 42-012933-0
C13 Vapour Discharge Flex ible hose DN55. 10 , D I 250 1 43-013832-0
F3 Ven I1g Expans 011 al1l< Fl ex ible 110se DN1 5, l, D I 250 1 42-012930-0
G1 .. Fresl1 Wa ler Il1 let Cel1 sa DN80, l , DI2501 42-012931-0

G2 . . Fr esl1 Wa ler l COIl1pel1Sa DN80. 1 0 , I 250 1 42-012931-0
1 Colnp essed r Il1 l F b e 1,0se DN40. 40, I 2501 42-012932-0
2 Exhaus l Gas Ou l Expansiol1 joil1l 350 , 10, 86044 42-01244 1- 1
~ Doosan En&ine
Doc
.
3--5179-0
1 2 ' 3 4 PACON ge : 3/9
. DESCRIPT ION S I ZE ' ' WT (kgJ REMARK
1 10A-SCH.40 12 1
2 flANGE SEE OWG. HBF22 2
\ 550
81 2
- ff; -J
\
'. -
'-,;>:
'\) ( -~ f-~)
'_ u
?,

~ 45'':-
1
/
1
"-
3
'"
~

'00,
-
~.
\
JJ
293

L S IZE: DN20
!i~
30 j(j~
4-:iZ5J5 L PCD75
- \ \
~ I ~~

~~

1 V;::i~
2j~
~
'i;;~i--;;
_:i3
20080117
Oote
OOOSAN
KARAM
Comp .
~~;!
;~~
Drown
"11i'~
b'1!"~
Chk'd
ol~1[!
~~
App'd
First i ssued
De s cript i on of ReY is ion ,

.
,
~

Il 7 . .8
40
-,'
i~i
~~
Doosan Enine
-
~:~ "' l .: .. "., d,,,,, ; n<;l no .:
loIa ( K~ ): IoIater l,
-
D 105 ~~i~ P,oj e ct ;0": T,pe:
COMMON
2i=8 - ~ 11iU l:
~~ri 5"01.: SL ""

L EXPANSION JO INT
ClASS P ICKLING PICKLING WORK ING 5 PAINTING
WELD NG ! :i w 1 4 3 CD 16)
PARKERIZING GA LVAN I ZING PRESSURE PRESSURE INS IDE OUISIDE &806
. ~ ... :;
"; '
t.IS/MC . : 0'0. 1.... . :
a_58 .0 .
- 10 Kg/f' 21 Kg/f' - ~!':Z' 0079 43-013831
-. F
Doc. . l J-5179- 0
.... ' ... '>'" ' <" "" ' '''11 ' n r- ur r .
LlOYD ' S REGISTER OF SHIPPING , 72359 1615705-2

NORSK E VERITAS 172359 1615706-4
BUREAU VER AS , 72359 1615707 - 6
A~ E R I CAN 8UR EAU OF $HIPPING 17 23 59 161 5708-8
17235 9
REG I$TRO 172359 16157 12-3
GERMANISCHER LLOYD 1723 59 161 571 3- 5
USSR REG ISTER OF $H IPP ING RUlES 172359 1615714 - 7
KOR~AN R ~r, IS~ R OF SHI PPINr. 1 7? .1 S g 16 36 5 3 0- 3
F3,
8
Nom i n a l si ze: 15
WARN I NG: be used

for pre he a te d fu e l
Ho s e 10 be tested occord i ng \ 0 demonds octual
clossificaiion ond nctiono l au t horitie s
Se e se rv i ce l ee r no.:S L9 0 - 2 5 7
I nsirucl a I mount i ng: See drowing no. 1602393-7

c and monufoctures instruct ions.
Fi eld , c oI a. W.cr l i c ol a.
..11500253-7, 1409203-0, 1610285-3.
Fresh
Th i s i s c CADAM drowing cnd shou Id not be crrec ed hond
Di ese l lub.
Pr e ssure
r woler
Max. work l ng
93 93 45 100
lo mn 'C
Mcx. work l ng
10 10 30 5
r e s s . bot
Doosan EnIne
FlEX IBlE HOSE

IDIN , PN16J
000. . : 13-5 179-0

~
C l oss f icot lo no. Par . PCD ,10
LlOYD'S REG ISTER QF SH IPPING 172359 1615741-0
D NORSKE VER 5 172359 1615742-2
BUREAU VER $ 172359 1615743-4
AMERICAN BUREAU OF SHIPPING 172359 1615744-6
172359
~I ~:
REGI$RO L 172359 1615747-1
GERMANISCHER LLOYD 172359 1615748-3
USSR REG I$TER OF SHIPP ING RUlES 172359 1615749-5
KOREAN REG ISTER QF $HIPP ING 172359 1636526-8
172359
172359 14
172359
172359
172359 650
8
Nom in e l s i ze: DN 40
WARNING: \ \0 be used
for preheo\ed fuel
See ser vic e l e \\ er no. :SL90 - 257
Hose 10 be tested occord i ng 10 demonds acIual
clossificotion cnd l outhoril i es
I nstruction for mounting: See draw i ng no. 1602393-7

manufaciures i nstructions .
Fe d f CQ t a: ne co t .
Th i s is CADAM drowing and should noI be corrected by hond

Di esel i l ub.
Pressure
r
M~ . work \ ng 11
93 93 45
...ll!!!JL. .:.<- i;
. work \ ng ~;~
10 10 30
~ress bo,
t~
~~
i ;;
~1~
~~! Doosan Englne
I~
;:;;
i~~i

F lEX I BLE HQSE
(D I N, PN4QJ
!"';i
: H'J
~!.!;
.r
OOt . . -; 3-5179-0
C l assificotion l . Por t .
LLOYD'$ REGI$TER QF SH IPP ING 172359 1615724-3
NORSKE VERITAS 172359 1615725-5
8UREAU VER AS 172359 1615726-7
AMERICAN BUREAU QF $HIPPING 172 359 1615727-9
~
REGISTRO
GERMANISCHER LLOYD

172359
172359
172359
1615729-2
161 5730-2
"-- ...:;;. c !..-6
USSR REGISTER QF SHIPP ING RUlES 172359 1615731-4
KOREAN REGI$TER QF $HIPPING 172359 163 6529-3
172359
172359
172359 ,
172 359
172359
Nominel size: 25
WARNING: Not to be used

f r prehea t ed fuel
Se e s e r c e e t t e r na.: S 9 - 257
Hose 10 be tested accord i n9 10 demcnds ac tu cl
clossificoIion ond l aulhorit i es
I nstruction for mounIing : See draw i ng . 1602393 - 7

c and monuIoctur e s i nstrucl ions.
F e d f co t : r ne . ,., : 1603255-4, 1600255-0, 1409205-4, 1408268-3
fRESH
Th i s is CADAM drowing and shouJd nat be corrected by hond
Die~el ' l ub.
Pressure
r WA TER
. work I ng
93 93 45 100
lemD . 'C
. wark l ng
10 10 30 5
es s . b
Doosan Enlne
Fl EX l8lE HOSE
D . 1 )
Doc, . : I3-5179-0
1 2 ' 3 4 PACON ge 7/9
. DESCRIPT I S I ZE IMAT'L b'TYI WTIkg) REMARK
1
418 PCD125
r- r-
\
..
-~ ~-
/ ~
- -- - - +
3
r-
r-lm
800
m~
L- ~ v1165
~!Y
10841 Supp ; e r ... .. 1089
- 14551 . . . . . . . ..
ype Power f e , . 0112085-063.
C l amp:E l af l e SK 2/76
13001 ter ; , .. Hose :Black synthet;c ; 16891 Sharp edges be removed.
res;stant r ubber tube
, w; th canvas i nsertion.
- Clamp :Steel
Flange:Stee l R St 37-2 acc.
16191 Med;um: ;
17100.
U ; r .
"
joo
!i~
-
17 601 emperature. -30'C - +70 ' C ~~ 20080 117
~<g;! o l ~~ ol~'
Firsl issued
~!
KARA~ ~ I~ ~ ~~: ~~
_: Oote Com. Dro..-n Chk 'd App'd DII I cripl i on Rew iJi on Re .
10021 Wo r k ; ng r e s s u r e. : .0.5 BAR io;
il"!
~ Doosan EgIne ]

Hose be mounted w;th f l a nge, w; t h ma t ; ng
d;mens;on occ. 50 , 10, 2501 . ) : IoIcIt .. , ! : R"I. l ~ .... o, 11''''' ; 1>9 .:
1638334-9 ".
~o!:! -
)
.E~~ Ptoj.~ti,,": ,.:
COMMON
!~B } .. 1 J{~ r t t:
Ii ....
:=~i Sl.: 5 1.: FLEX IBLE HOS E
ClASS P ICKLING PICKL I NG AND
PARKERIZ ING GAlVAN IZING
WORK ING
PRESSURE
1[5
PRESSURE
PAINING
INSIDE OOTSIDE
WElD I NG !:i'"
&808
1/2 3 <, 0)

~!ij 1oISJI.C .: D.". I"ll . : e"i" \ " no . :
- - - Kg/Z - g/- - - - ~!'.!.D' 0079 43-013832
F
Ooc. . "~vJ-5179-0
FIE l O OF A PP l l CA I ON
COMPEN5AOR . For mo r in e l i ca! .
m Med ium: Seo fres h coo l i ng wo t er Med ium: $ and fresh coo l i ng woter
~ Work i ng t emerotu r e il Wo rk i ng t empe ro t ure:

$ec 90 C Seo woter 50"C
Fr esh 90 C Fresh 90"C
f2I Work i ng pressu r e : 16 m Wo r k i ng pressure 10 Bor
m es t press u re: 25 ~ es t pressure ' 15 Bo r
rn Moke: 1030 cmb i enl cond i l i on

t emerotu r e 55"C
Supp l ier: 1089 5 C h um i d i ty
8 *~ ype: ERV-R ClA$S I F ICA I ON :

Sho l l be occordonce wi th
[JQQ] MoIerio l t he rules c l ossification vo li d
F Iange : D 17100 r . 51 37-2 . Remo r k: $pec i o l design wit h
l iner: { ) ll OY DS REG I S E R OF SHI P?I NG. s I i tted ho l es.
Re i nfo r cem: ny l onco rd (Oes : Bu rme i s l er & ) ,
Cover: ( ) NORSKE VER I TA5.
BUREAU VER I AS .
GERMANISHER .
AMERICAN BUREAU OF SH IPPING .
U.5. COA5 T GUARD.
USSR REGI5 ER OF SH IPPING .
KOREAN REG I SER OF SH IPPING
9>-
.
. INFQ . NQ . HOlE WE I GH
.
. PAR . 8 C
DI AM.
PCO (KG J

ERV-R 25 . 16 h i s , c CADAM drow i ng ond shou l d cor r ecied by hond

25 1635748-0 199986 25 115 130 18 4 85 2.3
32 ERV-R 32.16 1633955-3 199986 32 140 130 18 4 18 100 2.7
40 ERV-R 40, 16 1633956-5 199986 40 150 130 19 4 18 110 4
50 ERv-R 50. 16 1633957-7 199986 50 165 130 19 4 18 125 4.5
65 ERV-R 65. 16 1633958-9 199986 65 185 130 19 4 18 145 5.0
80 ERv-R 80. 16 1633959 - 0 199986 80 200 130 21 8 18 160 6.5
100 ERV-R 100.16 1633960 - 0 199986 100 220 130 21 8 18 180 8
125 ERV-R 125. 16 1633961-2 199986 125 250 130 21 8 18 210 9.5
150 ERV-R 150.16 165451<-- 1 199986 150 285 130 21 8 22 2' 0 13. 2
THIS DRAW ING 1$ REP l ACEMEN FQR 10 . .' 1827031. 1001389-0, 166704. 1827059, Doosan EgIne
692226-3, 16 14308 - 1, 692227-5, 10099 75-6 .
COMPEN$A TOR
(O IN, PN10J
F
Doc . . : ~517!rO
< , ."
" " ""
Min . mov eme nt . I Jpr ing 8e ll ows

l t m) [o I erolt[rn] l Lclerol ..f . .l
BC D Di Ln N,i25d l l: l l= (N/m) (N/nn ) plyes Convolul Ma s s IkgJ ! .
200 320 280 222 2 44 205 490 8 , 18 16 50 75 75 15 3 2,(5- 12) 21 1627934-3

25 0 3 75 335 276 294 255 350 12,18 16 68 28 54 37 3 2, ( 5 -12) 18 167 3 441 - 7
250 375 335 276 298 259 545 12,18 16 50 75 75 20 3 2, ( 5 -1 2) 28 1627935 - 5
&(
300 44 0 395 327 344 306 350 12,22 16 68 28 62 60 3 2, ( 5- 12) 22 167 0 058-0
300 440 395 32 7 353 305 5 60 12,22 16 50 75 75 20 3 2, ( 5 - 12 ) 38 1627936 - 7
- 350 490 445 359 38 4 337 490 12,22 16 100 50 75 30 3 2,(5 -1 2 ) 40 1627937 9
40 0 5 40 495 4 10 435 38 8 49 5 16,22 16 100 50 75 40 3 2,(5 -1 2) 43 1627938 - 0 -
4 50 595 55 0 4 61 486 439 500 16,22 16 100 50 75 50 3 2, ( 5-12) 48 1627939 - 2
5 00 645 600 5 12 53 7 490 5 20 20,22 16 100 50 75 60 3 2,( 5- 12 ) 54 162794 0 - 2
5 50 70 3 650 5 63 587 5 40 5 20 20, 22 20 100 50 75 70 3 2, ( 5-1 2) 65 162794 1- 4
600 754 700 614 6 39 592 535 20,22 20 100 50 75 80 3 2 ,( 5- 12) 79 16 27 942 - 6
65 0 805 750 665 689 643 535 2 0 ,22 20 10 0 50 75 100 3 2 ,( 5 - 12) 88 16 4 6653 - 0
700 856 800 7 16 740 693 555 24,22 20 100 50 75 110 3 2 ,( 5 - 12) 98 16 27 943-8
750 907 860 767 791 736 635 24 , 22 20 100 50 90 14 0 3 2 , (5 - 12 ) 1 14 1644984-9
80 0 958 900 8 18 842 787 6 35 24,22 20 10 0 50 10 0 18 0 3 2 ,( 5-12) 13 3 1644985-0
-
lill be s tomped. . WQRKING CONOli l ONS

N x0d (CJ: 500
-
,----- 010 . PRESSURE (BAR ): 2.5
[]

MATERIAL
c (( '\ 0
-
~0
<t as Q Q FlANGE : DIN- 17100 W. NR. 1.0038
MEMBRANE: OIN- 17 4 40 W.NR . 1. 4541
L, 00
'---
- R I NG : DIN-17 4 40 W.NR.l. 4 541
-
l..
- Fl onQ e s ocl dinq 10 8 6 044.
CQNNECT ING TUBE:

DIN- 174 40 W.NR 1.4541
,

I~!' DOOS AH ! ol1lt " :.''
~
(ffi] Mck e s im i lor: Ref. . 1349. 200O~13 Oe l. ! e c! DN3S0-57 6 L 1
KARAII 1111.1:. 'I t ~ I t:~
~OOSAN t;~f" 11 'l.' 'I~'
lillI !l r i s i ss u ed
Type Doub le corbin e d
Ger"ls e I !or re sil i ent mount i ng .

mo \'eme nt .
"
J::
2008010 '
"'"
.ll
,_
ooJ r ~
!, ""
1:1":
CM ,.
1:,:;
~p'" o i pl i on tt ' .~ ..
D
lillI
nom i ne l bore: 2 00mm - 800mm.
be mo r ke d with: Monuf o ctors trod e -
i
~
;1'1
:,
... " ... , ""0'"''
C03 "...Doosan
...... -
EngIne
16 182 66- 9
mo r k, ye or/month . !
~!,; COW.ON
1,0 1.. " .. t ... ,
.. , ~= ""
Compe n so to r ( e xhous t 9 0S on l y , ~= I.! "01 0, I , , CQMPENSATOR
-
, .,
i.r
. o51 j
~.liA
" ---N/S
0079
2
.'..'.....
(Q
4 2-01 24 4 1
)
1"'" -
Ooc. . : lA03-S 179-0
Client : Yangzhou Dayang 5hipbuilding Co.,Ltd.
Tier 1 Hull . : DY139/DY3071
Tier 2 Hull . :_
5ubject:
SYMBOL LEGEND FOR PIPING

DIAGRAMS
Note:
Attachments : Refer t o the content s f or drawing ist
201 01115 ~~ ~ EH ~ ~ EH ~ First Issued.
Date Drawn Chk'd Ap'd D escr i t i o n Rev.
~
Doc.
Doosan Engfne .
MR07 -5179-0
DOOSAN - DIESEL Page 1/ 9- #'
REVISION HISTORY
REV DESC RIPTlON
ENG INE

5L23 /30 PART Machinery
Doc.
DESCRIP- .
MR07-5179-0

SYMBOL LEGEND FOR PIP ING DIAGRAMS

Doosan Eng ine CO. ,L td.
CONTENTS
Rev . DESCRI PT ION DWG . . SHEET

APPROVAL DRAW ING FOR SYMBOL &LEGEND FOR PIP ING 44-0 12750- 1 7
ENGINE

5L23 / 30 PART J Machinery
Doc.
DESCR IP- .
MR07 -5179-0
10
SYMBOL LEGEND FOR PIP ING DI AGRAMS

Page : 3/9
Symbol & Legend for Piping Diagrams
Note:
3
2
20071220 ~~ -6:I .f1 ~~ O I~ cJ Improved image for basic symbol 1

200711 21 ~EH ~ ~~!!- ~12J First issued.
Date Drawn Chk'd App'd Description .
COMMON MS/MG COMMON
~
Drawing
Doosan Engfne .
44-012750
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CONTENT
1.0 Code Identification for lnstruments
2.0 Standard Text for Instruments
3.0 Basic Symbol for Piping
44-012750
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1.0 Code Identification for Instruments
~ Measuring device
~. Local reading
Te mperature Indicator - . 40
Measuring device
==

22 Se nsor mounle d ' / .l
engIne
Reading/idenlificalion mounled a panel
Press ure Indicalor - . 22
Ihe engine/unil
~
Measuring device

12 S ensor mounle d eng Ine
' / .l
Reading/idenlificalion outside Ihe engine/unil
Temperature Alarm High - . 12 *
~
Measuring device

22 Sensor mounle d engIne
' / l.
Read ing/idenlificalion a panel Ihe engine/ unil and
reading/indicalion outside Ihe engine/unil
Pressure Transmitting - . 22 *
: Refer 10 slandard 10 ca1on and lexl for inslrumenls Ihe following pages.
Specification letter code for measuring devices

First Letter Following Letters
F Flow Alarm
L l D Differential
Pressure Element
S Speed, System High
Temperature Indicating
U Voltage L w
V Viscosity S Switching, Stop

Sound Transm itting
Position Failure
V Valve, Actuator
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2.0 Standard Text for Instruments

L WaIer System
inlet 10 air cooler 04 l
10 alternator 07 il 10 lub. l cooler
02 l l from air cooler 05 utl 10 air cooler 08 l 10 FW cooler (SW)
03 l from lub. 0;1cooler 06 outtet from FW cooler (SW) 09
Water System
10 l l 10 engine 14 t
10 air cooler 17 l from FW coofer
10 FW 10 engine 1 4FW l 10 air cooler 18 inlet 10 FW cooler
11 ll l from each cylinder 148 FW oU Irom air cooler 19 preheator
12 outlel from engine 15 outlet fro m system 1 9 l 10 prechamber
13 inlet 10 pLlmp 16 outlet from tLIrbocharger 198 oullet from prechamber
Lubricating l System
20 inlet 10 cooler 24 sealing l . l engine 28 l l base frame
21 U!l from cooler l 10 l 25 prelubricating 29 main bearings
22 UI l from ll 10 engirle 26 rocker arm s and guides
23 l 10 turbocharger 27 inlermediale bearing alternalor bearing
Chargi ng SysIem
30 l
10 cooler 34 charge air conditioning 38
31 ul Irom cooler 35 surplus air l l 39
32 jet assisl system 36 l l 10 turbocharger
33 ou!let from TC f l l 10 TC comp . 37 charge air from mixer
FueI 011 System

40 l 10 engine 44 oullet from sealing l pump 48
41 tl l from engine 45 fuel-rack posilion 49
42 leakage 46 l l 10 prechamber
43 l 10 t 47
Nozz le Cooling System
50 l 10 l valves 54 58 il splash
51 outlet from fuel valves 55 valve liming 59 alternator load
52 56 injection liming
53 57 earth/diff. proteclion
Exhaust Gas SysIem

60 tl l from cylinder 64 68
61 ll from lurbocharger 65 69
62 l 10 turbocharger 66
63 combustion chamber 67
Compressed System
70 l 10 engine 74 l l 10 reduction valve 70 lel 10 engi rIc
71 inlel 10 slop cylinder 75 micro swilch for turning gear 71 l l10 slop cylinder
72 l ll bala nce arm l 76 l 10 turning gear 72 l 10 balance arm l
73 conlrol air 77 waste gate pressure 73 conIrol air
Load Speed
80 overspced air 84 engine slop 88 index - l injeclion pump
81 overspeed 85 micro swilch for overload 89 turbocharger speed
82 emergency stop 86 shutdown 90 engine speed
83 engine start 87 ready 10 start
Miscellaneaus
91 natural gas - l 10 engine 94 cylinder lubricaling 97 remote
92 l mist deteclor 95 voltage 98 alternator winding
93 knocking sensor 96 switch for operating localion 99 common alarm
~SE~ Doosan Engine ",~~Ingl 44-012750
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3.0 Basic Symbol for Piping
SYIllbol Symbol desigrlatroll Syrllbol Syrllbol dIi&lgIlalroll
1. GENEAAL CONVENTlONAL SYMBOLS 2.14 ~I- Spectacle 11l9
1. 1 -- pe 2.15
-I!f- Orifice
12 ~ i'Ii1l1IndicaIion d.recllOll 110'11 2.16 ~

Onfice
~
1.3 I><J , l v:.lVGs. cocks (lnd flaps 2.17 --1Uf- expansion
1.4
D Applk'tt1ces 2.1. < Snap coL pl ing
15
IndIC3ling and me3SUriIX) insIruments 2.19 V PI1QUnlJtic 110\',' &x/)3USt 10 alnlospl'lre
1.6 --- gh- re$~r r pipe $. VA.VES. GATE VALVES. COCKS AND FLAPS
1 --"--- Trilcirlg
c*: l . slraight througtl
Enclosure , seveml componenls lS

1.8 -_.- semblGd 0116 !J Vale.angl e
2. PIPES .JOINTS
ifJ lV. hr- ''l a
2.1 -+ Crossing 8.1101 cOI1f1&CIed ~ l-:l l/ "l (nap), slraJghI
2.2
+ CrOGSIllg pipos, co l
~ I valve () ,
' I al\'
angle
(1Iap), straight screw

2.3 --L
t>Lo do''!
2' v\. Rexible &

~ &II \'< (Ik..,p), 61191&, sc r'l/ (Jov/n
25 0- Expanson ppe {cor ru gn Ie(l) Qeneral

*J SafeIy vatve
2.6
+ Joil1l. scre\',ed
h Angle saIeIy
2.7 -+- Joint, fIal1ged

tk $ell-closil1g l
2.8 ........... JOIllt, sleevQ

c:J Ouick-or~nI I1g vatve
2.9
+ Joint, quick relessing
*J Quickclosing \'!
2. 10
2 11
---
.n....
Expcnsion n viU\
Expanson
gland
rJ<
&
AeguI"ting l\'
8.111vatve cock)
2. 12 ----J] Cpr1UI
>< 1 I l
2.13 -11 Blnnk 110119& r>k Gntevalv&
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Symbol
"" Symbol designaIion Symbol Synlbol,IesigooIion
3. 17
~ {)oLIbIQ-seaIGd cl'\angOvQr vaI'o'Q 4. CONTAOL D AEGULATION $
3 18 ~ SLlcIon vatve ches! 4.1 FarroperJted
319 ~ Suc1iorl VJ,le chest wittl IlonreUrn .1I\'6$ 4.2 ( Aelnole control
3.20
c*J DoL,I)le-seaIecl chuJlQOver , sIraighI 4.3
Sng
3.21
Js:3 Dooble-seaIod chngeover wle, angle 4.4 r-D MaS5
3.22 [;():J Cok, Stmig/1I tlnoLIgh 4.5 ~ FIoJ!
:;
3.23 QJ Cock,on918 4.6
PisIon
3.24
~ Cock. - . -! l1 lJ 4.7 MembrnrlQ
3.25 CJ Cock, Ihree-\vay. Tport plug 4.8 @-- Elct'lc molor
*
3.26 Cock, -,'/ , sIrIighl Ihrougtl plug 4.9 fY\ Electromagnelic
3.27 @J Cock " l 00110111 connecIioll 4.10 FC: l (at pneurnaticvalvesj
3.28 C@J Cock. sIrltigllt IJvough. I'/~Il boIIom conn. 4.1 1 c:C PUSll bIIIon
3.29
~ Cok, angle. I'/ll1 botlom COI1 nx:lion 4.12 '~L- Spnng
3.30
~ Cock. IhreQ\vay, \vith botlonl col'1nQCIion 413 rIL Solenoid
3.31 -~
1
llslalic vale 4.14 zsL Solel'1oid < l directiolnl 1l
3.32 r:J< l \viIh Iesl flo.nge 4.15 q plungeror Iracer
3.33
~ 3....vay l )':ith IlIol 0(1)1101(acUalor) 5. APPLIANCES
3.34 - Not- I'U1 .1l (air) 5.1 [] /I'1 ldbox
3.35
$ 312 sprir1g retu m vDle. no lf closed 5.2 ~ FiIIer SIr..,iner
3.36 -{C]- 2/2 spring relurrl l . normally dose{1 5.3 c;:::: MtIgrlelic lillQl
3.37 -JSj- 312 sg l1 valve oor1lr. by soleold 5.4 QJ S6paraIoI'
3.38 --9""1- RE"dcIng l (odjuslble) 5.5

~ SIoorn trap
/ ll ~' conIrolled by solenoid lnd lo

3.39 ..::J- directiolk11 l v/ilh 5pring relum 5.6 ,, Cenlrifugal
Englne 44-012750
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. SYlll001 Synlbo1 O)5:~o . Synbol Symbol d @signm kn
5.7
: ~ .screw 6. FITT INGS
5.8 r; Hand lm b.:k&l) 6.1

Funnl l wastOc'! tray
5.9 3 EjItor 6.2

..L

510
= rlOI$ rr.ce ssones {leX110 l>e O-dded, 6.3 '---r' \aS1e tray
.......,.,.
5.11
PiSIQrl plImp 6 .. 'l"flsle lray with plLIg
5.12 cg- Heal eXChaI l gBt 6.5

Tlrrbocllarger
5.13
\l Electr;c ~~t I a.;r r 6.6
~ Flel l lll1
..J.L.
5.14 -<!>- Aitfilter 6.7 -rr ~anng
515 -- ' fiIIer ,viII,rnanuaI conlrol 6.8

tl\ V{aIer jack(j:!
-
~
il l ...Il1 alac drflirl 6.9 o..'e~~d d",'J1ce
*
6.16
517
< V-liIter traj) with In:~ n ual conIrol 7 READING $ \OVITH O AOINAR DESIGNATlON$
5.18
-<>- , lr brica tor 7. 1 (') Sigl1t flovl indic"Ior
<
~
5. 19
...
Sileflcer 7.2 OL'SerVAton gass
Fixed capacily &Ll1<l c motor willl

5.20 - direction 0/ f ",Y'
73
~ Level i lldi~lor
5.21 8 Sitlg1e a::tit\9 c:ylit1det vt'ith spn t g telttnled 7.4 .; Otslance 19l indicator
5.22 8 Dobl actJg y1i Il d er II spirlg e.! 75

~ Re
5,23
~ Stmt <l
Doosan Englne 44-012750
Doc , , 07 - 5179- 0
'!NRI D0058n Enaine
5 23/30 720 RPM

5-1. FUEL IL SPECIFICA 10
5-2. LUBRICA T1NG IL SPECIFICA 10
5-3. LUBRICA T1NG IL QUANTlTlES BASE FRAME
5-4. FRESHWATER TREATMENT SYSTEM

Tier 1 ll . : DY139/DY3071
Tier 2 ll . :-
Subject :
FUEL IL SPECIFICATlON
Note:
Attachments : Refer the content s for drawi ng i st
201 01115 ~ ~ ~EII ~ ~EII ~ Fi rst Issued.
~
Doc.
Doosan Engine .
MR08-5179-0
DOOSAN - DIESEL aQe 1/15 - f'
REVISION HISTORY
DATE REV DESCRIPTION
20 10111 5 First Issued.
ENGINE

Doc.
DESCR IP- .
MR08-5179-0

FUEL IL SPECIFICATION

Doosan Engine CO., Ltd.
." DOOSAN - DIESEL aae 2/ 15
CONTENTS
Rev . DESCRIPT ION DWG . . SHEET

APPROVAL DRAW ING FOR FUEL I L SPEC IFICATION 44-012709- 0 11
VISCOSITY - ( ) DIAGRAMOF FUEL I L 34-030683- 0 2
ENGINE

Doc.
DESCRIP- .
MR08-5179-0

FUEL IL SPECIF ICATION
Doosan Engine CO .. Ltd.

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Fuel l Specification
Note:
3
2
1
20071115 idEH ~ o l ~~ o l ~~ First issued.
Date Drawn Chk'd App'd Descriptio n Rev.

Type COMMON MS/MG COMMON
~
Drawing
Doosan Englne .
44-012709
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CONTENT
1.0 Marine Gas l
2.0 Marine Diesel l ()
3.0 Heay Fuel l (HFO)
4.0 Guiding Heay Fuel l Specification
5.0 Blends
6.0 Vanadium / Sodium
7.0 Ash
8.0 Sulphuric Acid Corrosion
9.0 Fuel l Condition, When EnIering the Engine
10.0 Viscosity Adjustment
11.0 Fuel l Cleaning Recommendations
~ Doosan Englne Drawing

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1.0 Marine Gas l
MGO is a medium class disti llate oil which therelore must not contain any
residual components.
The key property ratings reler to CIMAC #21 12003.
Property Units Value

3
Density at 15 'C min . kglm 820
max. kg/m3 890

Kinematic Viscosity at 40'C cSt(mm 2 /s) > 1.50
2
cSt(mm Is) < 6.00
Flash Point 'C > 60
Water content % by volume < 0.05
Sulphur content % by weight < 1.50
Ash % by weight < 0.01
Carbon residue (10% ) % by weight < 0.30
Minimum injection viscosity at entering the engine > 1.5 cSt.
2.0 Marine Diesel ()
is offered as heavy distillate (CIMAC) as a blend distillate and

small amounts residual l (CIMAC) exclusively lor marine applications.
The common ly used term lor the blend, which is dark brown to black
colour, is Blended .
is produced Irom crude l and must be Iree Irom organic acids.

The key properties are based on the test methods specilied.
Reler to the lollowing page lor the property .
ffi D_. E~ 1 Drawing

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FueI Specification
CIMAC #21/2003 D DC
3
Density at 15 "C kg/m :;:; 900 :;:; 920
Kinematic Viscosity at 40 "C cSt(mm%) < 11 .0 < 14.0
Flash ! "C > 60 > 60
Water content % by volume < 0.30 < 0.30
Sulphur content % by weight < 2.00 < 2.00
Ash content % by weig ht < 0.01 <0. 05
Carbon residue % by weight < 0.30 < 2.50
Vanadium mg/kg - < 100
Aluminium + Silicium mg/kg - < 25
Minimum injection viscosity at entering the engine > 1.5 cSt.
3.0 Heay Fuel l (HFO)

Commercially available luel oi ls with a viscosity to 700 cSt at 50 0 C
corresponding to 55 cSt at 100 0 C can be used lor DOOSAN-MAN & lour-
stroke medium speed diesel engines.
For guidance purchase, relerence is made to ISO 8216/17, BS 6843 and

to CIMAC recommendations regarding requirements lor heavy luel lor diesel
engines, #21 /2003. From these maximum accepted grades are 55 and
55.
It means that engines can be operated the same luel oils as DOOSAN-
& two stroke lw speed diesel engines.
The data the HFO standards and specilications reler to the same luel type
as delivered to the ship, i.e. belore on-board cleaning.
order to ensure ellective and sullicient cleaning the HFO, i.e. removal
water and so lid contam inants, the luel l specilic gravity at 150 C (60 0 F)
should be be low 991 kg/m3. Higher densities can be allowed l special
treatment systems are installed.
~ _ gl. Drawing
.
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FueI Specification
Current analysis inlormation is not sullicient lor estimating the ignition and
co mbustion properties the l. This means that service resu lts depend on
il properties which cannot be known belorehand. Thi s especially app lies to
the tendency the il to l orm deposits in combustion chambers, gas
passages and turbines.
4.0 Guiding Heay Fuel l Specification

Based on general se rice experi ence h ae, as a supplement to the
aboe - mentioned standards, drawn the guiding HFO specilication shown
below.
Heay luel oils limited by this specilicati on hae , to the extent the
commercial aail abi lity , been used with satislactory results on &
lour-stroke medium speed diesel engines.

Density at 15"C kgIm 3 :5 991 1)
Kinematic Viscosity
2
at 40"C cSt(mm Is) :5 55
2
at50"C cSt(mm Is) :5 700
Flash Point "C > 60
Pour Point "C :5 30
Conradsen Carbon Residue % by weight :5 22
Micro Carbon Residue % by weight :5 22
Ash content % by weight :5 0.1 5
Total Sediment alter Ageing % by weight :5 0.1
Wate r content % by olume :5 1.00
Su lphur content % by weight :5 4.50
Vanadium mgIkg :5 600
Aluminium + Silicium mgIkg :5 80
CCAI - ** 2)
Asphaltenes - :5 23 carbo n residue
FIA Cetane Number - *** 3)
Drawing
.
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1) May be increased 1.01 (kg/m3) provided adequate cleaning

equipment is installed, and modern type centriluges.
2) 1I the CCAI value exceeds 840 ! is recommended have the FIA

index measured revealing l ignition and combustion problems may
arise.
1I the CCAI value exceeds 840 ignition and combustion problems can
occur.
3) 1I the FIA value is below 20 increasing ignition and combustion

problems may be loreseen at lw load operation .
1I heavy luel oils, with analysis data exceeding the besides ligures, are be
used, especially with regard viscosity and specilic gravity, the engine
builder should be contacted lor advice regarding possible changes the luel
il system.
5.0 Blends
Fuel l containing used lubricating l (ULO) has comply with the CIMAC
#21 /2003 luel l specilication.
The admixing used engine l the luel involves a substantial danger

because the lubricating l additives have an emulsilying effect and keep dirt,
water and catfines linely suspended. Therelore, they impede preclude the
necessary cleaning the luel. We ourselves and others have made the
experience that severe damage included by wear may occur the engine
and turbocharger components as a resull.
The admixing non-mineral l constituents (such as coal l ) and residual

products Irom relining other processes (such as solvents) is harmlull the
engine! The reasons are, lor example: the abrasive and corrosive effects, the
adverse combustion properties, a poor compatibility with mineral oils and, last
but least, the negative environmental ellects.
The order letter lor the luel should expressly mention what is prohibited, as
this constraint has ! yet been incorporated the common ly applied luel
specilications.
Drawing
.
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The admixing chemical waste materials (such as solvents) to the luel is lor
reasons enviro nmental protection prohibited by reso lution the
Marine Environmental Protection Committee 1 Jan. 92.
6.0 Vanadium / Sodium

Should the vanadium/sodium ratio be unlavourable, the melting temperature
the heavy luel l ash may drop into the range the exhaust valve
temperature which wl l result in high temperature corrosion and deposits build
up. precleaning the heavy luel il in the settling tank and in the centrilugal
separators, the water, and with it the water-so luble sodium compounds can
be largely removed.
1I the sodium content is lower than 30% the vanadium content, the risk
high temperature corrosion will be small. It must also be prevented that
sodium in the lorm sea water enters the engine together with the intake air.
1I sodium content is higher than 100 mglkg, an increase salt deposits is to

be expected in the combustion space and in the exhaust system. This
condition w ll have an adverse effect on engine operation (among others, due
to surging the turbocharger).
Under certain conditions, high-temperature corrosion may be prevented by a

luel additive that raises the melting temperature the heavy luel l ash.
7.0 Ash
Heavy luel oils with a high ash content in the lorm loreign particles such as
sand, corrosion elements and catalyst lines (catfines) in heavy luel oi ls
coming Irom catalytic crackin g processes. In most cases, these catfines wll
be aluminium oxides, silicium oxides, which causes high wear in the injection
system and in the engine.
8.0 Sulphuric Acid Corrosion

The engine should be operated at the coo ling water temperatures specilied in
the operating manual lor the respective load. 1I the temperature the
component surlace exposed to the acidic combustion gases is below the acid
dew point, acid corrosion can occour.
~ Doosan Engln. Drawing

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9.0 Fuel l Condition, When Entering the Engine

As praclically all fu el il specilical ions including Ihe above slandards reler 10
Ihe same luel lype as supplied, Ihe fuel supplied 10 a ship has 10 be Irealed
board belore use. For running Ihe l qualily menlioned above l is
necessary Ihal equipmenl exisls board, which can Ireal, respeclively clean
and preheal, Ihe luel l wilh oplimum efficiency.
For economical HFO operalion the fu el l condition al engine inlet should be

as recomm ended below.
Proper1y Units Value
Water % byvolume maX. 0.2

Solid par1icles ppm (mgIkg) maX. 20
Par1icle size Micron maX.5.0

2
Viscosity cSt(mm Is) Range 12-18
For luels above 180 cStl50 C a pressureri zed luel l syslem is necessary to
avoid boiling and loaming the luel.
The preheating char1 Ihe following page illustrales Ihe expected

preheating temperature as lu nclon ! Ihe specific fuel il viscosily.
The viscosity leaving the heaters should be 10-15 cSt and approx. 12-18 cSI
enlering Ihe engine.
10.0 Viscosity Adjustment

enable a proper injection viscosily and a to prevenl overloading the fu el
equipmenl it is essenlial to maintain a constant viscosily within the Iimits
slipulaled, see preheating char1 the following page.
vessel heated either by steam electricily adjusls the viscosity the luel.
There are Iw means adjusling the power supply 10 Ihe vessel :
Either by measuring the lemperature Ihe media,
by measuring the viscosity the media
II;ffi Doosn Enpne Drawing

.
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Page 11 / 15
Fuel l - Preheating Chart . viscosily

aft.r prel1eater
Ternperature sec.
cSt Rlv.
after prel,eater ' C
7 43
170
10 52
160
12 59
150
15 69
140
20 87
130
120
30 125
110
100
90
80
70
. plImping i!
50
40 1 - - - - - 1- - .. ........- -..
30
Log scales 10 15 25 $5 45 ~ 55 CS~100" C
30 60 100 180 380 700 cSV50' C
200 400 800 1500 3500 7000 sec, R~v/1 ? F.
Vlscostty fuel
ffl Doosan Englne Drawing

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FueI Specification
10.1 Temperature Controller

1I this method is chosen ! demands a laboratory apparatus enabling the stall
to test the luel l samples a regular basis and set the temperature
controller accordingly. The Irequency is dependent the homogenity the
luel ie. how olten charges are received and how well these are blended the
tanking system .
The reason being that the charges the luel oils may vary considerably
properties eg. Iractions, viscosity indexes, etc.
10.2 Viscosity Regulator (Viscorator)

1I this method is chosen the viscosity the luel l is monitored continuously
and the temperature is adjusted at the set value depending the quality
heating elements and the controls these.
11.0 Fuel l Cleaning Recommendations

Fuel oils should always be considered as contaminated delivery and
should therelore be thoroughly cleaned to remove solids as well as liquid
contam inants belore use.
The so lid contaminants the luel l are mainly rust, sand, dust and relinery
atalysts. Liquid contaminants are mainly water, i.e. either Iresh water salt
water.
Impurities the luel can cause damage to luel pumps and luel valves, and
can lead to increased cylinder liner wear and deterioration the exhaust
valve seats. Also increased louling gas ways and turbocharger blades may
result Irom the use inadequately cleaned luel l. Ellective cleanin g can
only be ensured by using a centriluge.
We recommend that the capacity the installed centriluge should, at least,

be according to the centriluge maker's instructions.
Cleaning distillate luel such as 180 8217 classes to is generally

! necessary. ! handling a Iiquid luel board ships gives a risk
contamination with sea water. Therelore ! is a good idea to centriluge all luel
board ships.
~ D....n Englne Drawing

.
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Fuel classes DMC to RMH55 require a treatment with centriluge all cases.
Automatic centriluges must be used. Fuel types RMK35 to RMK55 require

centriluges capable to handle to 1 kg/m density.
3
obtain optimum cleaning it is the utmost importance that the centriluge

is operated with a luel l viscosity as lw as possible, .. that the highest
possible temperature is maintained the centriluge l preheater.
Experience proves that l the centrilugal installation is dimensioned and

installed co rrectly - and operated correctly according to the supplier's
instructions - th is is a sufficient way clean ing the luel.
~ Doosan . Drawing
.
44-012709
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Viscosity - Temperature (VT) Diagram FueI
Note:
3
2
1
~ {f:
~ First issued.
20101007 ~ EII ~ ~ EH ~

Type COMMON MS/MG -
~
Drawing
Doosan EngIne .
34-030683
Doc. . : MR08- 5179- 0

Page 15/ 15
Viscosity - Temperature () Diagram FueI
, ~ ~ ~
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~ Doosan Englne D,~:;"g 34-030683
Doc, , MR08- 5179- 0

Tier 1 Hull . : 139/03071

Tier 2 Hull . :-
Subject:
LUBRICATlNG IL SPECIFICATlON
Note:
Attachments : Re fe r the contents fo r drawing i st
20101115 :d ~ ~ 8I ~ ~8I ~ First Issued.
Oate Orawn Chk'd App'd Oescription Rev.
~
Ooc.
Doosan Englne .
MR09-5179-0
DOOSAN - DIESEL age 1/10- "
REVISION HISTORY
REV DESCRIPTlON
ENG IN E

Doc.
DESCRIP- .
MR09-5179-0
10
LUBR ICAT ING IL SPECIFICATION

Doosan Eng ine Co . Ltd.

." DOOSAN - DIESEL age 2/10

CONTENTS
Rev . DESCRIPTION DWG. . SHEET

APPROVAL ORAWING FOR LUBR ICATING IL SPECIFICATI ON 44-0 12710- 0 8
ENG INE

Doc.
DESCRIP- .
MR09-5179-0

LUBRICATING IL SPECIFICATION

Page : 3/10
Lubricating l Specification
Note:
3
2
1
20071115 1dEH ~ O l {}~ O l {}~ First issued.
Date Drawn Ch k'd App'd Description Rev.

~
Drawing
Doosan Englne .
44-012710
Doc. . : MR09- 5179- 0

Page : 4/10
Lubricating Specification
CONTENT
1.0 Requirement
2.0 Guiding Values for
3.0 Treatment of Lubricating l
4.0 Criteria for Cleaning/Exchange
[ ~ ..." E"gI"e [ Drawing

.
44-012710
Doc. . : MR09- 5179- 0

Page 5/ 10
1.0 Requirement
Heavy Duty lubricating l has be used corresponding at least type CF
after serice system (http://apiep.api.org/fi lelibrary/ACF1 E1 .pdf).
Further the lubricating l should be rust and oidation inhibited.
Marine Application
SAE class 30' 105 cSt @ 40"C (For L23/30, L+V28/32H)
SAE class 40145 cSt@40 "C (For L16/24, L21 /31, L27/38, L32/40)
! cooling water temperatures above 32 0C SAE 40 l can be used.
In this case, please contact the engine builder.
Stationar Application
SAE class 40 145 cSt @ 40 "C
(For 16/24, L21 /31, L27/38, L23/3 0, L+V28/32H, V28/32S)
2.0 Guiding Values for
When selecting lubricating l, attention must be paid the fuel l sulphur

content.
Marine GenSet engines are normally running at lw load compared
propulsion engines, therelore the absolute luel consumption is lower and
consequently the lubricating l is eposed a smaller amount su lphur.
Therelore the BN-value (Base Number) the lubricating il has be lower
in order neutralize the sulphur input Irom the luel.
The lubricating il consumption has an inlluence on the recommended initial

value. When the lubricating l consumption is high, lw values is
recommended, and opposite.
The selection is based on typical load proliles lor marine GenSet (50-60%
rated power) and lor stationary GenSet (50100% rated power) .
BN(mg KOH/g)
il Type
For L32/40 For other engines
Gas l 12-15 8 12
Marine diesel 1525 10-15
Heavy luel l (S < 1.5%) 25-35 1520
Heavy luel il (S > 1.5%) 30-40 20-40

.
44-012710
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Page 6/10
For l loaded marine GenSet engines the lowest values are

recommended and for high loaded stationary engines the highest values
are recommended. the load is different, this should be taken
consideration . However, the operation results are the criteria that prove which
is the most economical one for efficient engine operation.
order to meet the emission regulations , more often fuel oils with different
sulphur co ntent are operation. ! harbor/coastal operation a l sulphur
fuel l ll be used and at sea operation a high sulphur fuel l ill be used.
he lubricating l value ll have to be evaluated from engine running
hours operating the two different fuel oils. Normally the value should
be evaluated from the fuel l with the highest sulphur content.
3.0 Treatment of Lubricating l
3.1 Operation Marine Diesel l (D)
! engine operation D we recommend to install a build centrifugal

by-pass filter as an additionally filter to the build ll l depth filter and
the lubricating l separator.
3.2 Operation Heavy Fuel l (HFO)

HFO operating engines requires effective lubricating l cleaning. order to
secure a safe operation ! is necessary to use a supplement cleaning
equipment together with the built ll l depth filter. For this purpose a
centrifugal unit, a decanter ! an automatic by-pass filter can be used.
Continuous lubricating l cleaning during engine operation is necessary.
he centrifugal unit, decanter ! and the automatic by-pass filter capacity to
be adjusted according to makers recommendations.
3.3 Cleaning Capacity

Normally, ! is recommended to use a self-cleaning filtration ! order
to optimize the cleaning period and thus also optimize the size
the filtration !.
Separators for manual cleaning can be used when the reduced effective
cleaning time is taken into consideration by dimensioning the separator
capacity.
~ Doosan Eglne Drawing

.
44-012710
Doc. . MR09-5179- 0
Page 7/ 10
3.4 he Required Flow

In order to evaluate the required lubricating l l through the separator, the
separator suppliers recommendation should be followed .
As a guidance, the following formula should form the basis for choosing the
required l for th e separator capacity :
Q = 1 .36 n/ t
Q = required l (I/h)
= engine output (kW)
t = actual effective separator operating time per day (hour)
n = number ! turnovers per day ! the theoretical l volume corresponding
to 1.36 l/kW 1 /
he following values for "n" are recommended:
n = 5 for HFO operating (residual)
n = 4 for operating
n = 3 for distillate fuel
3.5 Separator Installation

It is recommended to carry out continuous lubricating l cleaning during
engine operation at a lubricating l temperature between 95'C till 98'C at
enteri ng the separato r.
With multi-engine plants, one separator per engine in operation is

recommended, but only one separator is in operation , the following lay-outs
can be used.
common separator can be installed, possibly with one in reserve for

operation all engines through a system, which can be carried out in
various ways . Fig. 1 and 2 show a principle lay-out for a single plant and a
multi-plant.
he aim is to ensure that the separator is only connected with one engine at
a time. his to ensure that there is no suction and discharging from one
engine to another.
provide the above-mentioned it is recommended that inlet and outlet
valves are connected , so that they can only be changed-over simultaneously.
~ Doosan Enpn. Drawing

.
44-012710
DOG. . MR09- 5179- 0

Page 8/10
fl!J:NI~ 1
" N~'
09. c 2
Engil1e To/fronl $eparator ,
" ~' TdffQII1II!!)rjr;

l:;~!lI,!!!{
1'\9. Nc $
Fig 1. Fig 2.
Principle lay-out lor direct separating Principle lay-out lor direct
on a single plant separating on a multi plant.
With on ly one engine in operation there are no problems with separating,

but l several engines are in operation lor some time ! is recommended
split u the time so that there is separation on all engines, which are
operating in turns.
The capacity the separator has correspond with the separating l on

the single engine n times during the available time, every 24 hours.
4.0 Criteria for Cleaning/Exchange
4.1 Replacement Lubricating l

It is not possible to predict the epected l le time lor lubricating il , as ! is not
possible lor the engine manulacturer know which luel and lubricating l
qualities ll be used and under which operation conditions the engine ll be
operated.
replacement l lubricating l is required when the oi l's identilication values

have changed no that the lubricating cleaning and neutralization properties
no longer are sufficient.
Echange the lub. l has be based on the l supp liers evaluation

samples l in service. Samples shou ld be lorwarded at appropriate
intervals at least once every three months depending running-mode and
results last analysis.

.
44-012710
c. . MR09- 5179- 0
Page 9/ 10
he il sample should be taken after the lilter and, l possible, while the
engine is running as this ll ensure that the test ll be representative lor the
whole change in the engine.
4. 2 Evaluation the Lubricating l Condition

For evaluating the conditions a used l , the lollowing guidance condition s
are normally sufficient, Anyway, all param eters have to be evalu ated as a
whol e, and no single can be taken as a criterion lor changing l.
Vi scosity
Limit value : < 1 viscosity grade
Unit : SAE-units
Possible test : ASM 0 -445 (modilied)
method
Flash Point
Limit value : > 185'C
Possible test : Setallash test
method (cut point correlates with 204 'C, ASM 0 -92(coc))
Water Content
Limit value : < 0.5, prelerred < 0.2 (higher value is permissible in a
shor1er period)
Possible test : Patable test unit gas chromatography (or inlra red distil).
method 1I the limit value is exceeded, a supplementary test lor
chlorides (ASM 0-878) can be made.
Guiding otal Base Number (TBN -Number)
Limit value : Reler to Iresh l % : > 70%
Unit : mg KOH/g
Possible test : ASM 0-2896
method
Oue to the generating running mode, where the lub. l consumption depends
on running time and the luel il consumption and lollowing the sulphur input
the lub. l depends on the load, a lower BN-value than normal lor main
engines is needed.
Drawing
.
44-01 2710
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Page 10/10
Lubricating l 5pecification
Following guiding values can be given:

l Type
(initial) (equilibrium)
Gas il 10 7
Marine diesel 15 10
Heavy luel (8 > 2.5) 15 10
Heavy luel (8 > 4.0) 20 14
The is normally reduced gradually with the time operation. The

inlluential elements are the sulphur content in the luel l, the lubricating il
amount and the amount re-lilling due normal consumption . Alter a
certain time operation, the wl l stabilize at a lower value, the
equilibrium.
Neutralization Number
Limit value : 0.4-1.0 above typicallevel
Unit : mg KOHIg
Possible test : 8 0-974
method
Total Contamination IInsoluble Content) Heptane Insoluble

Limit value : < 1.0 generally, depending upon actual dispersant value
and the increase in viscosity
Unit : Weight %
Possible test : 8 0 -893 procedure in n-Heptane
method
Additional test : 1I the level in n-Heptane insoluble's is considered high lor
the type l and application, the test could be lollowed
by the supplementary determination in Toluene.
Also inlra red test can be used.
~ Doosan Drawing
.
44-012710
Doc. . MR09- 5179- 0

Cient : Vangzhou Oayang Shipbuilding Co.,Ltd.
1 Hull . : 139/03071
2 Hull . :-
Subject :
LUBRICATlNG I QUANTlTlES BASE

FRAME
Note:
Attachments : Ref er the cont ent s f or dr awing i st
20101112 :d21* ~;;~ :d ;;~ Firs! Issued.
Date Drawn Chk'd App'd Descri pti on Rev.
~
Doc.
Doosan Engine .
MR10-5179-0
DOOSAN - DIESEL age 1/ 5- #"
REVISION HISTORY
REV DESCR IPTlON

ENGINE

5L 23/30 PART Machinery
Doc.
DESCRIP- .
MR10-5179-0
10
LU8R ICAT ING IL QUANTI TIES 8ASE FRAME

Doosan Eng ine CO . ,Ltd.
DOOSAN - DIESEL aae 2/5
CONTENTS
Rev. DESCRIPTI ON DWG. . SHEET

UBR I CATING I L QUANTI TIES BASE FRAME 44-0 12747-0 3
ENGINE

Doc.
DESCR IP- .
MR10-5179-0

LUBR ICATING IL QUANT ITIES BASE FRAME

Page : 3/5
Lubricating Quantities Base Frame
Note:
3
2
1
20071 120 fd EH ~ fd~V ol~ ~ First issued.

Type L23/3 0 MS/MG COMMON
~
Drawing
Doosan Engfne .
44-012747
Doc. . : MR 10- 5179- 0

Page : 4/5
Lubricating Quantities Base Frame
CONTENT
1.0 l Quantities
2.0 Lubricating l n Base Frame
44-012747
Doc . . : MR10- 5179- 0

Page 5/5
Lubricating l Quantities n Base Frame
1.0 l Quantities
The appro i mate quantities il necessary lor a new engine, bel ore starti ng
are given in the lollowing tab le.
1I there are connected eternal , lull-Ilow llters etc., the quantity l in the
eternal piping must also be taken into account.
2.0 Lubricating l Base Frame
,

, . .
Descripti on 5 Cyl. 6 Cyl. 7 Cyl. 8 Cyl.

Min. l ee l 2 (mm) 200 200 200 200
Ma. l l 3 (mm) 250 250 250 250
Min. lter 2 291 344 397 450
Ma. l 3 373 441 509 577
~ Doosan Englne o,~:o 44-012747
Doc. . MR10- 5179- 0

1 Hull . : 139/ 3071

2 Hull . : -
Subject:
FRESHWATER TREATMENT SYSTEM
Note:
Attachments : Refer t o the cont ents for dr awi ng is t
20101 115 ~ ~ ~ EH ~ ~EH ~ First Issued.
~
Doc.
Doosan Engfne .
MR11-5179-0
-
DOOSAN DIESEL aae 1/ 11 - '
REVISION HISTORY
REV OESCR IPTlON
20101115 First Issued .

ENGINE

Ooc.
OESCR IP- .
MR11-5179-0

FRESHWATER SYSTEM

DOOSAN - DIESEL aQe 2/ 11
CONTENTS
Rev. DESCR IPTION DWG . . SHEET

APPROVAL DRAW ING FOR FRESHWATER SYSTEM 44-0 12708-0 9
ENG INE

5L23/30 PART Machi nery
Doc.
DESCR IP- .
MR11-5179-0

FRESHWATER SYSTEM
Page 3/11
Freshwater System Treatment
Note:
3
2
1
20071115 ~EK ~ o l ~~ o l ~~ First issued.

~
Drawing
Doosan Engine .
44-012708
Doc. . MR11 - 5179- 0

Page 4/11
CONTENT
1.0 Protection against Corrosion n Freshwater Cooling System
2.0 Cleaning Cooling Water System
3.0 Cooling Water - Inhibitors
4.0 Checking Cooling Water System and Cooling Water

during Service
5.0 Cleaning and Inhibiting Procedure
6.0 Degreasing
7.0 Descaling with Acid Solution
8.0 Adding Inhibitors
44-012708
Doc. . MR 11 - 5179- 0
Page 5/ 11
1.0 Protection against Corrosion Freshwater Cooling System

he engine Iresh water must be carelully treated, maintained and monitored so
as avoid corrosion or the lormation deposits which can result
insullicient heat transler, ! is necessary treat the cooling water.
We recommend that this treatment is carried ! according the lollowing
procedure:
Clean the cooling water system
Fill with deionized or distilled cooling water(lor e ample Irom the
Ireshwater generator) with corrosion inhibitor added
Carry ! regular checks the cooling water system and the condition
the cooling water
Observance these precautions, and correct venting the system, ll
reduce service dilliculties caused by the cooling water to a minimum.
2.0 Cleaning Cooling Water System

Belore starting the inhibition process, any eisti ng deposits Iime or rust, or
any il sludge, should be removed order to improve the heat transler and to
ensure unilorm protection the surface by means the inhibitor.
he cleaning shou ld comprise degreasing to remove l sludge, and descaling

with acid afterwards to remove rust and lme deposits.
Ready- mied cleaning agents, specially made lor cleaning the cooling water
system , can be obtained Irom companies specializing coo ling water
treatment. hese companies oller assistance and control the treatment all
major ports. number these companies are mentioned the enclosed list.
We point ! that the directions given by them should be closely lollowed. It is
particular importance Ilush the system completely after cleaning.
Cleaning agents emulsilied water as well as slightly alkaline cleaning agents

can be used lor the degreasing process, whereas ready-mied cleaning agents
which l the risk lre must obviously not be used. For descaling with
acid, especially products based amino-sulphonic acid, citric acid, and
tartaric acid are recommendable, as these acids are usually obtainable as solid
substances, easi ly soluble water, and do ! emit poisonous vapours.
he clean ing agents should not be directly admied, but should be dissolved
water and then added to the cooling water system.
~ Doosan El. D.. w'". i

.
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Page 6/1 1
Normally, cleaning can be eecuted without any dismantling the engine. We

! ! that the water should be circulated the engine achieve the best
possib le resull.
As cleaning can cause leaks become apparent poorly assemb led joints
partly delective gaskets, in spection should be carried ! during the clean ing
process. The acid content the system l shou ld also be checked
immediately after cleaning, and 24 hours afterwards.
3.0 Cooling Water - Inhibitors

The lilling-up with cooli ng water and the adm i ture the inhibitor is be
carried ! directly after the cleaning order to prevent lormation rust
the cleaned surlaces.
3.1 Raw Water

The lormation lim e stone cylinder liners and cylinder heads may
reduce the heat transler, which ll result unacceptably high temperatures
the material.
Therelore, ! is recommended that deionized distilled water (Ior eamp le

Irom the Ireshwater generator) is used as coo li ng water. However, account
its lack hardness, this water ill be relatively corrosive, and a corrosion
inhibitor shou ld therelore always be added.
1I deionized distilled water can not be obtained, normal drinking water can be
used eception a l cases. 1I 50, the total hardne5s the water mu st
eceed 90 dH (German hardness degrees) . The chloride, chlorine, su lphate,
and silicate contents are also be checked. These content5 should
eceed the lollowing valu es:
Ch loride 50 ppm (50 mg/litre)

Chlorine 10 ppm (1 mg/litre)
Su lphate 100 ppm (100 mg/litre)
Si licate 150 ppm (150 mg/litre)
There should be sulphide and ammonia co ntenl. Rain water must ! be

used, as ! may be heavily contam inated.
! shou ld be noted that softening water does ! reduce its sulphate and
ch loride contents.
~ Doosan EIe D"w;",

.
44-012708
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Page 7/ 11
3.2 Corrosion Inhibitors

protect Ireshwater cooIing systems marine dieseI engines against
corrosion , various types inhibitors are avaiIabIe.
Generally, l nitrite-borate based inhibitors are recommended.
number the products marketed by major companies are specilied the

enciosed Iist, together with the necessary dosages and admi ing procedures.
We recommend that these directions are strictIy observed.
reatment the cooIi ng water with inhibiting oi Is is ! recommended , as such

treatment invoives the risk il adhering to the heat transmitting surfaces.
Chromate inhibitors must be used plants connected a freshwater

generator.
Evaporated cooIing water is to be repIaced with non-inhibited water, whereas a

Ioss water through Ieakage must be rep Iaced with inhibited water.
When overhauling individuai cyIinders, a new dosage inhibitor must, l

necessary, be added immediateIy after compIeting the job.
4.0 Checking Cooling Water System and CooIing Water during Service
the cooIing water is co ntaminated during service, sIudge deposits may
lorm. he condition the cooIing water system shouId therelore be reguIarIy
checked, especiaIIy l deionized distiIIed water is ! used. deposits are
lou nd the cooIing spaces, these spaces , l necessary, the entire system
shouId be cieaned.
According to epe ri e n ce, a zinc gaIvanized coating the Ireshwater coo Iing
system is often very susceptibIe to corrosio n, which resuIts heavy lormation
sIudge, even l the cooIing water is correctIy inhibited. he initiaI descaIing
with acid w , to a great etent, remove th e gaIvanized coating. GeneraIIy,
therelore, W advise against the use gaIvanized piping the Ireshwater
coo Ii ng system.
he quaIity th e cooIing water is to be checked reguIarIy, l possibIe once a
week. BasicaIIy the inhibitor co ncentration , the vaIue and the chIoride
concentration shouId be accordance with Iimits stated by inhibitor
manufacturer. For this purpose the inhibitor manulactures normaIIy suppIy
simpIe test kits.
~ Dtosa. .I 44-012708
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Page 8/11
As a general guidance values the value should be 7-1 measured at 200 C

and the ch loride concentration shou ld ! eceed 50 ppm (50 mg/litre).
The water sample lor these tests is to be taken Irom the circu lating system,
and ! Irom the epansion tank the leading to !.
The concentration of inhibitor must under circumstances be allowed fall

below that recommended by the producer, as this would increase the risk of
corrosion.
clear record all measuring results should be kept, so that the actual
condition and trend the system may be currently ascertained and evaluated.
sudden gradualincrease the chloride content the coo li ng water may

be indicative salt water leakages. Such leakages are to be traced and
repaired at the lrst opportunity.
ch loride content the cooling water higher than the 50 ppm specilied might,
eceptional cases be tolerated. However, that case the upper Iimit
specilied by the individual inhibitor supplier must not be eceed.
clear record all measuring results should be kept, so that the actual
condition and trend the system may be currently ascertained and evaluated.
sudden gradual degrease value, an increase the sulphate

content, may indicate ehaust gas leakage. The value can be increased by
adding inhibitor; however, l major quantities are necessary, the water should
be replaced.
Every third month a cooling water sample shou ld be sent ashore lor laboratory
analysis, particular to ascertain the contents inhibitor, sulphate, and ,
as well as the total sali nity the water.
5.0 Cleaning and Inhibiting Procedure

The engine must not be running during the cleaning procedure, as this may
l the risk overheating when draining.
6.0 Degreasing
Use clean tap water lor filling-up. The cooling water the system can be used,
l it does not contain inhibitors.
~ Doosan Englne D"W;" I

.
44-012708
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Page 9/ 11
Heat the water to 60 'C and circulate the water continuous ly.
Drain to the lowest water level epans i on tank.
Add the amount degreasing chemical specilied by the suppli er, prelerably
Irom the suction side the Ireshwater pump.
Drain to the lowest water level the epansion tank directly afterwards.
Circulate the cleaning chemical lor the period specilied by the supplier.
The cooling water system must not be kept under pressure.
Check, and repair any leaks.

Drain the system and lll complete ly with clean tap water, order to Ilush
! any l grease Irom the tank.
Circulate the water lor 2 hours, and drain again.
7.0 Descaling with Acid Solution

Fill with clean tap water and heat to 70-75 C.
Dissolve the necessary dosage acid compound a clean drum with hot
water.
Fill the drum hall with water and slowly add the acid compound, while
stirring vigorously. Then lll the drum completely with hot water while
continuing to stir (e.g. using a steam hose).
Be careful- use protective spectacles and gloves.
For engines which have been treated belore the trial trip, the lowest
concentration recommended by the supplier ll normally be sufficient.
For untreated engines, a higher concentration - depending the condition

the cooling system - ll normally be necessary.
Drain some water Irom the system and add the acid solution via the epansion
tank.
The cooling water system must ! be ! under pressure.
Keep the temperature the water between 70 'C and 75 'C, and circulate !
constantly.
Doc. . MR11 - 51 79- 0

Page 10/11
The duration the treatment will depend on the degree louling. Normally,
the shortest time recommended by the supplier will be sullicient lor engines
which are treated belore the trial . For untreated engines, a longer time
must be reckoned with. Check every hour, lor example with pH-paper, that the
acid in the solution has not been used up.
number descaling preparations contain co lour indicators which show the

state the acid solution. 1I the acid content is exhausted, a new acid solution
can be added, in which case, the weakest recommended concentration should
be used.
The solubility acids in water is often limited. Therelore l , in exceptional
cases, a large amount is required, descaling can be carried out in stages
with a new solution compound and clean water. Normally the supplier will
specily th e maximum solubility.
After completing the descaling, drain the system and Ilush with water.
Acid residues can be neutralized with clean tap water containing 1 kg soda
per ton water. Circulate the mixture lor 30 minutes, then drain and Ilush
the system. The cooling water system must not be put under pressure.
Continue Ilush until water used is neutral ( approx. 7).
8.0 Adding of Inhibitors

Fill the cooling water system with water Irom the evaporator the lowest
water level in the expansion tank.
Weight ! the quantity inhibitors specilied by the supplier and dissolve in a

clean iron drum with hot water Irom the evaporator.
Add the solution via the expansion tank to the system. Then lll to normal
water level with water Irom the evaporator.
ll the engine to run lor not less than 24 hours to ensure that a stable
protection the cooling surfaces is lormed.
Subsequently, test the cooling water with a test kit(available Irom the inhibitor
supplier) ensure that an adequate inhibitor concentration has been obtained.
This should be checked every week.
The acid content the system il is to be checked directly after the descaling
with acid, and again 24 hours afterwards.
~ Doosan Elo 44-012708
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Page 11/ 11
Nitrite-borate corrosion inhibitors

for cooling water treatment
Maker's Min .
l
Company Name Inhibitor Recommended
Form
Oosage*
Castrol Limited, Swindon Castrol So lve 4 Powder 3 kg/10001
Wiltshire, England Castrol Solve 2 Liquid 201/1000 1
Orew Ameriod OEWT-NC Powder 3.2 kg/1000 1
Marine Liquidewt Liquid 81/10001
Boonton , N.J.lU.S.A M aig u a rd Liqu id 161/10001
Houseman Scandinavia Cooltreat 651 Liquid 51/10001
3660 Stenlese
Oenmark Cooltreat 652 Liquid 51/1000 1
Nalfleet Marine Chemicals Nalfleet Liq (9-108) Liquid 31/1000
Northwich ,
Cheshire CW80X, England Nalfleet 9-131 C Liquid 10 i 1 0001
Nalfleet 9-111 Liquid 1 1/1000
Nalcoo l 2000 Liquid 10 fI1 000 1

Rohm & Haas ( Ouolite) R011 I PROS IM Powder 3 kg/10001
Paris, France R025 I PROSIM Liquid 501/1000 1
Unitor Rochem Oieselguard Powder 3 kg/1000
Marine Chemicals Rocor Liquid Liquid 10 fI1000 1

Oslo, Norway
* Initial dosage may be larger
The list is for guidance on ly and must not be considered comp lete. We undertake no
responsibility for difficu lties that might be caused by these other water
inhibitors/chem icals.
The suppliers are lsted in alphabetical order.
Suitable cleaners can normally be supplied by these firms .
~ Doosan Egln. [ D':.:;n, [ 44-012708
Doc . . MR11 - 5 179- 0

Doosan Engin.
5 23/30 720 RPM

6-1. PRE-LUBRICA T1NG PUMP l MOTOR
6-2. JACKET WATER PREHEATlNG I

Tier 1 Hull . : 139/ 3071
Tier 2 Hull . :-
Subject:
PRE-LUBRICAT1NG PUMP l MOTOR
Note:
Attachments : Refer the contents for dr awing ist
20101112 ~~~ t! Q t! Q First Issued.
Date Drawn Chk'd App'd Descri ption Rev.
~
Doc.
Doosan Engine .
5-5179-0
DOOSAN - DIESEL aQe 1/4- #'
REVISION HISTORY
20 10111 2 First Issued.

ENG INE

Doc.
DESCRIP- .
5-5179-0
1 0
PRE- LUBRICATING PUMP l

DOOSAN - DIESEL aQe 2/4
CONTENTS

pRE-LlJBRICATING pUMp l 43-016330- 0 1
pRE- LUBRICATING pUMp l 43-0 16253- 0 1
ENGINE

523/30 PART Machinery
Doc.
DESC RIP- .
5-5179-0
1 0
PRE-LUBR ICATI NG PUMP l
Doosan Eng ine Co.,Ltd.

2 3 4 Page 3/4
RO TA
210 4- _,2
PUMP DATA MOTOR

c L23/30 ( Hl) FRAM E. 8
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DOOSAN-MAN DIESEL Page : 1/ 15
Tier 1 U . : 139/ 3071
2 ll . :-
Subject:
JACKET WATER PREHEATING I
Note:
Attachments : Re f er the contents for drawing i st
20101119 ~2t~ (;! .2 (;! .2 First Issued.
~
Doc.
Doosan Engine .
07 -5179-0
DOOSAN - DIESEL age 1/15- "
REVISION HISTORY
REV DESCRIPTlON
20101119 F irst Issued.
ENG INE

Doc.
DESCR IP- .
07 -5179-0


DOOSAN - DIESEL age 2/ 15
CONTENTS

JAa<ET NG 34-03 1256- 0 13

ENG INE

5 L23 / 30 PART Machi nery
Doc.
DESCR IP- .
07 -5179-0
10
Doosan Eng ine Co . ,Ltd.

Page 3/ 15
"
Jacket water preheating unit
Note:
1. Duty module
- 1 100% covering two(2) engines
2. Electric heater
- 10.0 kW , 1 100%1 module
3. Electric pump
, 1.0 m3/h 2.0 bar, 1 100% module
4. Unit q'ty
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3
2
1
20101119 ~~~ ol ~ ~ ol ~ ~ First issued.

Type 5L23/30 MS/MG 0096
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34-031256
Ooc. . 07-5179-0
Page 4/ 15
1 2
3
4 5
D R W G
F R r-
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MESSRS : DOOSAN Engine Co .,LTD

SETAO39-ls r-
. : DYl39, DY307l
ENGINE 5L23/30H
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COLOR Munsell .7.5 BG 7/2
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Page 5/15
1 2 3 4 5
J.W.PREHEATER I
SHIPYARD CLASS
MES$R$ $ Engine Co . LTD PJT $ 0139-1s

FRONT SELF SUPPORTlNG 45'C
.
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SIDE COVERS SHEET STEEL
LA$ SHEET $
$ :
COLOR $ . 7.5 BG 7/2
SIDE :
LEER OF
LA
ENGLlSH MATERIAL PHENOLlC
DRAWING &
DOCUMENT ENGLlSH
-
AC 440 3 60 10 kW 1 $
HEATER
AC V kW $
PUMP AC 440 3 60 0.37kW 1 mh 1 SET C

SOURCE
CAPACITY
TRANSFORMER AC 440/220 ~ 1 60 100
1 SET
CONTROL CIRCUIT AC 220 60
-
SOURCE C440V360
POWER CIRCUIT CONTROL CIRCUIT : NUBMERING

COOR OF R(U) : RED , (+) : RED EARTH : GREEN/YELLOW
CAP S(V) : WHITE , (-) :
T(W) :
D
INTERNAL POWER CIRCUIT : 660 $CP BLACK

WIRING CONTROL ClRCUIT : 660 $CP 600 STYLE 1015 1.25mm'
REMARK CIRCUIT :
-
PART WEIGHT
REMARKS
$$1000 $$01552 120k9
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GENERAL SPECIFICATlON
DRAWING . ; SSEOO1552
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Page 6/15
1 2 ~
4 5
SYMBOL SYMBOL
O'~~~\'<~ $0
MOLDED CASE CIRCUIT F FUSE
BREAKER W/CONTACT
~~<NFB
1-1-1- MAGNETIC CONTACT
---- ..... FUSE BREAKER 3
SWICH
'" OVER ~ -<:NFB FUSE BREAKER 2

-
CONNECTION OF
~~~ HEATER
ELECTRIC WIRE
,
AC MOTOR TERMINAL OF PARTS

COIL OF TERMINAL FOR
AUXILIARY RELAY -0-- SIDE WIRE
COIL OF ~ ''o"CONTACTOR OF
MAGNEC RELAY Q PUSH
SIGNAL
~
"b"CONTACTOR OF
PUSH
-
PUMP . MOTOR JTG TOGGLE SWITCH
LL VALVE
C
~ SAFETY VALVE
~ ALARM & BUZZER

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( ~ TEMPERATURE SWITCH D
Q
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''o''CONTACT
NORMALL
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NORMALLY COSED r-
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1 POWER SOURCE CL
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7 SOP CL
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Page 8/ 15
1 2 3 4 5
SYMBOL SPECIFICATION REMARK Q'Y MAKER
1 NFB FUSE BREAKER A8S-53 AC440V 3 30 1 LSIS
2 MC1 MAGNETIC CONTACTOR GMC-40 60

AC220V 1 LSIS
3 Th1 OVER CURRENT RELAY GTH-40 (12~18)A 1 LSIS
4 MC2 MAGNETIC CONTACTOR GMC-12 AC220V 60 1 LSIS
5 Th2 OVER CURRENT RELAY GTH-22 (0.63~1 ) 1 S I S -

HA,R5,PM
6 CONTROL RELAY HR705-4P AC220V 60 5 KACON
ER
7 TR TRANSFORMER 440/220V,24V 10 1 SINSUENG
8 F1,F2,F4 FUSE SB-C1 2 3 SB FUSE
9 F3,F5 FUSE SB-C1 3 2 SB FU5E
10 LA YSPL2 24V, 25 I 1 YONGSUNG

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11 GL LA 5 2
24V, f,5 GREEN 1 YONGSUNG
12 LA YSPL2
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13 RL LA YSPL2 24'2
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14 SP PUSH YSP12 AC250V, 25 RED 1 YONGSUNG

C
15 ST PUSH YSP12 AC250V, 25 GREEN 1 YONGSUNG
16 RST / W/LAMP YSPBL2 AC250V, 25 RED 1 YONGSUNG

SH OFF
17 S51 CAM SWITCH 5Q5-3302 1 HANYOUNG
6'~f?~f}
- t-
18 TC1 ' CONTROLLER 0~99'C 1 HANYOUNG
8200S 70'C OF
19 TC2 THERM OSAT 1O~11O'C 85'C(OFF) 1 E.G.O
20 PRESS GAUGE SS-3070 0~1MPo

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1 2 3 1 4 5
CONTROL
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WATER
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Page 15/15
1 2 3 4 5
-,

SKETCH WORKING SPARE REMARKS

Ai
CONTROL HR705-4P
1
RELAY riOQ
.1 42
AC220V
5 1
SB-CI , 2 2 2 -
2 FUSE ~ID SB-CI , 3 2 2
.
.1
GLOVE , 250 1 1 WHITE
, 250
C@~
GLOVE FOR GOVE 1 1 GREEN
3
SIGNAL LA GOVE , 250 1 1 YELLOW
2' GOVE 250 1 1 RED
FOR
4
SIGNAL LA ~I5l? 6.3V IW 5 5
-

5 L BEARING '3() 6201
6204
2
2
C3
C3
ISET I SET
620 1 6204 C
6 SPARE
~Hl NP=SPARE 1
f-
f-
(
SHEET .
-
12
(
SCAI..E
CHK
/ S
2010.1 1.18 FR APPROVAL
REV 1 DESCRI1'1I0N DWN . .
f3--$-
ESS) @nl1iJ!n@I1iJ@ ~U@W'@ ~ @]. . ; F
'EL : +82-55-231-67070-8, FAX : -6709

SPARE PART L1ST
DRA1IING . ; SSEOO1552
~
Ooc . . 7-5179-0
tHIlM Doosan Englne
5 23/30 720 RPM

7-1. LIST OF SPARE PARTS
7 -2. LlST OF TOOLS

DOOSAN-MAN DIESEL PAGE : 0000 - 1 2

Tier 1 ll . : DY139/DY3071
Tier 2 ll . : -
Subject:
List of spare parts
Note: 1. COLUMN OF 'SUPPL PER SHIP' THI S LI ST IS

'' MEANS CYLINDER NUMBERS OF DIESEL GENERATOR ENGINE.
2. COLUMN OF THIS LI ST IS
1) ' MEANS ENG. ROOM INSTALLATl ON.
Attachments : Refer 10 Ihe Revision Hislory and conlenls for drawing lisl
2
Corrected the spare of LCP (Spare .0035-3-8) and air
20110712 ~~ l!{!j ~ ~~~ 1
cooler (Spare .0092-02-04)
20101118 ~~ ~ EH ~ ~ EH ~ First issued.
Dale Drawn Chk'd App'd Descriplion Rev.
Doc
Doosan Engine .
11-5179-1
DOOSAN-MAN DIESEL PAGE . 0000 - 1 / 2 - # '
REVISION HISTORY
REV DESCRIPTl ON
2010 11 18 First issued.

Changed spec. luse & luse holder LCP . (Spa re . 00 3 5- 3- 8 )
20 11 07 12 1 Cha nged spec. and q'ty spa re lor air cooler according 10 maker's sta ndard. (Spare
. 009 2 -02 - 04 )
ENGI
NE 5 L23/30 MS/MG 0000
1-'-'-'-..::...-----------'----'--------jD c.
DESCRIP- . 11-5179-1
Li s t spar e par ts

'. DOOSAN-MAN DIESEL PAGE : 0000 - 2 2
CONTENTS
Rev . MS/MG OESCRIPT ION OOC . PAGE

0002 CRAN KCASE II - 5 1 79-0002-0 0002- 1/ 1- 1/ 1
0003 COVER I I- 5 1 79-0003-0 0003- 1/ / 1
0005 CYL INDER II -5179-0005-0 0005- 1/ /1
0006 CYL INDER D II -5179-0006-0 0006- 1/ 2- 2/ 2
0008 CONNECT ING D I I- 5 1 79-0008- 0 0008- 1/ 2- 2/ 2
0010 PISTON/CON. D I I- 5179-00 1 0-0 00 10- 1/2- 2/2
0012 GEAR ASSEMBLY I I -5179 - 00 1 2-0 0012-1/2- 2/2
0017 FUEL I I -5 1 79-00 17-0 0017-1/ /
0025 GEARFORV V II -5 1 79-0025-0 0025-1/ /
1 0035 ELECTRIC I I- 5 1 79-0035- 3 0035- 1/5- 5/5
0036 FUEL PUMP I I- 5 1 79-0036-0 0036- 1/ 1- 1/1
0057 TURBOCHARGE I I - 5 1 79 -0 057 - 0 0057- 1/ 1- 1/ 1
0072 FUEL OIL I I -5179-0 072-0 0072- 1/ /
0077 GENERATOR II- 5 179-0077- 0 0077- 1 / /1
1 0092 COMBUSTION COOLER II -5 1 79-0092- 1 0092-1 / 1- 1/1
0096 I I EQUIPMENT I I- 5179-0096-0 0096-1 / 3- 3/3
ENGINE

5 L 23/30 MS/MG 0000
Doc.
DESCRIP- .
11-5179-1

List of spare parts
Ooosan Engine Co. ,Ltd.
DOOSAN-MAN DIESEL PAGE : 0002- 1/ 1
p 'TY/ SHI
AEMAAI<S
SPAAE
e OESCAI PTI ON S <ETCH STO. .
.

I
CON
WOAI\ ING W' T(I<G)
8EAAING 51101- 157
!~, Eaill
1 AIS,,6
0002-
OOO2- 1509S
Nt1 1.600
'1.?
THAUST WASHEA 51101-253
1

2 AIS/1
0002-
02
- p- - -J- - ~ -
1b<!7Q
0002- 162 1S
2 0 .400
8 NG STUO 51101- 169
'1<12 .5 2 SCM44
13~!EiI '-
0002-
03
, ,
~
ooo2- 1503S
2( Nt1 ) 4.800
FOA 511 01-170

8EAAING STUO
0002-
- - ~ ~
2 SCM4400
04
oo02- 1523S
~7S 2(Nt1 ) 1.080
5
4
3
2
1
2010 111 2 ~2l* ~~~ ~~~ Fi rst issued.
Cff< ' ' OESCAIPTION OF AEV ISION
LL . 1 39/ 03071
ENGINE
5 L 23 / 30 MS/ MG 0002

Ooc .
OESCRIP- .
11- 5179-0002-0

CRANI<CASE

DOOSAN-MAN DIESEL PAGE 0003- 1/ 1
Q'TY/SHI
R REMARI<S
SPARE STO.
e .
OESCR SI<ECH .
v I
WORI<ING ' (<
PACON
O-RING 5 11 06- 58
1 N8R
0003-
1~7

329 . 5
0003- S624S
5 0.030
5
4
3
2

20 101 11 6 ~ I~~
== ~ ~~ ~ 8~ First issued.
Cff< OESCR IPTI ON OF REVIS ION R

. 1 39/ 03071
ENGINE
5L 23/30 MS/MG 0003

Ooc.
OESCR IP- .
11-5179-0003-0

CDVER

p'TY/SHI REMARI\S
R
e
SPARE OESCR IPTI ON SI<ETCH STO. . L
.

I
WORI\ ING W' T(I\G) PACON
SEAL ING RING 506 10-31
\11290
:II~
\11275 1 SS400
0005- 11" ,
i

ooo5-2622S
0.050
Q-RING 50610 43
\11242 2 !fflJ
0005- ~ I'
..
02 t1I i

OOO5-062 1S
2 0.060
5
4
3
2
1
20101116 01) 101 ~~ ~8~ F i rst i ssued .
CH\ 'O ' OESCRIPTION OF REVISION R

LL . 139 / 03071
ENGINE
5L23 / 30 M
S/ MG 0005

Ooc.
OESCR IP- .
11-5179-0005-0

CYLINOER LINER
Ooosan Eng ine Co . ,Ltd.

Q'TY/SHlf
R 'L REMARI<S
SPARE
e
.
OESCR IPT ION SI<ETCH STO . . L
v I
WORI<I NG ' ( <
PACON
PACI<ING 50510-26
...
, . ., -
~
1 T13AI>F2100
~
0006- -

~ ...
- -/
424 0006-S625S
0.077
PACI< NG 50510-75
I .~
I1

+ ! 1 Tl3Al>F2100
0006-
~ --+-~--~
02
h.. i +-'
1_ 4;,>4
ooo6-S626S
0.030
L VALVE SEAT 50501-64
RING
r ~ ~
2 SCM4400
0006-

03
f%;:7
~ ~
~ 2 0. 680
0006- 1624S
L
RING
VALVE SEAT
."

50501-76
0006-
04
j

?
C
~
4 s&

.85 oo06- 1603S
2 0.680
10.681
5
4
3
2

20101 116 OIJ lof ~~ ~8 ~ Fi r st i ssued.
Cft<'O ' OESCR IPT ION OF REVISION R

L L . 1 39/ 0307 1
ENGINE

5 23!30 MS/MG 0006
Ooc.
OESCRI P- .
11 -5 179-0006-0
CYLINOER

Ooosan Engine Co. ,Ltd .

DOOSAN-MAN DIESEL PAGE . 0006- 2/ 2
p'TY/SHlf REMARKS
R
SPARE DESCRIPTION S< ETCH STD . ADD.
e . I
v
WORK ING w'T (I<G) PACON
O-RING 50501- 184
j1} 16
8 VITCN
0006-
'~.! 1

05
OOO6-S624S
8 0.001
D-RI NG 50501- 338
1<1299 . )
0006-
06 1\, :
() 2 C512
OOO6-S623S
2 0.059
IO. C69t

ENGINE

523 / 30 MS/MG 0006
Doc .
.
11-5179-0006-0
DESCRIP-

CYLINDER D
Ooosan Eng i ne Co . ,Ltd.

DOOSAN-MAN DIESEL PAGE 0008- 1/2
Q' TY/SHlf
AEMAAI<S
e
SPAAE OESCA IPTION STO . .
S<ECH L
.
v I
WOAI<ING W' (< PACON
BEAA ING SHELL .. 50601 139

----1-- 1 W>J<ER
0008-

1 - t~
ooo8-2505S
. ~ 196.5 , 1. 100
BEARING SHELL 50601-139
1 W>J<ER
0008-
+~
02

. ~ 196 . 5
.1 1. 100
0008-2506S
BUSH FOR 50601 56

CONNECT NG
1 3
0008- ,.- --,

"Q
03 i== f==J
99 . !J 0008-2602S
1. 600
CONNECTING 50601-152
STUD
266 2 SN043ro
0008-
04
,

,
~
~
0008-2622S
2 1.370
5
4
3
2
1
20101 116 OIJ lof ~~~ ~~ Fi s t issued.
C< OESCRIPTION OF REVISION R

LL . DY1 39!DY307 1
ENGI NE
5L 23!30 M
S/MG 0008

Ooc.
OESCRIP- .
11-5179-0008-0

CONNECTI NG ROD

DOOSAN- MAN DIESEL PAGE . 0008- 2/2
p 'TY/SHI AEMAAI<S
SpAAE DESCA lpT ION S< E TCH STD. ADD.

e . I
l< 1 NG W'T(I<G) pACON
50601- 164
~-
~
2 SNCM43
0008-
05
~
~
~
I~ /";
." 2 0.350
0008-262 1S
ENGINE

5L 23 ! 30 MS/ MG
0008
Doc .
DESCA I- .
11 -5179-0008-0

CONNECTING ROD
DOOSAN-MAN DIESEL PAGE : 0010- 1/2
Q'TY/SHIF REMARI\S
R
SPARE
e
.
DESCR IPTION SI<ETCH STO. ADD. L
I
WORI<ING ' ()
PACON
PISTON 50501- 19
COMPLETE .,
-
1
00 10-

-+- + -1-1-

1 0-2502
8.800
RETAIN ING RING 50601-32
/ ~ 2 3G,I
00 10-
02
~~
~ lo~.
OO 10-2522S
2 0.037
PISTON RING 50601-93
1 '
]
00 10-
03
[ . ''''
oo 10-2504S
0. 166
PISTON RING 50501 103
1 ~\AI<EA
]
00 10-
.
04
1122,.
00 10-2505S
0.1 66
5
4
3
2
1
20101 116 01] 101 ~~ :J~ Fir st i ssued.
OAA~IN CfI< 'D OESCRI PTION OF REVIS ION R

LL . 1 39 / 0307 1
ENGINE
5L23 / 30 MS/MG 0010

Ooc .
OESCRIP- .
11-5179-0010-0

PI STON/CON. ROO

DOOSAN-MAN DIESEL PAGE . 0010- 2/2
p 'TY/SHI REMARI(S
R
SPARE OESCR IPTION SKETCH STO . . L
e .
I
v
\YORI(ING ' (<
PISTON RING 50601- 115
1 MJ<EA

0010-
05
[ 0225 .1
00 10-2506S
0. 166
I L SCRAPER RING 50601-127
1 .MR
00 10-
06 '~I ,+
;" J
oo lO-2507S
0. 125

ENGI NE

5L23 / 30 M
S/MG
0010
Ooc .
1 1 -5179-0010-0
OESCRIP- .

PI STON/CON. ROD
Q'TYISHlf
R REMARI<S
SPARE STO. ADD .
e
.
OESCRIPTION SI <E CH
v I
\ I< 1 NG W' T(I<G) PACON
VALVE CONE 50502 512
11

6

00 12- i
"

00 12-3301S
L~ 4 0.900
COMPRESS ION SPR ING 50502-489
RIGHT
6 &r:'f3C-
0012-
02
00 12-393OS
4 0.120
10.121
COMPRESS ION SPRING 50502-490

LEFT
6 &r:'f3C-
00 12-
03
00 12-3931S
4 0.380
IO.XI
VALVE CONE PIECE 50502-465

-
7'--- 1
/ F= F= ~ 6 SCM4150
00 12- ~
/
04
',-
." 4 0.025
00 12-3630S
5
4
3
2
1
20 101 116 OI J lof ~~ ~ ~ Fi rst issued.
/ Cfi< OESCRI PTI ON OF REVISION R

. 1 39/ 03071
ENGINE
523 /30 MSIMG 0012

Ooc.
OESCRIP- .
11-5179-0012-0

GEAR ASSEMBLY
Ooosan Engine Co . ,Ltd.

p'TY/SHIF RR<S
R
SPARE OESCR IPTION S< ETCH STO . . L
e . I
v
WORI<ING W' (<
ROTOCAP 50502-477
"".6
~
4
0012-
05
...., l
--,;;;;;;-
00 12-3604S
4 0.300
,.

ENGINE

5 L 23 / 30 MS/MG 0012
Doc.
OESCR - .
11 -5 179-0012-0

VALVE GEAR ASSEMBLY

DOOSAN-MAN DIESEL PAGE 00 17- 1/ 1
Q'TY/SH lf
R REMARKS
SPARE
e . OESCR IPT ION SKETCH STO IAOO.
I
lI< 1 NG ' (
PACON
FUEL VALVE 151402- 177
;
3
10017-

Ci
32.
00 17-3301
4 .800
5
4
3
2
1
20101 111 g~{! ~$~ ~~~ IFirst issued.
1 C OESCR IPTI ON OF REV ISION R

. OV 139!OV3071
ENGINE
5L 23 ! 30 MS/MG 0017

nnc.
OESCRI P- .
11-5179-0017-0

FUEL VALVE
Ooosan Eng ine CO.,Ltd.

DOOSAN- MAN DIESEL PAGE : 0025-1/ 1
' TY/SH
R REMARKS

SPARE OESCRIPTION SI<ETCH STO. .
.

I
WORKING W'T(KG) PACON
O-RING 50801-185
31
~
4 l
0025-
\-
0025-C621S
4 0.005
5
4
3
2
1
20101 111 ~~e ~~ ~~ First issued.
D CHK'D OESCRIPTION OF REV ISION R

. 1 39 / 0307 1
ENGINE
5 L23/30 MS/MG 0025

Doc.
OESCRIP- .
MA11 - 5179- 0025-Q

GEAR FOR / &PUMP
Ooosan Engine Co . . Ltd .

DOOSAN- MAN DIESEL PAGE : 0035-1/5
Q'TY/SHIF
R REMARI<S
SPARE
e . OESCRIPT ION SETCH STO. . L

I
WORI<ING W'T( I<G) PACON
ANN .CARO (For L
Local Control , CARO
Panel)
0035- ~
=
=
-
-
--
5
1
1 =
= -
-
OO35-6100S
45 0.000
ANN .CARO (For - COMMON
Local Control 80 CARO
Panel)
0035- ;;
=
=
-
-
1
1 -
2 =
= -
-
0035-6100S
3 0.010
FUSE (Fo r Loca I
Control Panel)
311
15
0035-

3
[DJ Ql 15 0.010
0035-6100S
FUSE (For Local - 4

Control Panel)
311
2 M'J<ER
0035-
4
[DJQl 2 0.010
OO35-6100S
5
4
20110614 :jgi=t Ol~ 011 Mod ified specification of fuse and fuse holder 3
201 10516 d~t OIQj Ol~ Modi f ied descript ion ANN.CARO(OO35- 1) 2
2011033 1 Ol~ OI~eJ OIMeJ ChangedJ~gyc . luse & luse holder due the change
of subsu 11
201011 17 0121 ~EH~ ~EH~ Fir st issued .
CHK'O ' OESCRIPTION OF REVISION R

LL . OV139/0V307 1
ENG INE
5 L23! 30 MS/MG 0035

Ooc.
OESCRIP- .
11-5179-0035-3

ELECTRIC PART

fJ 'TY/SHI f REMARI<S
R
SPARE OESCRIPTION SKETCH STO . . L
e . I
v
WORI< ING PACON
' (
FUSE (For Loca 6

Control Panel)
311
' 18 MJ<EA
[]Ol
0035-
1 5
OO35-6100S
18 0.010
FUSE (For Local - l
Control Panel)
311
6 MJ<EA
[]Ol
0035-
1
6
OO35-6100S
6 0.010
FUSE (For Local - 16
Control Panel)
311
6 MJ<EA
[]Ol
0035-
1
7
OO35-6100S
6 0.010
FUSE L (For CMS101

Local Control '
Panel) .~ -
~ 4 MJ<EA
0035- ro.
8 1

78
lk 47 0.010
-
OO35-6100S
YS8RL34-0L24-W
. L (For
Local Contro l
Pane ) 2Q
1
0035-
9 cii G-
~
~
ocxx>o
oJCX)
1 MJ<EA
OO35-6100S
3 0.010

ENGINE

5L23 /30 MS/MG 0035
Doc .
.
11-5179-0035-3
DESCRIP-

ELECTRIC

DOOSAN-MAN DIESEL PAGE . 0035- 3/5
fJ 'TY/SHI REMARI<S
R
SPARE OESCRIPT ION SI<ETCH STO . .
e .
I
v
W
ORI<ING PACON
' ( <
. (For - YSBRL34-0L24-G
Loca l Cont rol
Panel )
1
0035-
10
~
~
[~ 00000
00000
D= 1 f.W<IA
oo35-61ooS
3 0.010
. (For YSBRL34-0L24-Y
Local Control
Panel )
1
0035-
11 ~
~
~
00000
00000
D= 2 f.W<IR
0035-6 100S
12 0.010
. (For - YSBRL34-0L24-R
Local Cont rol
Pane l )
0035-
1 12 ~
~
~
00000
00000
D= 5 f.W<IA
OO35-61 OOS
54 0.010
MAGNETIC CONTACTOR - GMC9
(For loca l AC220V
Cont rol Pane l )
1 <
{~ ~
0035-
1 13
0035-61OOS
3 0.010
(For Local SZR 4-
Control Pane l ) OC24V
1 <
m

0035-
1 14 @@@
0035-6100S
3 0.010
ENGINE

5L23/30 S/.3 0035
Ooc.
.
11 -5179-0035-3
OESCRI P-

ELECTRIC PART

DOOSAN-MAN DIESEL PAGE . 0035-4/5
'TY/SH
R REMAAKS
SPARE OESCR IPTION SETCH STO. . L
e .
I
v
WORKING W'T(KG) PACON
L (For Local - SZA-LY2- NI
Contro l Panel) OC24V
2 <
I ~~I ~[
0035-
1 15
0035-6100S
21 0.010
L (For Loca l - SZR-MY4- NI
Cont rol Panel) OC24V
10 <
~

0035-
1 16 @@"
OO35-61OOS
109 0.010
BULB (For Loca - E- 10 ,24V, IW
Control Panel)
1
0035-
17 ~I I II I
---;-
18 6 <
0035-6 ooS
6 0.010
FUSE PULLER (For PF 36
Loca l Cont rol
Panel )
~ ~
1 MJ<EA
0035-
18
OO35-6100S
0.010
I (For Local - I 5408
Control Panel)
10 MJ<EA
0035-
1 19 -==1 11 F
OO35-61OOS
39 0.010

ENGINE

5 L23!30 MS/MG 0035
Ooc .
.
11 -5179-0035-3
OESCRIP-

ELECTRIC PART
Doosan Engine CO . ,Ltd .

DOOSAN-MAN DIESEL PAGE . 0035-5/5
fJ 'TY/SH lf REMARKS
R
SPARE OESCR IPT ION SKETCH STO. ADD. L
. I
v
WORI( ING W'T(KG) PACON
(For Loca -
Contro l Panel)
~
1
0035-
20
/ "-'
1 W>J<IA
". oo35-6100S
1.000
ENGINE

5L23 ! 30 MS/MG
0035
Ooc.
.
11 -5179-0035-3
OESCRIP-

ELECTRIC PART
Doosan Engine Co.,Ltd.

Q ' /SH f
R REMARKS
SPARE OESCR lpTION SETCH STO . .

.
I
WORKING ' (
pACON
FUEL pUMp 51401 - 057
0036- ~
~~ 1

- ::!
m~ m,
0036-3201
* 150 8 . 100
5
4
3
2
1
2010111 1 ~~e ~~ ~8~ First issued.
CHK'O ' OESCRlpTION OF REVIS ION R

. DY139 / DY3071
ENGINE
5L23 / 30 MS/MG 0036

Ooc.
OESCRlp- .
11-5179-0036-0

FUEL PUMP

DOOSAN-MAN DI ESEL PAGE : 0057- 1/ 1
Q'TY/SHlf
R REMARI<S
SPARE OESCRIPT ION SI<ETCH STO. .
e
.
v I
I< NG ' (<
PACON
O-RING 51202-264
i1> 16
2 l
'~< r

0057-
1 - 1
0057-G623S
2 0.00 1
PACI< ING 51202-024
1HD< 1.5
~( ~- 1
NOlfoo.l
~<
0057- ~
2
."-..J~ 177 0057-G62GS
0.000
5
4
3
2

20 101 11 7 ~~~ i;! :2 i;! 2. Fi r st i ssued.
OAA.t> CH( 'D OESCRIPTI ON OF REVIS ION R

HU . 1 39/ 0307 1
ENGINE
5 L 23 /30 MS/MG 0057

Ooc .
OESCR IP- .
11 -5 179-0057-0

TURBOCHARGE
Ooosan Eng ine Co. ,Ltd .

DDOSAN-MAN DIESEL PAGE : 0072- 1/ 1
'TY/SH
R REMARI<S
SPARE
e . DESCRIPTION S<E TCH STD. ADD. L
v I
W
ORI<ING ' ()
PACON
FUEL INJECTION 5 1404- 10

0072- ~- " 1 MI>J<ER

'"

~
'="" 0072-FS08T
1. 960
5
4
3
2
1
20 1011 17 ~&~ (;1 Q (;12 Fi rsl issued.
CH< 'D DESCRIPTION OF REV ISION R

LL . DY139 / DY307 1
ENGINE

5L23 / 30 MS/MG 0072
Doc .
DESCRIP- .
11 -5 179-0072-0

FUEL IL
Doosan Engine Co. ,Lt d.

DOOSAN-MAN DIESEL PAGE : 0077- 1/ 1
Q'TY/SHI REMARI(S
R
e SPAR
.
E DESCR IPT ION S(ETCH STD. ADD.
v I
/ NG ' ()
PACON
SPARE FOR -
GENERATOR
OO77-610 1S
0.000
FILTER - HFC7
5O.FR
'Jq
8
4
OO77-610 1S
6 0.500
FI LTER - HFC7
50 .FR
re~g
4
5
0077-6101S
3 0.500
5
4
3
2
1
20101117 01~2I ~EH~ ~EH~ Fir st issued.
D DAA~N CH( 'O ' DESCRIPT ION OF REVIS ION R

. DY1 39/DY3071
ENGINE
5 L 23/30 MS/M
G 0077

DOG.
DESCR IP- .
11 -51 79-0077-0

GENERATOR
Doosan Engine CO . ,Ltd .

Q'TY/SHIF
REMARI\S
SPARE STO.
e .
OESCRIPTION SKETCH .

I
WORI\ ING W'T(KG) PACON
O-RING 51203-234
119 . 6
"
"; [ 1 l
0092- i

OO92-C622S
1 0.028
GASET 5120 1-054
[Q~
NON-ASffS
3
0092- TOS
02
6 10
I,2
oo92-3927S
1 0.280
GASKET 51201-137
Q]
NON-ASffS
3
0092- ( ~
TOS
03
i I~2
oo92-3927S
1 0.250
SPARE GASKET -
J,I /- ... _~ 1 \\00)

0092- . ~
04 j: :1~1~~~~~"'~
oo92-3927S
2.000
5
4
3
2
20 110414 ~~{;! ~~ ~~~ ChangeQ n~he spec . and quantity spare parts 1
accordIn to manufact ur er
20101111 ~~e ~~~ ~~ First issued.
R C OESCR IPTION OF REVIS ION
. DY139/DY307 1
ENGINE
5L23 /30 MS/MG 0092

Ooc.
OESCRIP- .
11-5179-0092-1

COMBUSTION COOLER
Doosan Engine Co .. Ltd.

Q' TY/SHI F
R REMARI<S
SPARE
e OESCRI PTION SI<ETCH STO. . L
.
v I
WORI<ING W'T(I<G) PACON
SPARE FOR JACI<ET

NG
I
000
0096-\VM21
0.000
CO L L - HR705- 4P
AC220V
001 ,[ jg 1
5 0.033
FUSE SB-C 1,2A
002 {
50
g 2
2 0. 250
19:/'\.: 1, ""
FUSE - SB- C1,3A
003 {
50
g 2
2 0.250
I ~-C', :; 1
5
4
3
2

20 101117 ~~ ~ Ol tJ ;;;: Ol tJ .Q Fi rst issued.
CH<'O ' OESCRIPTI ON OF REVISION R

L L . 1 39 / 0307 1
ENGINE
5L 23/30 MS/ MG 0096

Doc.
DESCR IP- .
11-5179-0096-0

AUXIL IARV EQUIPMENT
Ooosan Engine CO, ,Ltd ,

DOOSAN-MAN DIESEL PAGE : 0096- 2/3
Q'TY/SHIF REMARI\S
R
SPARE OESCRIPTI ON SI\ETCH STO. . L
e
. I
v PACOI~
W
ORI\ ING W' T(I\G)
GLOVE FOR SIGNAL - GOVE,25PI
L
I
~
1
004
1 0.010
IGLOVE. 250 "/( )
GOVE FOR S GNAL - GOVE,25PI

L
GREEN
{~
1
005
1 0.010
IOLUV1:.. ,6 / GAEE NI
GOVE FOR SIGNAL - GOV E ,25 PI

L
LL
{~
1
006
1 0 .010
161..0\1( . 250 / YELLDWI
GOVE FOR SIGNAL - GOVE , 25PI

L

[~
1
007
2>
1 0.010
IGLOE, 2S tP / ROI
8UL8 FOR SIGNAL 6. 3V

L 1
008 e[1 '1If mJ

5
- 2'
5 0.020

ENGINE

5L 23 / 30 MS/MG 0096
Ooc .
.
1 1 -5179-0096-0
OESCRIP-

AUXIL IARY EQUIPMENT

p'TY/SHlf REMARI\S
R
SPARE OESCR SI<ETCH STO. ADD . L
e . I
v
\'/ORI\ ING 1'T(I\G)
PACON
LL BEAR ING - 6201
2
')
C3
009
cw 6201 C3
1
1 0.350
L L BEARING - 6204
2
C3
~
1
010
620<\ C3
1 0.150
SPARE - NP-SPARE

~~
1
011
l
~~~
0.500

ENGINE 0096
5L 23/30 MS/MG
Ooc.
.
11 -5179-0096-0
OESCR IP-

AUXILIARY EQUIPMENT
Doosan Engine Co. ,Ltd .

DOOSAN-MAN DIESEL PAGE : 0078 - 1 2

Tier 1 ll . : DY139/DY3071
Tier 2 ll . :-
Subject:
List of tools
Note:
Attachments : Refer to the Revision History and contents for drawing list
Revised sketch (1001 .000-09) & changed air cooler

201104 15 ~~~ ~$~ ~~~ 1
1001(000-44,45) accord ing 10 manufaclurer
20101112 ~~~ ~~ ~~ Firsl issued.
~
Doc
Doosan Engine .
12-5179-1
DOOSAN-MAN DIESEL PAGE' 0078 - 1 / 2 - #'
REVISION HISTORY
REV DESCRIPTlON
20101112 First issued.

Revised sketch (tool .000 - 09) & changed air coo ler tool(000-44,45) according to
20110415 1
man ufactu rer

ENG INE
5L23!30 MS/MG 0078

Doc.
DESCRIP- .
12-5179-1
L i st tools

'\ DOOSAN-MAN DIESEL PAGE : 0078 - 2 2

CONTENTS
Rev. Code . DESCRI PTION DOC . PAGE

1 000 GENERALTOOL 1 2-5179-000-1 000- 1/10- 10/10
00 1 HYD. L 1 2-5179-00 1 -0 00 1-1/6-6/6

ENGI NE

5 L 23/3 0 MS/MG 0078
Doc.
DESCRIP- .
12-5179-1

List of tools
Doosan Engine Co .. Lt d.
DOOSAN-MAN DI ESEL PAGE 000 - 1/ 10

~ ' TY/SHI REMARI\S ,
R .
e DESCR SKETCH

POSI - STD. ADD. WEIG1T(kg) PACON

.PRESSURE
INDICATOR 95
-

000
~
~ - 1
-0 1
.~'I~0l).fS
~...,..~,.-
2.100 0078-9401
LIFT ING
SS4OO,
STPG370S ,
000
S45CN
1
-02
-
"" 5.080 0078-9701
MOUNTI NG FOR

~

000
- 03
1
3.230 0078-9821
GA INDI NG
~
r-'
SS400
000 , ~
1
,
-04
~ ,.,. 11.411 0078-9621
5
4
3
2
201 104 14 ~~~ ~@ Ed~ Changed ai r cooler 1001 according 10 manufaclurer
20101112 Ed~~ Ed~ Ed~ Fi rsl issued.
D D\ CHK'O ' DESCR IPTION OF AEV ISION
. 139 / 0307 1
ENGINE CODE
5L23 / 30 MS/MG 0078 000
.
Doc .
DESCR IP- . 12-5179-000-1

GENERALTOOL
Ooosan Engine Co . ,Ltd.


R ~ ' /SH F REMARI<S
.
e OESCRIPT ION SI<ETCH
v POSI - STO. . WEIG-IT(kg) PACON

FOR GRINOING
OF
SS400
(? ~
000 (
1
-05 j
.,. J 0.250 0078-9622

GRINO TOOL-FUEL
SEAT
000
-06 r~~l , 1
<
1.723 0078-9623
EXTRACTOR FOR FUEL

<
000 1
-07
1. 900 0078-9529
LIFT ING
000
(J S15CN
1
1 (

-08
IM I 2J 0.180 0078-9539
SHACI<LE
-
) SF44CAN
000 1
1 -09 ~-R--I-
~
20 0.975 0078-9521
S.W. L : 1.6 ton
ENGINE
MS/MG 0078 COOE 000

523 / 30 .
Ooc.
OESCR IP- . 12-5179-000-1

GENERALTOOL

DOOSAN-MAN DIESEL PAGE 000 -3/ 10
L
R 'TY/SH L REMARKS
.
OESCRIPTION SKETCH
v POSI - STO. . GiT(kg) PACON

RETAINI NG
TOOL-CYL .LINER

000 ..
,.;
.1
LJ10
STPG370S
- 10 2
L '" .
1. 940 0078-9721
L FOR RETAIN ING
RING --
S35CrVX
000
- 11
m
, 1
0.200 0078-9522
PI STON RING

000 fI
"';

- 12

Q
1
n
<
0.500 0078-9523
L L
GAUGE
3l3 1

000 1+
1
- 13
0.050 0078-9321
L LI
GAUGE
~l3 1

000 1+
1
- 14
0.050 0078-9322
ENGINE

5L23/30 M
S/MG 0078 COOE 000
.
Ooc.
OESCRIP- . 12-5179-000-1

GENERALTOOL

DOOSAN-MAN DIESEL PAGE . 000 - 4/ 10
L
R ~ ' TY/SHI L REMARI<S
.
OESCR IPTION Sl<ETCH
v POS I- STO. . WE ICI,T(kg) PACON

GlJIOE FOR PISTON

~
000
- 15
r~I)
~ I
1
<
7:r
10.210 0078-9524
LI FT NG L
000
- 16
dt-1 1
<
8.029 0078-9702
GR INOING L
000
- 17
lfr . .
1
SS400
6.000 0078-9624
HONING L
000
- 18
.e !- 1

3.000 0078-9625
FUNNEL
.258
~

<
000 8
1
- 19
W
1. 713 0078-9525
ENGINE
0078 CODE 000
5L23!30 MS/MG .
Ooc .
. 12-5179-000-1
DESCRIP-

GENERALTOOL

DOOSAN- MAN DIESEL PAGE 000 - 5/ 10

.
Q'TY/SH I R REMAAKS
e DESffi lPT ION SKETCH
v POSI -

STD. ADD. WE IGiT(kg) PACON
GU IDE R
000
-20
-~.~ 2
S45CN
1.920 0078-9526
SCREW
000
-21
-~~!
.. ~IO 1
S45CN
0.500 7-9527
FEELER GAUGf
.... SUP4
000
-22 2
T- I.Om.O.9rm 0.200 0078-9323

FEELER GAUGf
).. SUP4
000
-23 2
T;O.5mm. O.6nvn 0.200 0078-9324

DISTANCE TU8E
~t STPG370
000
-24 -8 1
0. 180 0078-9528
ENGINE

5L23 / 30 MS/MG 0078 CODE 000
.
Doc .
DESCR IP- . 12-5179- 000-1

GENERALTOOL
Doosan Eng ine Co., Ltd.

DOOSAN-MAN DIESEL PAGE 000-6/10
AEMAAKS
~ ' TY/SHI
,
DESCA IPTION SKETCH
POS I- STD , ADD, WEIG1T(kg) PACON

SPANNEA FOA
OVERSPEED STOP ' 00
.,
~ ! - ..

000 1
-25 ~ !
.-
0,213 0078-9530
AAA,OF TUANING Attached engine

SUPPOAT

000 + -+--
- 26 [ '20 1 3
5,1 50 0058-2822

GAUGE
~~~~~~~

000 ~
1
- 27
21 0
RAN;;E 60-500
1,050 0078-9325
II FT NG STAAP
~~

000 ~,.
. 1000 -\
";
2
- 28
0,295 0078-9722
SUPPORT
:::::14
,- S45CN
000 2
- 29 ! ~
.~ 0,530 0078-9532
ENGINE
0078 CODE 000
5L23!30 MS/MG ,
Doc,
, 1 2-5179-000-1
DESCRIP-

GENERALTOOL
Doosan Engine Co"Ltd ,

DOOSAN- MAN DIESEL PAGE 000 - 7/ 10

R .
p 'TY/SHI REMARKS
OESCR IPTION SKETCH
v POS I- STO. . CI-IT( kg) PACON

FOR
BEARING
000
- 30 ,~ 1

0.250 0078- 9703

SMANTLI NG
FOA BEAAING . ,..---,
SHELL

000 ~
1
- 31
..!!1,
0.847 0078- 9704
TEST FOA FUEL
VALVE
000
~ '='
1

tr l ~ 4
- 32
~~ ~
40.000 0078- 9101

TAIGGEA
ffi1
S45CN
000
- 33 1
L ~.
0.300 0078- 9533

IIRENCH
~
S35CrW
000 ~: '~D
. _._.- _. 1
- 34
4
0.500 0078- 9534

ENG INE

5 L23 ! 30 MS/MG 0078 CO
.
000
Doc .
DESCR IP- . 12- 5179- 000-1

GENERALTOOL

DOOSAN-MAN DIESEL PAGE 000 - 8/ 10
REMARKS
R p 'TYISHl f
.
OESCRIPT ION SETCH
v POS I- STO . ADD . W
EICI1T(kg) PACON

CLEAN ING FOR

000 1
-35 i A[?prox. 7q
'O',tl"\ Steel W,rel ''S'c!> 1'10100-1
3 , :) lO!u
0.040 0078-9730
SUPPORT
---=cTL
~,-~
000 1
-36
1.578 0078-9535
TOROUE SPANNER
lIj')I') 463
000
-37 l :) , ',Imoowl 1
STEEL
1.200 0078-9536
Ro::nge , 25- 1<:CNn
TOROUE SPANNER
"8
000
-38 l :) , IHIJ 1
STEEL
2.000 0078-9537
R->ge , 70~
SOCET SPANNER
~~
S35CrVV
000 1
-39
0.570 0078-9538
Test Torque : ~70~
COOE

ENGINE 000

5L23 / 30 MSIM
G 0078 .
Ooc .
. 12-5179-000-1
OESCRI P-

GENERALTOOL
Doosan Eng ine Co.,Ltd.

DOOSAN-MAN DIESEL PAGE 000 - 9/10
L
R p 'TY/SHI L REMARKS
.
DESCRIPTION SKETCH
v POSI- STD. ADD . WEIGHT(kg) PACON

MAGNIFIER
~ ~
000
~
- 40 )1 ~ 1
'-~
f,bgn, r ,ccl: 10<"> : X3Q 0. 150 0078-9326
DL
'"
~~'= :..,J

000 1

-41
~~
0.500 0078-9327
WASHING
DEVICE
000
- 42
r ;:'0334
~i 1

8.500 0078-9901
WASHING INCLUDED TURBOCHARGER

DEVICE FOR SUPPL SCOPE
COMPRESSOR SIDE

-JO
c
000
1
- 43
1.000 0057-9022
CLEANING BRUSH
, STEEL
000 ;;: 11 11 111111 1
1 1
- 44
. .00
.1
0.500 0092-9921
CODE

ENGINE

5L23/30 MS/MG 0078 .
000
Doc .
DESCR IP- . 1 2-5 1 79-000- 1

GENERALTOOL
Doosan Engine CO .. Ltd.

DOOSAN-MAN DIESEL PAGE . 000 - 10/ 10
L p 'TY/SHI L REMARKS
R .
e OESffilPT ION SETCH
v POS I- STO. . GHT(kg) PACON

PUG
~B~
BRASS
000 30
1
-45
0 .010 0092-9921
ENGINE COOE

5L23 / 30 MS/MG 0078 .
000
Ooc .
OESffi IP- .
MA12- 5179- QQQ- 1

GENERALTOOL
Doosan Engi ne Co . . Ltd .


R ' / S L REMARI\S
.
e OESCR SI<ETCH
v POSI- STO. ADD. W
EI GHT(kg) PACON

L C JACI< FOR
CYL .HEAO
~ <
00 1
~ 1
-01 ~

.'"
33Q~.5Q:.Z50
12 .000 78-994
C JACI< FOR
CYL .HEAO
00 1
-02
I !j':rnJ 4
<
5.200 0078-9706
SEALING RING l
BACI<-UP R NG 90.0
1#
,
8: . 5
= ,, 1;1,
;

00 1
-03
[ 85
90
]
8
0.008 0078-9706
SEALING RING l
BACI\-UP R NG 55 . 5
.~, = , #,
4Q . ~

; ;
00 1
8
- 04
[ 50
'j!:';
J]
0.005 0078-9706
5
4
3
2

2010 1112 ~~~ ~~~ =d~~ Fi rs1 issued.
ORAWN Cft< ' ' OESCRIPTION OF REVIS ION R

. 139 / 03071
HIGINE COOE
5 L 23/ 30 MS/MG 0078 00 1
.
Ooc.
OESCR IP- . 12-5179-001-0

HVO. L
Ooosan Engine CO.,Ltd.

DOOSAN-MAN DIESEL PAGE . 001 - 2/6
L AEMARI\S
R p 'TY/SHlf L
.
e OESCR IPTION SI\ETCH
v POSI- STO . AOD . WE GHT( I<g ) PACON

-- _.
,..
(
00 1
-05 4
!2... -.
" , 0.075 0078-9706
( FOR HEXAGON
SOCI\ET SCAEW
S(S3
00 1 2
-06
~W'b
0.030 0078-9706
OISTRIBUT ING PIECE
1- .- - -
~ <
00 1
~ W ~- \- ~
1
-07
~
''''
0.562 0078-9706
L C JACK FOR
CO OD STlfJ
F== (

00 1 ~
1
-08
1==
..."'" """"" 12.000 0078-994
L C JAC( FOR
CON STUD
00 1 _
W @
(

; ~ -. 2
-09 - , "
4. 100 0078-9707
HIGINE
5L23 / 30 M
S/M
G 0078 COOE 00 1
.
Ooc.
. 12- 5179- 00 1-0
OESCRIP-

HYD . L
Doosan Engine Co. ,Lt d.

DOOSAN-MAN DI ESEL PAGE 00 1 - 3/6

R ' /S REMARI<S
.
e DESCR SI<EC H

POS I- STD. ADD. WE IGHT(kg) PACCI

<
-
,
00 1
- 10 J I . 5
1 1
0.230 0078-9707
SEALING RING l
CI<- R NG 95.'
k, - =
,
85.'
, ~.,
001 ; ,
2
- 11
[ 5
95 11
0.007 0078-9707
SEAL ING RING l
CI<- R N
G c,o . G
~",, =, jJ,
49 . 2
. J

00 1 i ;
_60;0 _ J]
2

- 12
0.006 0078-9707
THRUST PIECE
SCM4400
00 1
- 13 !; ~~-~!I~$
. t- 2
=(
0.850 0078-9707
ANGLE PIECE
~
<
001 .
t? ~
;
'
"'

- 14
:t
0.442 0078-9707
ENGINE CODE

5L23 / 30 M
S/MG 0078 .
00 1
Doc .
DESCRIP- . 12-5179-001 -0

HYD. L
Doosan Eng ine Co .. Ltd .


R .
p 'TY/SHI REMARI<S
e OESCR 011 SI<ETCH
v POSI-

STO. . GHT( I<Q ) PACON
PRESSURE PUMP
COMPLETE
<
001 ~
- 15 1
':;0
3:O~"~.2'""..O
12.000 0078-9709
PRESSURE PUMP
COMPLETE
)15
00 1
- 16
~~~.
~ ~
1
<

4.008 0078-9709
PRESSURE TESTING

001
- 17
rI E.E 11
r&1P 1
<
'2. J
2.800 0078-9709
OI STANCE PIECE
001 ,
!{.
+ - 1
<
- 18
! i --
0. 700 0078-9709
HIGH PRESSURE HOSE
. 3000
III~
<
001 !fFIII
- 19
00 1
1. 700 0078-9710
ENG INE

523 / 30 MS/MG 0078 COOE 001
.
Ooc.
OESCR IP- . 12-5179-00 1 -0

HYD.
Doosan Engine Co. ,L td.

DOOSAN-MAN DIESEL PAGE 00 1 - 5 / 6

R .
' / S REM
ARI<S
e OESCR SI\ETCH
v POS I- STO. . W
EIGHT( I<g) PACON

HI GH PRESSURE HOSE
""
001
-IIIlJ [111
1+'- 4
<
- 20
1. 200 0078- 97 11
C JAC< FOR
L
BEAR ING STUO
\
001 ~
1
- 21 ~

450
35Q.SO~15O
9.000 0078-9712
HYORAULIC JACI\ FOR
BEAR ING STUO
:~ ~-
<
00 1
- 22 2
3.610 0078-9712
CYLINOER
"
<
00 1 ~ 2"~
2
- 23
<,
1.500 0078-97 12
SEALING RING l
BAC<-P R N
G 105 . 5
~, ~,
9".5
. = .

001 ! ,! !
4
- 24
[ "
o~
]
0.240 0078-97 12
ENG INE

CO

523 / 30 MS/MG 0078 .
001
Ooc .
OESCR - . 12-5179-001-0
HVD.


DOOSAN-MAN DIESEL PAGE . 001 - 6/6

R ~ ' TY/SHI REMARI<S
.
e DESCRIPT ION SKEC H
v POS I- STD. ADD . WE IGHT( kg) PACON

SEAL ING RING l

BACI<-UP R NG 6'5 . '5
.~, "J,,
59 , ::'
=,
, ;
001 4
]
-25
[ ..
60
,
0.006 0078-97 12
-- -
<
00 1
-26 2
!L - 0.075 0078-97 12
'"
FOR HEXAGON
SOCl<ET SCREW
S<S3
00 1 2
-27
~W'b
0.030 0078-97 12
GU IOE
~~ <
00 1 ~I~ 2
- 28 ~ ~
((/
0 1Q"JO
0.679 0078-97 12
ENG INE M
S/MG 0078 CODE 001
523/30 .

Doc.
DESCR IP- . 12-5179-001-0

HVO.

Doosan Englne
5 23/30 720 RPM

8-1. ENGINE AUTOMA T1C SYSTEM
8-2. LOCAL STARTER
8-3. GENERATOR
Tier 1 Hull . : 139/03071

Tier 2 Hull . :_
Subject:
ENGINE AUTOMATIC SYSTEM
Note:
Attachments : Refer the content s 'o r drawing ist
2010111 7 ;j ~ EH ~ ~ EH ~ First Issued.
Oate Orawn Chk'd App'd Oescripti on Rev.
~
Ooc.
Engine .
1-5179-0
-
DOOSAN DIESEL age 1/ 14-.,..
REVISION HISTORY
REV DESCR IPTlON
20101 117 Fi rst Issued.

ENGINE
5L 23/30 PART lC c

Doc.
DESCR IP- .
1-5179-0
10
ENGINE AUTOMAT IC SYSTEM

. ~. DOOSAN - DIESEL age 2/ 14
CONTENTS
Rev. DESCRIPT ION DWG . . SHEET

ENG C ARRANGEMENT 42-0 13059- 1 1
SENSOR L IST 1S-5179- 0 3
START ING L 34-03 11 95-0 8
L I 43-0 13929- 1 1

ENG INE

5L 23/30 PART El ectr iC
Doc.
DESCR IP- .
1-5179-0
1 0
ENGINE AUTOMATI C SYSTEM

6

GQVERNOR:
62
12 SHUTDOWN SOLENO ID & 21-22 4;3-40
SYNCHRON IE ING MQTOR
5 :: 89 PRESSURE GAUGE
5 1AR NGrB" O
:..X ,-_ _...,
&( ==::><: ! ILj PDDD

ZS
81
L/2 8
, !, ,.
OoC. . : 00 1-5179-0
Page 4 ~
Sensor Lst
Sensor Measuring Normal Alarm Autostop

Code Name Q'ty REMARKS
Type Range Range Setpoint of Engine
1 42 F.o. Leakage Level 1 LS -- -- Leakage
2 40 F.o. Inlet Press. Alarm 1 0-1.6 0.5-1.6 0.4
3 43-40 F.o. Filter High Diff. Press. Alarm 1 DPS 0.02-0.25 -- 0.05
4 PSL 22 .. Inlet Press. Stop 1 PS 0-0.8 0.31-0.45 0.25
5 22 . Inlet Press. Alarm 1 0-0.6 0.31-0.45 0.3
6 21-22 Filter High Diff. Press. Alarm 1 DPS 0.02-0.25 0.05-0.1 0.15
7 22 . . Inlet Temperature 1 RB 0-200 'C 45-65 'C 75 'C
8 25 Prelubricating l Level 1 LS -- 0.01-0.05 Level
9 LAUH 28 . . Sump Tank Level 1 LS -- -- / Level
10 TSH 12 . Water System Outlet High Temp. Stop 1 TS 70-120 'C 70-85 'C 95 C
11 12 .1. Water System Outlet Temperature 1 RB 0- 200 l: 70-85 C 90 C

0.04+()
12 10 .. Water System Inlet Press. Alarm 1 0-0.6 0.15-0.46

13 62 Eh. Gas T/C Inlet Temperaure 1 0-600 l: 425- 475 C 550 C

"' Legend
- PS : Pressure Switch - LS : Limit Switch - : Pressure Transmitter - MS : Micro Switch (Position Switch)
- DPS : Differential Pressure Switch -() : StatIc Pressure - TS : Temperature Switch - : Temperature Element
- RB : Temperature Sensor ( -100 ) - SE : Speed Element - : Temperature Sensor (Thermocouple) - ZS : Position Switch
--
Doosan Engine CO . ,Ltd.

Doc . . 1 -5179-0
Page 5/14
Sensor List
Sensor Measuring Normal Alarm Autostop
Code Name Q'ty REMARKS
Type Range Range Setpoint of Eng ine
14 L 70 Starting ll L Press. Alarm 1 PS 0-0.8 0.5-0.7 5
15 SE89 Turbocharger RPM 1 Pick-up 1 kHz --

16 SE 90 EngineRPM 1 Pick-up 1 kHz --
17 SSH/SAH 81 Engine Overspeed (Electric) - -- -- 815rpm 815rpm
18 ZS 81 Engine Overspeed (Mechanical) 1 MS -- -- 825rpm
19 ZS75 Tuming Gear 1 MS -- -- Interlock
Legend
- PS : Pressure Switch - LS : Limit Switch - : Pressure Transmitter - MS : Micro Switch (Position Switch)
- DPS : Differential Pressure Switch - () : Static Pressure - TS : Temperature Sw~ch - : Temperature El ement
- RB : Temperature Sensor ( -100 ) - SE : Speed Element - : Tem perature Sensor (Thermocouple) - ZS : Position Switch
Doosan Engine CO. , Ltd.
Doc. . EA01 -~ / 9- 0
Page 6/14
Starting & Terminal
Note: SETA0139-1s (Yangzhou Dayang Shipbuilding Co., Ltd.)
3
2
1
20101115 ol.gi!1 ~EH ~ ~EH ~ Firs! issued.

Type 5 L23/30 MS/MG 0035
~
Drawing
Doosan Engine .
34-031195
000. . 0 1 -5 1 79-0
a\,jo ' ~
MESSRS DOOSAN ENGINE Co., Ltd.
SHIP . DY0139!3071
PROJECT SETA0139!3071
ENG. 1 B&W 5L23!30H
CLASS
STARTING (-1) & TERMINA1
( 07 ) SHEETS W!COVER
ffi
ffi
& 2010.11.12 ISSUED FOR APPROVAL S.H.SUNG
REV. BIBLlOGRAPHY OWG. CHK. CHK. .
. POR. .:
i.tt~:t
S.G.HWANG
CHK.
MACH.& ELEC.CO.,LTD.
O.S.YOON
CHK. REF. . :
OWG. S.H.SUNG : 2010.11.12

DWG. . D10S216
n,
." :: lh&J
age . 8/14

" .' ,
1. ClASS & RUL.E ; BV
2. . ; 45C
3. CONS1RUCTlON OF ENCOSURE
- MOUNTlNG D ; MOUNTlNG
- MATERIAL ; SHEET SEE 3.21 & 2.31
- COOR [ STARTlNG ; BLACK(DKOO06)
TER~INAL ; MUNSELL .7.5 BG 7/2
- PROTECTlON DEGREE OF ENCOSURE ;
[ SARTING ; I44
TERMINAL ; I44
4. l.ETTER OF DOCUMENT & DRAWING ; ENGUSH
5. LA
- l.ETTER ; ENGUSH
- MATERIAL ; SARTING - PHENOUC
TERMINAL - SUS 304
9. SCOPE OF SUPPLY ; SARTlNG & TERMINAL 3SETS/SHIP

-
. S.G.HWANG ~
I,tll:(;
CHK. O.S.YOON ill GENERAL SPECIFICATION
IJJI IlACH.I WC.CO.,LTD.
CHK. &
, .
DWG. S.H.SUNG &, UNIT: mm REF. . DWG. SHT. .
D 2010.11.12 & SCALE: N!S KD1OS216 02

Doc. . : 1- 5179- 0
----- -- -- -- - - - - - ---
(')-
~
1.
~ ~

~

i5

rrn. DESCRIPTION SIZE SPEC. REARKS
CO'IER 55400, l .
!\.)V) 0[1)
(;)
::: n. 2 55400, l.
. .n =<
c: ~ 120 '-' 3 DIGITN.. 996(1) DllH 60V
~ ~ 1QQ (OOIPING RUBBER) !.!~_+-_--=_.:....____t-_+.c::.--=.c::.--j
1-_l-!!!:.!<JC!!i!!.!ElER
'" " + RECEPTACLE 15 CONTACTS CASI. .. \lS3102A28-17S
G;> 6i> f9> 13> ~ 5 . SARTlNG . 5 LA II0000000H) PHENOUC

6 DAltPING RUBBER W6 RUBBER 4
.. _
3 2 7 P.B(GREEN) 22.51 10
~=
14, tw: \.
wH cER ' ~.".. lE[R: SAI
"" _ _ P.B(RED) ~.D32.2 \[ 1
~ ~ ~ 8 wi1 MR 22.51,10 ~:~ lE[R: STP
~ ~ ~ ] r!) [! ~ 9 P.B(RED) 22.5f 10 ~:~ !WE
. wH MR ' ~."... Lr!R: oc;
~ 3
(J) 3 e::B:!I ~~
;:
~~
~:=j
~~~
r
"'1 ("')G">
.:
~ ~ ~
'-'----+-t-+-_ J-\---'.
GROUNDING STRIP
1 SLO t.4S3102A28- 17S
.......... S
"';
U> 164 4-f8
-<:: - ~
'- CA8LE LENG1H : 1800 -- -f' .S3102A28- 17S
:~
::'
-
'51"

~
~

~
i
~ ~
,~
s "-...J

9 ANGL.E PLUG 14S:S108A28-17P

V
~
S
MOUN11NG
<>

'" '"
~
g ...
= SART1NG TERt.4INAL
-
'"
<
<D
~ R- ;;
~ s::; ~ 1. ~ER : KOMECO
1'1
~
:> '"

n
S
'

~
9
~
81

. 2.
3.
4.
5.
.. : I-01
ENCOSURE PROTECON :
WEIGHT : bo 5Kg
P~NT COLOR : DKOOO6(8I.ACI<)
--

.>-
:>

~ ::;: "
?' ?' :u
"'"
1
'"

::

in '"'" FRONT VI EW SI DE VIEW REAR VI EW
in '< ::
c:
~
~

G> 96 --
63
'" '"
~~~~~ R 7
ENGIN E RPt.!
~ c:
"'I ~
::!
-;
~ BBBB I]
F.i ;-; ;;
TIC 10 RPM <
> >
~13
'" 3 IBBBB j' (EIIG.)
IN PU 1
~~~
(T/ C) ""'"
INPUT2 sJRC(
~ [i~[~~[~[~[~[:[:[[

G)
,.,'"
:'1
~~
~
s::
8J[!)1B0
DTt.!-160V
~ + .-..d+ ttWd +
~ '-.--' '-.-"
Q-SVdc Q... SVdc DC2.V
>! '--
-
",
00
.ss::
~
'"
GENERAL SPECIFlCAoN CUT OU DIMENSIDN
1. MAER : KOMECO
2. : - 160V
3. SCALE
' 1) ENG.RPM : D 1DOO(FOR 720 RPM ENGINE)
N
8\
2) T/C RPM : 60000
21 '" '".'" ~ 4. DISPLAY : 4DIGIS, 7SEGMENT LED

(ENG. : RED, /C : GREEN)
~
51 . S!_ 5. Rc : I54
~I li
!:: ::~ 6. ACCURACY : 0.2%F.S1DIGIT
g; 7. RA . : - 1ON60'C
m
'" ;.-!rj 8. POWER SOURCE : DC24V 207.
9. POWER CONSUMPTION : obt. 2.2Wott.
~I"I
~O
- '"
(J1
--.
...
'"....
::
.

~
~
~

---
.t>
:>
~ : :: :: "
:u
1
'"a "
!"
?" ?"

'" [Wr- ~: !ooOR LOCKER b
200 DAMPING RU88ER
..../ M1O,040,30H,60L
--- "
;)
n h
:: j
n
C

C)
"

~
C)
'"
~~~~~ CA8UE GLANO
PG9,15
@@@@ PUCA 8 CONNECTOR #1Ox3(PF1/41
@@@
@@@
18@@1
"'I

~
.. ~
C
--<
=;
r
~~@~
GROUNDING STRIP
14SQ
'" M10,60L
,1
'" 33

~
RIGHT SIDE
0-<
c:: T1
:'1 -<'"
c ~ RECEPTACLE(FOR SARTING CONNECTlON)

rr> 15P(MS3102 28- 17S)
r
550

$ro SLOT POSITlON
~ ~ 470
: ----- -~ DUCT(OPEN 1)
I @I
{1 1
~
TERM INAL W75

10 ____
~ __ :.J CI!ED
~~ 1"'"
(")
~I
"

~
! _
1
1
MATERIAL - SUS304
11
n "'"
a
!S:
-
-
'"'" g ..
CA8LE GLANO 35b,2. 30b,1.
250,3. 25cx1
CA8LE GLAND
PG9,7 '"
<

m" '" .R-I! PUCA U8E C~;CR #10,3
>- 1. ENCLQSURE PROTECTlON : I44
2. 80 THICKNESS : 3.21 VIEW (F1j
s;J~ 3. Al COLOR : MUNSELL . 7.5 8G 7/2

<"> ..
(J1 '"~ n

4. CONNECTlON DLo\GRAM SHALL 8 PROVlDED
5. PG CA8UE GLAND : MS
V CASE.
INNER I ---
::::jl <=>
~ 6. WEIGHT : obI. 40kg .j:>.

CD '"

Page . 12/ 14

STARTING TERMINLS TERt.lINAl
\
, (]W (]W
~ ~~
EJIG. RPIl{D-6V)
1+) ""'j . ~'1
_8
(SOO) -, ,-)
T/C RPII{Q-1iV)
.--, ,.) t+~
4
C

~
~I-t
~~
...::.
~
(SIOI)
'-)r- F ~r-
~~
r,-6
~ ~,.;.~
G
POWER S<JUR<:<1DC24~ ~ ~8 fROIIl.>
"" r..::.
S1('
r-Q"
'1'_ J
~NO ~ fgf;'
w.<ER
smy
~
~
~
~ fi'i"

~
srN
" lTi ~
CONTROL
~
~. fif
G~i

r-Q"'"
..""'"
}-

}-
( .!!- '5 AC110V OR -

...::. AC220V L- 2

+~ lOWFR ' ,
UOOR r ~
GJ ' ~~ ~ I,.:
SYNCHRONIZING
oorERNOR
OC24V) , -~
...::.
~,'
' 4
+- SELECQR L-
SOP SOLENOID
GOVERNOR :mG:~~
~ ~SW~~
YARD S~Y
-
m INSAU..ED
....,. - SHIP'RD SWC BORD
31 D..J5" IIROWN ~
~
lt
OW PRESS. STOP BLUE [~
SA!1NGAIR I f#
210J5 D
r~
LOW PRESS. I.RU
(COSE NORt\L) @ .....
""'"
L f
r' ~
. COOUNG WATR
LOW PRESS. AlARId
INLET
@ ~ 110.15"
I~....
''''''
BAOWH I L=~
BJCK : ~~ -
W8. 0Il
LOW PRESS.

AL.AR1rI @ ~ (~ ....
110.15"
BROIIIN j L=~
Bl.CK !r
FUEL INLff
@ ~ 11IJ50 30
-~
LQW PRESS. Al.Rt.I I~ ....
~
n LTER HIGH ~
OIFF. PRESS. AL.AR1d f
*
BI.CK r~
~~
(COSE NORI.A~ 2 0.15"
(t.l oEl.).y SE'T:IOs BROWH L .34
f.O FLTER ttCH
Dlff. PRE5S. AL.AR1I
r;:::;::::::o:;
~
2 0.1511 ~ Lr ~36
.....
(COSE NORIIAI.~
( OEI.A" SET:IO$ ff,
~
, / W11 i ff,
=1 ~ f.':'
~~
1= -~ BCK ~
40 --, .. 210.,,1]
PICK- UP TC
~Y 41
PICK- UP ENGINE
., 3'fXW. CI.E 2 0.,,"
PROEJ::M: HOSE '10
l.CK , r~
'~"L fT,
. ' - 42
fT.
~""
~
110.151] l.CK ~
SOO SOLENOID ..
'- 46
PROEJ::M: HOSE '10
J[[ SSTEU
2 0.15" ~, ~~
"""1 1': 48
~ +~
!iCIf ! 3 0.15 l.CK ~
PICK-UP FQR J[[ SSTEM
~ W PIiOIECTJ''E HOSE '10 BWE -ff,.:c.
. S.G.HWANG &, T1TLE

1i.4tt,:;4t
CHK. O.S.YOON &, TERMINAL ARRANGEMENT
1lACH.& EIEC.CO.,LTD.
CHK. ,1;
DWG. . SHT. .
.' DWG. S.H.SUNG ~ UNIT: mm REF. .
KD1OS216 06
2010.11.12 & SCALE: N/S
Doc. . 1 5179
Page . 13/ 14

TRM INALS TERMINAL
.....,.,1"
~
2.0.75"
MECHAIIICAI. OVERSPEEO ..,.. ~--s3

PROTrC'IM: tE , 10 BROWN
( NORMAl) -=-
...... ,1 54
~
. WATER OJ 2 O,:r."
HIGH . 510 ..,.. 1. 55

BRQWN
( NORMAl) -=-
FUEI. L.E:AAGE ORAJN """,,1 56
HIGH Al..ARII
~ 1.
"56

I'RItC't'EfDSE"O IlROWN
(CLOSE NORMAl) ~
. I
oACl< ~
LOW LNL LlRM
(CLOSE NORMAl)
@ PIII(C1M; 1m: , 10 BLUE 1. .
-"'-
. I SUMP IAC-twtirrE 60
I~
~
O~GH LEVEL Al.ARM 2 ,
(CL NORMAl) II

I~ I PII(II(C1I''E l:sE , 10 ROWN
lURNING DEVlCE Al.ARM "

""" ,.1 .,-
-"'-
6
D STRT BLOCKING 2 0.15
(CLOSE NORMAl) I'IIOT[CIM HOS , 10 ROWN ' - " ~
-'-'-
65
66
-=-
=r; .,-
Ir .... ii
. WATER SYSTEM our 3 0..75
HIGH . LlRM

a>~ 66

...:..:..
. I
HIGH . AlARM 00 I ~l
....
3 0.15"
""" ,.1
ROWN
a>l~ ,-
"n
' - rf,-
-'-'-
-,,-
I-f.-
,j-
f.-
r-'-
(. :+) , ~
I-;g
EXHAUST GAS T/C
HIGH . LlRM ~ I -....,"'" : 1 J.H ~
r
AS* r-
r-
-
~
/. AL
r/C
<>
[
~

(4- )
2.fVdc
1. GENERAl TERMINAl BLOCK : Z.5sq(ZDUZ.5-Z/3AN) - 8

.MARKED TERMINAl BLOCK : Z.5sq, EARTH(ZPE2.5- Z/3AN) - 1"
3. AMPU~ER : 4-ZDmA/O-600'C(TC- 4Z0) - 1"
4. LlRM LA S SET A.M.S
. S.G.HWANG &. 1
I4 IE~4.
CHK. O.S.YOON &, TERMINAL ARRANGEMENT 11
U IlACH.& EIEC.CO.,LTD.
CHK. ,1,
DWG. .
OWG. S. H.SUNG Lt UNIT: mm REF. . SHT. .
2010.1 1.12 ffi SCALE: N/S KDlOS216 07

Doc. . 1 5179
1 2 F :3 4
P,ge . 14/14
r--- .
- - -
-,
100
~
70 4~5
/
/
--8272.582
{). -< ~
- 1 2 3 4

,
l<Jl)
'-~
. AC110V - AC220V
U

/
r -.
SELECTOR SWITCH
/
i
' ,.
-- -

~

<>
L __ -~
'-./
- II~~~~]
OUTP UT (OC24V)
GOV. OR
-- - INST ALLE O SW IT CH BOARD

MAK ER PA RT . : 8272.582(WOODWAR D)
...
t
>
:, 20081104
DOOSAN
KARAM
~~~
~J~
<EJeJTT Ol2J"e.!
O l ~~ O l ~~
Added drowing spec.(unit : ) 1
,< DOOSAN 1iI~1!! O I ~ eJ OI2teJ
~
20080304 Fi rst issu ed
- !!~~ Ol~~ gj~~
,;
KARAM

Dote Comp. Drown Chk'd App'd Oescrip tion of ReVsion
"".

"
.~ J
~
~ Doosan Engine
~ ~ IoI c... (9): IoIcI8ttal: R.r. ........... ~rc.lng n...:

~
- - ~
D ,ti8~'
!;J ~~
110 &

Projoc1lot! :
.. . !!! ".
)fIe:
L23130H !
;
,
ijff ~i i MOTOR CONTROL I
Scde: Si.
1: 1 3
MJo !.
,111 !i 1'.- 1';;[~1] i~
: IIS/IoIC .: Or<wing .:
!: 0042 43-0139 29
F
000. . : EAD1-5179-Q
Tier 1 ll . : DY139/DY3071
Tier 2 ll . :-
Subject:
LOCAL STARTER
Note:
Attachments : Refer the conten t s fo r dr aw ng st
2
Mod ilied the sec. luse & l use holer due the change
2011 0317 O I ~HI ~eJ ~eJ
subs u li e r
1
20101 117 O I ~BI ~ EH ~ ~EH~ First Issued.
Oate Orawn Chk'd App'd Oesc ri ption Rev.
~
Ooc.
Doosan Engfne 2-5179-1
.
DOOSAN - DIESEL aQe 1/50- '
REVISION HISTORY
DATE REV DESCRIPTlON
20101117 First Issued.
Modified Ihe spec. fuse & fuse holer due 10 Ihe change subsupplier (Page 12,14,50)
- Subsupplier: S8 FUSE ~ FERRAZ
20 110317 1 - Fuse : 3 ~ 4A , 5 ~ 6A, 15 ~ 16
- Fuse holder: FH -3 0 ~ CMS101

ENGINE
5L23/30 PART Electr ic

Doc.
DESCR IP- .
2-5179-1
10
LOCAL STARTER
Ooosan Eng ine CO. ,Ltd.

DOOSAN - DIESEL age 2/50
CONTENTS
Rev . DESCRIPTION DWG . . SHEET

1 LOCAL CONTROL 34- 031194-1 48

ENGINE

5L23 / 30 PART Electri c
Doc.
DESCRIP- .
2-5179-1
10
LOCAL STARTER

Page 3/50
, '
Local Control Panel with Starter
Note: SETA0139-1s (Yangzhou Dayang Shipbuilding Co" Ltd.)
ReV.1
- Changed spec, of fuse & fuse holer due change the subsupplier (Sht. 09,1 , 11,47)
Subsupplier : SB FUSE -> FERRAZ
Fuse : 3 -> 4, 5 ->6, 15 -> 16
Fuse holder: FH-30 -> CMS101
3
2
201 10315 01%21 71..2 :2: ~
o= ~ fd~~ Refer l nole, 1
20101115 0 1 %~1 t! EH ~ fd EH ~ Firsl issued.

Type 5 L23/3 0 MS/MG 0035
~
Drawing
Doosan Englne .
34-031194
Doc. . 02-5 1 79- 1

Page 4/50
MESSRS DOOSAN ENGINE Co . Ltd.
SHIP . DY0139!3071
PROJECT SETA0139!3071
ENG. B&W 5L23!30H
CLASS
DjG LOCAL CONTROL WjL.O PRIM. PUMP STARTER
( 47 ) SHEETS W!COVER
&
ffi
ffi 2011.02.21 ISSUED FOR WORING ..LE
& 2010.11.12 ISSUED FOR APPROVAL S.H.SUNG O.S.YOON S.G.HWANC
REV. BIBLlOGRAPHY OWG. CHK. CHK. .
. POR. .:
l~t.tIlEt:t.
S.G.HWANG
CHK.
MACH.& ELEC.CO.,LTD.
O.S.YOON
~K. REF. . :
I OWG. ..LE : 2010.11.12

DWG. . D1 0 S22 0
;. "u. .
ffi
t:MUL- :J' ( >;1' r
Page 5/ 50
1. CLASS & RULE : fN
2. . : 45'C
3. CSTRuc OF ENCLOSURE
- MOUNlNG D : WAll & DECK MOUNlNG
- IMTERIAL : SSWO, 2.31 & 3.21
- COOR : MUNSELL . 7.5 8G 7/2
- Rc DEGREE OF ENCOSURE : I23
4. lEER OF DOCUMEN '" DRAWING : ENGUSH
5. PlTE
- LETTER : ENGUSH
- IMTERIAL : PHENOUC
6. ElECTRIC SOURCE
- AC220V. 1, 60 3FEEDERS
- C44, 3, 60 3FEEDERS
(FOR C44, 1 MINIMUM FEEDER MUST CONNECED FROM EMERGENCY POWER)
- DC24V 3FEEDERS
-
7. CA8LE (INERNA)
- POWER CRCU : 66OV, SYP-2.5mn!
- CONROl CRCU : 660, SYP-O.75mrl & 1.25mn!
FW.tE RETARDANT
8. DI5GUIS BETWEEN COOR OF CA8LE UG CAP

- D.C POWER CRCU : ( RED ), ( )
- A.C POWER CRCU : R-U( RED ), S- V( WHE ), T-W( BlCK )
- CONROl CRCU : WHE WH NUMBERING
9. SCOPE OF SUPPlY : l SET/SHIP
. S.G.HWANG &.
H8tEC:8
CHK. O.S.YOON &. GENERAL SPEClFICATION
IJII IICH.!c ELEC.CO.,LTD.
CHK. .&.
OWG. ..
~ : mm REF. . DWG. . SHT. .

2010.1 1.12 &2010.02.2 1 SCAlE: N/S KD10S220 02

uoc. 1\10. . :f1v :.-J , .,--
Page 6/ 50
FUNCTlON DESCRIPTlON
1. Ready to Start Condition

1-1. urning Disengage
1-2. Not Engine Stopping.
1-3. Not Start Fail.
1-4. Not Common .
(Overspeed trip, . low press. trip, C.F.W high temp. trip)
1-5. . Primed.
1- 6. Sofety Start Condition.(Eng . stopped)
1-7. Not Tacho Fail.
1-8. Not Blocking Push - Button On.
2. START
2-1. .
Engine- Local- Remote Position Selection.
r .Engine : Engine Start Push - Button .

local Position : local Start Push-Button .
Remote Position : Remote Start Push-Button .
2-2. When the Ready to Start Lamp is , The Engine can started.
2- 3. Engine Stopping Condition.
3. STOP
3-1. locol Stop Push-Button . (l Stop) -
3-2. Remote Stop Push - Button . (l Stop)
3-3. Start Fail. Condition.(Auto. Stop)
3-4. Common Condition.(Overspeed, . low press., C.F.W high temp.
trip(Auto. STOP), Remote Em'cy stop)
4. BOCKING
4- 1. Engine Stop(Blocking) local & Remote Not Starting Condition
5. SHUTDOWN
5- 1. Overspeed trip.(above rating speed 112%~ 115%)
5-2. . low press. trip.
5- 3. C.F.W Outlet high temp. trip.
5-4. Remote Em'cy stop.
Page 7/50
FUNCTlON DESCRIPTlON
6. CABLE SUPERVISION(Cable Cutting Detection)

6- 1. Cable Detection For Stop Sol. /.
6-2. Cable Detection For Overspeed S/W.
6-3. Cable Detection For . Low Press. S/W.
6- 4. Cable Detection For C.F.W high temp . S/W.
6-5. Cable Detection For Remote Em'cy stop
7. ALARM BOCKING
The Locol Control Panel is provided with output for alarm blocking,
so that ALARM is avoided during starting and stopping of the engines.
8. START FAIL.
After Engine start button is , if engine is not running during time 15 s,
the start fail. signal is activated to stop the engine stop. And start fail. Lamp is .
. S.G.HWANG &.
eIEt:8
CHK. O.S.YOON &. FUNCTION DESCRIPTION
u: IlACH.& ELEC.CO.,LTD.
CHK. &
DWG. K.H.LEE : mm REF. . DWG. . SHT. .
12.'>
&. 201 0.02.2 1 SCALE:

2010.11.12 N!S KD1OS220 04

UUli . l'4U . . CMUL- \.J 11 \1 --
Paae 8/50
GRAPHICAL SYMBOLS
SYMBOL SYMBOL
-'I/IIV- RESISTOR
~ CONTACT(NO)
~ RES ISOR WITH TAPPING

r BREAK CONTACT(NC)
----.,- WINDING, INDUCTOR
WINDING, INDUCTOR TAPPING

<Yr
~
CHANGE-OVER CONTACT
CHANGE-OVER CONTACT
- BEFORE - BREAK
~
CONTACT,
-- CAPACITOR
( TIMER)
---jfL -t
BREAK CONTACT,
POLARIZED CAPACITOR
(DN TIMER)
-j~ ~
CONTACT
R
(OFF TIMER)
-.L
~
EARTH(GROUND) CONNECTION
>-t BREAK CONTAC
(OFF TIMER)
~
TRIPLE - CIRCUIT
...L FRAME OR CHASIS CONNECTION
BREAKER
[2] CONVERTER. TRANSMTER

~ CIRCUIT BREAKER
f\
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UOG. "u. . CtUL- ;J ,;;: '
Ter 1 ll . : DY139/DY3071
Ter 2 ll . : -
Subject:
GENERATOR
Note:
Attachments : Refer the content s for drawing ist
20101117 O l g~ ~EJj ~ ~ EH ~ First Issued.
~
Doc.
Doosan Engine .
3-5179-0
DOOSAN - DIESEL ,.
Page 1/ 19-
REVISION HISTORY
REV OESCRIPTlON
20101 117 Fi rst Issued .
ENGINE

5L23/30 PART ec t c
Ooc.
OESCRIP- .
3-5179-0

GENERATOR

., . DOOSAN - DIESEL age 2 / 19
CONTENTS

GENERATOA 34-03 1196- 0

ENGINE

5L23 / 30 PART Elec tri c
Doc.
DESCRIP- .
3-5179-0

GENERATOR
Doosan Engine CD . ,Ltd.

Page 3/ 19
Generator
Note: SETA0139-1s (Yangzhou Dayang Shipbuilding Co., Ltd.)
1. Engine Type 5 L23/30 720 rpm

2. Class. Society
3. Generator Output 762.5 kVA 1610 kW

4. Ambient Temp . 45 C
5. Rated Voltage AC450V 3ph 60
6. Insu lation Class Class F F

7. Enclosure I23
8. Cooling Method Self Cooling

9. Lub. Method Self Lubricating
10. Coupling Type Rigid Coupling
11. Bearing Type Single Sleeve Bearing
3
2
1
20101115 l%~1 idEH~ idEH ~ First issued.

ype 5 L2330 MSIMG 0077
~
Drawing
Doosan Engine .
34-031196
Doc. . 03-5179-0
Page : 4/19
CUSTOMER DOOSAN ENG INE Co.,L TD.

ISSUED Oct. 09, 201
CLASS
SPEC/F/CAT/ON
for
SYNCHRONOUSGENERATOR
(762.5 K VA , 1, 450V, 60 , 3SETS)
FOR APPROVAL
,'<
Oc 09, 201 For App roval H.G.Kim S.R.Cho i o.S.Song D.S.Kim

Prepared Checked Checked Approved
. Date Issued Co ntents
by by by by
(TEL:82-52-202-0383, FAX:82-52-202-6995)
HVUNOAI HEAVV INOUSTR IES Co.,

Electro Electri c Systems
http://www. hhi. co.kr
Doc. . : 3-5 1 79-0

Page 5/19
CONTENTS
1 CAUON
2 SPECIFICAON OF GENERATOR HFC7504-14K-Rev .0
3 PROCEDURE OF A.C GENERA TEST MG 1
4 SECONAL D WING 3-076653- .0
5 L OF GENERATOR 3S-000003-ReV .2
6 DIMENS ION OF SHAFT 3S-001007-Rev .0
7 L SS 3G-001777 -.1
8 AVR CONNECON DIAGRAM 3-001002-.0
9 L BLOCK DIAGRAM 3-001008-.0
10 REFERENCE VALUE SEnER 3-0541 -.
11 D CHARACTER I SC ... 4 -001050- . 0
12 SPARE FOR A.C GENERA 4 - 023970- .2
13 D.G SET L VIEW 4-057762- .0
Doc . . 03-5 1 79-0

~5 OI.l'.I~ ~Ail, ~f, HH!l 5
Page 6/ 19
CAUTlON
. Phase Sequence
Phase seq uen ce these generators are U-> V->W regardless rotating directi on
prime mover.
Please connect all cab les as shown in below ligure 1.
Generator Side MSBD Side
U U
V V
W W
'" MSBD : Main Sw itch Board

< Figure 1 >
. Manual Synchronizin g
Please be carelul at synchronizing each generator during on board test normal
operating as lollows .
1) Check th at in co ming generator voltage level and Irequency in its no-Ioad cond ilion
is co rrecl.
2) After rolal ing Ihe sy nchronizing swilch 10 Ihe "" posilion . please check Ihe
condi li on Ihe sync hro scope poinler . and ad ju st Ihe speed Ih e inco min g
Engine/Generalor unlil l is rolaling slowly 10 clockw ise direclion (no more Ih an
1 revolulion / 20 seconds) .
3) Th e in co ming generalor breaker shou ld be c losed as close 10 Ihe 12 o'c lock
pos ition as possible.
Warn ing
/1 generalor breaker is clo sed al co nditions other th an the above. Ihe
generalor exc ilalion syslem (Diodes . Varislors. Translormer ... ) & rolor
sl ato r can be damaged by transi enl reacli ve currenl.
Doc. . 3-5179-0
Page 7/ 19
SPECIFICATION OF GENERATOR
USE DI ESEL ENG GENERATOR QUAN'f I Y SIlIP 3 S S II P
OF ENCOSUIlli 23 CLASS
COO ING SYSEM AIR AIR ' . 15 '(;

EXCITING SYSEM SELF EXC NG BRUSIILESS INSULATION CLASS F
sCTUlli OF roro CYLINDRICAL ROII ' R SE F
COUPLING DIRECT RIGID J MtJlI C
SPECIFICATION BEARING
IIFC7 5()1 - 14 OF BEARING SLEEVE BEAlI NG
OUTPUT CAPACITY 762 .50 VA LOCATION DRIVED -
RATI NG CONTINlXJUS SIZE ' I2 0
PIIASES ,W , CONN 3 , , (' WIND ING ) QUANTIY 2.3 LITER

VOLTAGE AC 150 V SYSEM SELF LUB .
CURRENT 978.3 GRADE ISO VG 68
FREQUENCY 60 PRESSUIlli - bar
POLES 10 . Max - '(;
SPEEIJ 720 AIR COOLER

I'O\\'ER FACTOi! 0. 8 LAGGING CAPACIY -
GD' ! J 244 .4 g.m ' 61 .1 g.m ' FLUID -
roro WE IGIrr 1585 g QUANTIY - m' Ih
WEIG I r 4.0 . - '(;
CHARACTERISTICS .' RISE - '(;
OVER CURENT REFER . . PRESSUIlli - g/n'
VARIATION OF GENERATUR VOLTAGE 2. 5 \, WEIGIrr - g
OVER SPEED 120 % 2 min. DETECTING SYSTEM

VOLTAGE ADJUS 5. 0 % WI NDING . OIThI 2EA/ PIlASE
MOUNTI NG MtJlIOD 816 BEARING . ROJ
REACANCE & NSANT COOLING AIR -

( CALCUATED VALUE ) LEAAGE DETEC!OR -
Xd 240 %(UNSATUIMTED) ' d 0.0837 Sec . roNFIRMED OWNER
' d 23. G%( SATURATED) " d 0.0027 Sec . LOCATION OF TERMINAL .
IIG IlT SII)E
" d 12.6 %(SATURATED) Ta 0.0267 Sec . (VIEWD FROM VE
,. 1.4 % CABLE ! S II J
SPACE , 220V, 315W

PAINTING COLOR 7.5 BG 7/2
-RElIMENDED ALARM/ TRIP SETTING W.T .IJ
) : 150'(; LOCATION AIR CLER FLANGE
-
2) TRIP : 155'(; (VIEWD FROM PRIME )
IOATI NG DlRECTION GENEIMTOR C.C.W
(V IEWD RO PRIME MOVER)
REMAR
mTS . I SPECIFICATION MAR SIIOULD I N FOIMED
YOUR DRAWING
2 HFC7 504-14K-Rev.O
3 DESIGN CHECED CHECED APPROVED
1
Oct .09 , 2010 S.R.QIOI S.R.Choi O. S.Song D.S.Kim
5
RW- W230- 158-0 A4( 210mm 297mm)
Doc. . 3-5179-0
Page 8/19
TEST PROCEDURE OF A.C SYNCHRONOUS GENERATOR MG 1 1/ 2

Tes111em Proced ure Crilerion Remarks
Th e generalor l l be operaled wilh raled

currenl unlillhe l emp era1ure each
sec!ion are sa1uraled acord in g 10
Tempera1ure 115. Slalor : < 100 'C
1 Type lesl
Ri se Tesl The lempera1ure ri se shall be measured by Rolor : < 105 'C
resislanc e melhod acco rdan ce wilh IEC
60034-1 adjusled as necessary l or Ihe
ambienllempera1ure spec ilied Rule.
Th e generalor ll have 10 wilhsland

Wilhoul damage
2 Over load Tes! 50% ecess ra!ed currenl lor 120
visually
seconds af1er lempera1ure ri se les1.
Overspeed l esl 11 be carri ed l

lor 120 seconds wil h 1.2 limes Ihe Wilhoul damage
3 Overspeed Tesl
raled speed und er ec ilalion visuall y
condilion .
The lesl VOllage wil h commercial

Irequency ll be progress ively applied
Hig h Vollage and mainlained 10 lull valu e lor 1 minu1e Sl alor : 2,000 V
4
Tesl belween each windin g and mass (Irame Rolor : 1,500 V
and magnelic circuil) co nnecled wilh Ihe
olher windings .
In sulalion resi slan ce each separal e

Measuremenl
winding ll be measured wilh
5 In sulalion More Ihan 5
DC megger belore and af1er
Resislance
high vollage lesl.
Meas uremen l
Each winding resislance ll be
6 Winding
measured by l ! - amp ere melhod.
Resislance
Doc. . 3-5179-0
Page 9/ 19
TEST PROCEDURE O F A.C SYNCHRONOUS GENERA TOR MG TB 1 2/2

Test Item Proced ure Cr iteri on Remarks
Alter power circuits are shorted with

Steady State ec i tati o n ,
givin g eci t at i o n whil e runnin g
With out damage
7 Short Circu it at rated revo lution, th e generator with Type test
visuall y
Test ec i tati o n system ll have to with stand
300% rated current l or 2 seco nd s.
Th e generator, t ogeth er with its vo ltage

regu lati on system, ll be veril ied suc h G
Veril icat ion
way that , at alll oads I rom no-Ioad runni ng
the vo lt ag e
8 to l ulll oad , th e rated vo ltage at t he rated
reg ul ation
power l acto r is maintain ed wit hin 2.5%
system
un der steady co ndition . Test shall be
carri ed out acco rdin g to approval draw in g.
Th e generator ll be operated at no-Ioad

and rated speed with rated voltage.
9 Load Test
Th e generator vibrat ion and bearin g
lubri cati on systems shall be chec ked.
Veri l icati on Th e louver l or the air inlet ventil ati on

10 degree shall be reviewed l its drawing is Repo rt Revi
pro tection acco rdance with IEC 60034-5.
Verili cati on co mpl eti on th e test, th e bearin g With out damage

11
Bearin g shall be overh aul ed. v is uall y
* 1. Typ e Test : Test th e lrst generator a serIes. Rev. 1

*2. Above test items & proced ure are sati sl ied with requirement.
Doc. . 3-5179-0
,---- 2 3
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~ UOC 1'10. Ect-:J ~-
Doosan Engine
CLlENT Yangzhou Dayang Shipbuilding Co ., Ltd

ENGINE 5 2 3 /3 0
. DY3071
DOCUMENT . MSPH - 5182 - SETA3071 s
SUBJECT :
L HISTORY
- - - - - - -
~ .~ .. - _.. . -
3
L MANAGEMENT
- Medium Speed -
2
/
1 LEADER I.M . E ~
{JJf:; "
FI RST ISS UED. S. . YANG 16-Aug- 11 MANAGER P.G. CHOE~~

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REV. DESCRIPTlON CHECKED DATE INSPECTOR : S. H/:f."~
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ENGINE INFORMATION
ENGINE DOOSAN-MAN DIESEL : 5 23/30
ENGINE BUILDER DOOSAN ENGINE CO., D.
PROJECT SET3071 -1, 2, 3
ENGNIE . - 5182 5183 5184

~-- - YARD-- --
Yangzhou Dayang Shipbuilding Co., Ltd
ND. 3071
. eWNE;R -SE-TAF-GAGE~Tc . .
CLASS
CERT' 10049PSN11
SPEC. . .
TEST D 28 Ju ly 2011
PARTICIPANTS SHOP TEST
OWNER REPRESENTATIVE(S)
YARD REPRESENTATIVE(S)
Peter .
Jorgensen
L1CENSE REPRESENTATIVE(S)
DIES EL & TURBO SE
Shi yun Ryu(Official Test),

Sang-Ryong Park(Overhaul inspection)
CLASS REPRESENTATIVE(S)
8 SURVEYOR
..... -
J ':
INSPECTION RECORD(A)
: ~ Ai
Record
71~Ai ~.2:
Page
.
.
:
5182 - LlST -
1 1
1
11 " \'J:2:
PJT Name : SETA3071 -1 , 2,3 ll . DwgfTr .
3071 LlST
PJT . : 1 - 5182 5183 5184 ~ ~~ ~ ~~I~~J~
Shipyard . Yangzhou Dayang . ~'(.\~~

. Engine Type
5 23130
3 tj ::t. . Shipbuilding Co., Ltdk~ :t.~(""' ~~~6.J
Perso n Charge (r~I "' 08 1 U __
: S .H YANG . V .. '7 / 1 "
g " ~ '10 .; , / /
Record . Kind of in spection Ins pected by
7 1 ~ Ai ~.2 J Rev. .ff ~ ~ * ShOp: QM !cl assbwneI'
518 2 - 3 01 - Bearing Clearance (Main & Guide bearing) W R

2 5182 - 302 - Camshaft Bearing Clearance W R '
3 5182 - 304 - Big End Bearing Clearance W R
4 5182 - 7101 - Adjustment Conical Antivibration Mounting W R
5 5182 7101 - 02 Crankshaft Deflection (Co ld Condition) W W R
6 5182 - 7204 - Timing Check - Normal Condition W W R

-------------+-------------------------------~4__+--+_-1
7 5182 - 7204 - 02 Official Shop Test W W W
8 5182 - 7204 - 03 Crankshaft Deflection ( Cond ition) W W R
9 5182 - 330 - Overhaullnspection W W W
- 1-
- - - - - -.. ---------------I----If---+---I---I---I
--
C:Confirm( :!!f'i:l ) W:Witness( ~ ~I) R:Review('EI ~ )

O:Owner 9J f ~& H:Hold po(~ ~I)
Doosan Engine Co., Ltd

Record .
5182 - 30 1 - 1
IN SPECTION RECORD(A) 71,,\j \':1:2.
A:i'LmJ 7~
D
7 1 ~
-, 1 Page .
1 1
illO I AI \':1:2.
PJT Name : SETA3071 -1,2, 3 ll . Owgrrr .
3071 31
PJT . : DMM1 - 5182 5183 5184 ~I:!{~~ ~~/~~!~
Shipyard . Yangzhou Oayang Cl ass En gine Type

3t!~ . Shipbuilding Co., Ltd t! ~
~~~~ , 5 L23/30
Result . Salisfaclory Prepared '- ' . --'" ul.11 Approved .~~;<~'; 4.JuI'11
>iI :ill . Unsali slaclory ~ ~ A~ '--;jItJ/
S.H . G f
'" ::J ...... P.G CHOE Oale
Kind of inspection
Bearing Clearance (Main & Guide Bearing)
f! A~ %{f-
Witnessed Witness ed Witnessed
~ :2:1 gJ ~I A~ ~ 2.1 f
Unit: mm
,.i'-
- ~
D
.,
:-

f"~f\
~// ~/
r-
~
~,p
cr~ rn /! 1
... '/.,/,'-/. W,
~X1*~
-- - , .. - .- -- ~
-
;;"",~,
;~-i(?'
,........- ///-%',.
! :~-nli~:1

1\
._-- _.- - - -
_

!, -- - . -

.L \ /~
- .- ,.
- - :.!R ~ "" ~ ...
-
-
FREE ORIVING
'
Main & Guide bearing clearance
Project Name SETA3071 - 1

Main bearing cIea rance SPEC.: 0.20 - 0.30 mm
RG. 1 2 3 4 5 6 7 8 9
F
~
F F F F
..
F F F
CICfnce
0.20 ' 0.20 0.20 10.20 0.20 0.20 0.20 10.20 0.20 : 0.20 0.20 10.20
Guide bearing cJearance
Position +
Clearance ( 0.15 - 0.44 mm) Max.0.8mm 0.22

Main bearing cIearance SPEC. : 0.20 - 0.30 mm
RG. 1 2 3 4 5 6 7 8 9
F ~ F F F F
**
F , F
ClcaraIce
D.2Q' 0.20
0.20 10.20 0.20 0.20 0.20 0.20 0.20 10.20 0.20 10.20
Guide bearing clearance
Position +
Clearance ( 0.15 - 0.44 mm) Max.O.Bmm 0.24

Main bearing clearance SPEC.: 0.20 - 0.30 mm
BRG. 1 2 3 4 5 6 7 8 9
Clear3JC(l F F F F F F F F F
0.20 . 0.20 0.20 10.20 02010 .20 0.20 10.20 0.20 10.20 0.20 10.20 ..
Guide bearing clearance
Position +

Clearance (0.15 - 0.44 mm) Max.0.8mm 0.19
Ooosan Engine Co ., Ltd

.- Record .
5182 - 302 - 1
INSPECTION RECORD(A)
t"N1I
71"'~ \':!~
:3 71 -, Ai .. Page .
1 of 1
llilOlxl \':!~
PJT Name : SETA3071 -1.2.3 u . Dwg r .
DY3071 302
PJT . : 1- 5182 5183 5184 ~~~~ ~~/8gI~
Shipyard
:~.:7::
. Yangzhou Dayan g
. Shipbuilding Co., Ltd
Class
i! ~ JV Engine Type
r!I~~~ ,-
5 23f30
Re5uIt . Sati5factoy Prepared ,oJui11 Approed ~~I-11

~?~-
.
~ .1l~ . Unsat i sfactor :&t ~ ~ S. (UANG Date - <ZJ ~ . '"P~G CHOE 'Oate
Kin d of inspection
Camshaft Bea ring Clearance
-~~
Witnessed 8 Witne55ed Witn essed
~ :0:1 ~ :21 ~ ~ ~
: mm
CyI.1 5 ! cyI. Driving end

-- - - .-
-. --
~f -. - r -.. '
=e~-. =~~"
-
- , . ":: -
- ~
--, . -
"U~'-
-
,
- !_ _
- 'I --J - D~
F lF F F ~
h.. h.. ~ h..
""
FREE D DRlVING D
Project Nam e SETA3071 - 1

Cam5haft bearing cIea rance: 0.11 - 0.20 MAX. 0.35mm

BRG. . 1 2 3 4 5 6 7 8
-
C/earan ce 0.11 0.12 ! 0.12 0.11 0.11 0. 12
Camshaft Axiai CIea ran ce (Spec. : 0.11 - 0.20) 0.20

Camshaft bearing c I earace: 0.11 - 0.20 MAX. 0.35mm
BRG. . 1 2 3 4 5 6 7 8 9
C leara nce 0.11 0.12 0.11 0.13 0.12 0.12
Camshaft CI earance (Spec. : 0.11 - 0.20) 0 .20

Camshaft bearing cIearance: 0.11-0.20 MAX. 0.35mm
BRG. . 1 2 3 4 5 6 7 8 9
--
C lea rance 0.11 0.12 0.11 0.13 0.11 0.13
Cam5haft CIearance (Spec. : 0.11 - 0.20)

0 .20
Doosan Eng Ine Co ., Ltd
Re cord .
5182 - 304 - 1
INSPECTION RECORD(A) 71~Ai \!J.2:
::J 71 ~ -l Page .
1 1
iiljOjXj \!J.2:
pJT Name : SETA3071 - , 2, 3 . DwglTr .
307 304
pJT . : - 582 5 83 5 84 ~t:!/"~~
Shipyard . Yangzhou Dayang CIass Engine Type
~~ ::::: . Shipbuilding Co., Ltd ~ => ~
~~~6.J \
5 2330
Result Satisfactory Prepared 'L'" _ 16-Jul-11
~ ilr . D Unsatisfactory , ~ -
Xf .. 7l. rr{YANG -Date
-
Kind of in spection
Big End Bearing Clearance
?:j At%ii-
Witnessed Witnessed Witnessed
~ ~I xf ~ ~ Xf ~ ~ xf
: mm
<:::
=

Main bearing F>

- = C>
Big end bearing

- -_ -
..
~ .
--
r
-
DRIVING
FREE

Big End bearing clearance (SPEC. : 0.13 - 0.24mm )

Projec t Name SETA3071 - 1
BRG. . 2 3 4 5 6 7 8
Clearance 0.14 0.16 0.15 0.14 0.16
Proiect Name SETA3071 - 2

BRG. . 1 1 3 4 5 6 7 8
Clearance 0.15 0.14 0.15 0.15 0.15

BRG. . 1 2 3 4 5 6 7 8
--"--r----'---j---'---j
Clearance 0.14 0.14 0.15 0.14 0.15

Doosan EngIne Co. , Ltd
Record .
5182 - 7101 - 1
INSPECTlON RECORD(A)
_: 71S}Ai ~~
: 71 ..
-. A-j Page .
1 1
\'J ~
PJT Name : SETA3071 -1,2,3 . wg r .
3071 7101
PJT . : DMMI- 5182 5183 5184 ~~~~ S: ~/g~~~
Shipyard . Ya ngzhou Dayang Class Engin e Type
~~~ . ShipbuiIding Co., Ltd ~ ~ /V ~~~~
5 23/3 0
Resull . Sati slactory Prepared 8 Lo.JuI-1 1 Approved A~2',JuI-11

fij "'f . UnsatislacIory ~ ~ ~ s:l?'('G Da te ~ ~ xf P.G CHOE Oate
Kind of inspection
A d jus tm e nt Con icaI An t ivibration Mou nt ing
.f:f~*
Witnessed 8 Witnessed 8 Witnessed 8
~ ~ I A~ ~ 3t1 xf g ~I At
: mm
EXH/JUSSIDE
' /2<2 ,,.
. -
- ,. - - -
- - -
- ' t.1 ,.
", m- i1 = Ihe lolaI nnber
11)}' .,,.
,.
.!
Go nIcal anOvbrano n mOUI'1Ing
FREE
~ -IOI OI I C -10101 )
'-!
-
-
Generator ~ fr:; :. "'

u ,.
., . u~
.
Ji ~- "h"
". ,."
,
.,; ~ ~
~. ~ ,
.- ::
* W L. ;.~ ~.
:u ,.
, ,. <- ' 1
rU MrS IDC
Tole rance : Max. Deviation :$ 2 mm
PJT. . : - 5182 PJT. .: - 5183

Type: TR314K1002A 45 Type: TR314K100 2A 45
1 124.5 5 125.0 1 124.0 5 124.5
2 124 .5 6 125 .0 2 124.5 6 124.5
-
3 124.5 7 124. 5 3 124.5 7 124.0
4 125.0 8 124.5 4 125.0 8 124.5
Max. Devi alion 0.5 Max. Devialion 1.0
PJT. .: - 5184 PJT. . : -

Type: TR31 4K1002A 45 Type:
1 124.0 5 125.0 1 5
1- - , - --
2 124.5 6 124.5 2 6
-- -
7 124.5 3 7
3 123.5
4
--
4 124.5 8 124.0 8
Max. Deviati on 1.5 Max. Devi alion
Doosan EngI ne Co . ,Ltd

Record .
5182 - 71 01 - 2
INSPECTlON RECORD 71!1\Aj \!:!~
'\ftl ~ ~ 71 -, Ai ~ Page .
1 1
IilIOlxl \!:!~
PJT Name : SETA3071 -1,2,3 U . Dwgrv .
DY3071 7101
PJT . : DMMI- 5182 5183 5184 ~~~~ ~ t2:J / tiHH~:! :2.
Shipyard . Yangzhou Dayang Shipbuilding Class Engine Type
. Co., Ltd / BV 5 23/30
2~.:1: ~~ ~~~~
Resu lt . Satisfactory Prepared :; ul - 11 Approed . / ' \ / . " offl' 25.Jul -11
~ "f . D Unsatisfactory - ~ ~ S~{gNG --
Date ~: ~ P.G CHOE" Date
Kind of inspection
Crankshaft Deflection {Cold Condition}
f:lA~g.*
Witnessed Witnessed Witnessed
~ ~ ~ ~ :: xf ~ :: f
: 1/100 mm
~~
Vert ical and horizontal Def Iection BotIom 51art
Crank throws (Cold engine) lefI side
- . lor 3/100mm
-~~JP
-- - AccepIable 5/100rm S Aj1I side -
Vertical Deflectioo Crank throws V 8 "
1/100 mm /Q .; at yv,!1ee
- CoJd -Vertical :=-
Rigid coupl ing (}-3/1(X)nm 16=0.5 )
- f r nmJoo.Lend
~Iexible coupl ing 1 11 . --- - Hor izontal : - - S

Cylinder . 1 2 3 4 5 6 7 8 Remar

Cold Condition 1
-1 1 3 1
Tem p. : 30 c S -1 1 2 1
1 1
Ver1ical -1 1 2.5 0.5
Horizontal () 1 -1 -1 -1

Cylinder . 1 2 3 4 5 6 7 8 Remar~

Cold Condition 2 2
1 1 3 2
Temp. : 30c S 1 2 -1
1 1 -1
.-
Ver1ical (V) -0.5 0.5 1 3 2.5
Horizontal () -1 3

Cylinder . 1 2 3 4 5 6 7 8 Remark
J
Cold Condition 1
1 1
Tem p. : 30 c S 1 -1
-
-2
Ver1ical 1 1 1
Horizontal () 1 -1 1
Doosan Eng ine CO. ,Lt d

- , ,
pJT Name : SETA3071 -1, 2, 3

INSPECTlON RECORD
-fI 7 1 ~
ll .
Ai
3071
Rec ord
Page
illIOI"1
.
.
7 1~ Ai ':! :[
':! :[
OwglTr .
5182 - 7204 - 1
1 1
7204
PJT . : 1 - 5182 5183 5184 t! t3{~ ~
Shipyard Yangzhou Daya ng Shipbuilding Class Engine Type
Co., Ltd
.5 23/30
<z!!~J~ \.
Result u a " " a c <v, , Prepa red Approved ,?/'/,?r<
~ .I!.~ D Unsalislaclory . S.rl> . ~P.G CHOE . Oate
Kind of in specti on
Timing Check (NormaI Condition)
i:1A~ *
W itnessed 8 Witnessed
.. 1':1 Xf ~ ~I ~
Unit : mm
FUEL INJECTlOO TltING( BTDC) ' IESLfIEMEN
- FIRING OROER -
5 : 1 - 2 - 4 - 5 - 3
6 : 1 - 4 - 2 - 6 - 3 - 5
7 : 1 -2-4-6-7-5-3
OL . , - < . - . - - .0
Project Name : SETA3071 - 1

Cyl. . 1 2 3 4 5 6 7 8 Average
Angle(BTOC ' ) 11 .8 11 .2 11 .2 11.6 11.2 11.40
Meas _ "" 4.95 5.23 5.26 5.10 5.30 5. 17
Cam l ea d 6.31 6.31
- 6.31 6.31 6.31 6.31

Shim () 3.8 3.5 3.5 3.7 3.5 3.60
Ca m Gear Adjustm ent 0.5 '
Project Name : SETA307 1 - 2

Cyl. . 1 2 3 4 5 6 7 8 Aerage
Angle(BTOC') 11 .8 11 .2 11.2 11.2 11.2 ! 11.32

Meas - "" 5.06 5.37 5.21 5.25 5.31 5.24
Cam Lead
- 6.31 6.31 6.3 1 6.31 6.31 6.31
Shim () 3.7 3.4 3.4 3.4 3.4 3.46
Cam Gear Adjustment 0 .5 '
,
Project Name : SETA3071 - 3
Cyl. . 1 2 3 4 5 6 7 8 Aerage
Angle(BTOC' ) 11.4 11.4 11.4 11.4 11 .4 11 .40

-
Meas - " " 5.26 5.26 5.37 5.36 5.34 5.32
Cam l ead 6.35 6.35 6.35 6.35 6.35 6.35
Shim () 3.4 - 3.4 3.4 3.4 3.4 3.40
Cam Gear Adjuslmenl 0 .5 ' .
Doosan Engine CO. ,Lt d

~ Doosan Englne
L OF SHOP TEST
PROJECT SETA3071 -1,2, 3
- -- ___ ENGINE_ND. - 5182 5183 5184
ENGINE 5 23/30
ENGINE 650 kW, 720 rpm
SHIPOWNER SETAF GAGET
SHIP YARD Yangzhou Dayang Shipbuilding Co., Ltd
SHIP NUMBER DY3071
CLASS
TEST DATE 28 July 2011
P.G. CHOE MANAGER OF QM , MEDIUM SPEED
DOOSAN ENGINE CO.,LTD.

-
Record .
5182 - 7204 - 2
INSPECTlON RECORD 71~Ai ~~
i:J ~ 71 ..
-, Ai Page .
1 4
JIll ol,,1 ~~
PJT Name : SETA3071 -1,2,3 U . wgrv .
3071 7204
PJT . : DMMI- 5182 5183 5184 {:j"!~ ~ .s:~/i'I~~~
Shipyard Yangzhou Dayang Shlpbu1ldlng
Co., Ltd
Class . : /V Engine Type
5 23/30
e~ .~ /
~t:!~ '1'!~~"! "-
Result 0 Satislactory Approved . ~AJ{ ? . ;;;::;<
l!f Unsatisl actory ril7e. 1' SAG'ANG Oate " ~ "f - -. e;- CHO-E oa;
Kind of inspection V
: IShODT- '
.f:iA~~ff.
Witnessed " . Witnessed ~v:vr:_:7/9V"/
.. :: .. ::
"~~ ~ B~~'P ,"

"f "f
Engine type 5 23/30 .~* ./. ."....

~ SIGNA1JlF ~ '>
Output at MCR 650 kW, 720 rpm
- Shop test date 28 July 2011 "TF ~1~~f'ofr f'-.
Overhaul date 29 July 2011
Test place _.! & Com missioning shop
Production Medium Speed, Doosan Engine

: Safety device confirmation test

: Over speed test
I- 6: Load test
C : Governor test
D : Generator characteristic test
=
t Load(%)
6 CDE
-
11
100
- - -- --
-
4! - 5 1 - ,
- - l/i !i\
,
1
~1 i!-ji
90 - '. - --- .. - -- - -- - ,-
,

80 -- --1- - - - ~~ - ,
_. 1-
!
'~~ 41
70 -- - -
"!
60 _. -- -2 - 1- .. ~.: .. _. -- -- -
50 - ,!

,

,

40
30
-

... -
.-
- ---
-
~1
---
-/
-
c---
1- ,

j
-
jl , , ..
- .- - -
-
---
,
!.

!
. - ,-
.
..r
_. ---'1- -- -- - -! -----

20 ... - 1 -- . - - "1
- ..

,

,~- !
-
'-i!
J. _
-
10 . - ; -1- _.
-- 6
---
!
j ! ! ' ,
5 35 40 70 75 10511 1701 75 205
--+ TIM E(min)
Doosan Eng i ne Co. ,Ltd

Record .
5182 - 7204 - 2
INSPECTlON RECORD 711!1 Aj !! ~
~ ~ 71 .
-, Ai Page .
2 of 4
!iI " !! ~
1. OFFICIAL SHOP TEST

T he diesel engine shall be applied to coupli ng test combination with alternator the common
bed plate as fo llowing sched uIe.
1) SAFETY DEVICE CONFIRMATlON TEST

- ---
- - - -
This test shall be carried in the state of the engine being load for following items.
(lfS'FARTlNG"FES - . - -
SETTING ACTO VALUE

STARTlNG TEST I
AUE NQ 1 22 23
Emergency sIart - -
Emergency sIop - -
Turning gear inIer lock test - Interlock
Local start frm operation box - -

Local stop from operation box - -
SAFETY FUNCTlON TEST

SETTING ACT'L AUE
SAFETY FUNCTlON TEST I
VALUE 1 22 23
Over speed (Electric) within 815 810 812 809 rpm
Over speed (Mechanical) within 825 820 824 823 rpm
Lub. l engine in leI lw press. 2.5 0.1 2.50 2.49 2.52 bar
Fresh water engine outlet high temp 95 2 95.4 95.1

95.3 "C
Alarm test : be omitted bece.use AMS is supplied by yard.
Doosan Engino Co. ,Ltd

, Record .
5182 - 7204 - 2
INSPECTlON RECORD 7I"1 Ai \!:!~
f:j A ~ 71 ..
-, A-j Page .
3 4
JliIOIxI \!:!~
2) LOADTEST
This test shaII be carried ! the state the engine coupIed with aIternator under rated
speed. Load test is be carried ! based engine power and testing order and durati on l or
each Ioad are as 10IIows.
GENERATOR
D ENG INE RPM DURATlON
SHOP TEST PF=1.0
load - - 720 One measurement
25% 163 kW 155 kWe 720 30 min
- ._-50% 325 kW 312 kWe 720 30 n'1in -

75% 488 kW 467 kWe 720 30 min
100% 650 kW 620 kWe 720 60 min

-- - -~-
110% 715 kW 680 kWe 720 30 min
The time requi red lor load-up is 5 min at each load.
The measurements lor each load range are performed and recorded Doosan's test record sheets.
3) GOVERNOR TEST
Instant and permanent speed variation and voltage variation shall be measured respectively
by rapidly changing the load the engine as lollowing method .
When lullload is suddenly taken off --- 50% --- 100% load, the speed is to control within 10%
momentary variation and 5% permanent variation rated speed.
Speed variations with load changes accordance with aboves are to return and remain within 1%
lnal
steady state speed more th an 5 seconds.
Governor load 100% is based 61 kWe board conditions.
Loa d
100%
50% -
T1me
Speed
.
110%
--------- -1\/--------------------------------- ----
~ Ir
100%
Ir
90% ---------- ~ -------- --- -------------- - ----- -- ---
--< ,max. 5 seconds
tm.
Doosan Engine Co. , Ltd

Record .
5182 - 7204 - 2
INSPECTlON RECORD 71 ~ Ai ~ ~
~ Ar 71 ~ Page .
i " ~ ~
4 4
4) LOAD CHARACTERISTlC TEST

After setting frequency(speed & oltage) at the rated a l ue, change the load as follows.
100% -75% - 50% - 25% - 0% - 25% - 50% -75% -100% - 110% - 100%
During the each load condition , frequency and o l ta g e a l ue shall be recorded without regulation.
5) Parallel running test

In condition of 75% load of alternator, the frequen cy and oltage are regulated the rated alues . After
regulation , parallel running test shall be applied for 3 gensets at once.
Load aria ti on of parallel running test is as follows

- 75% - 100% -75% - 50% - 20% - 50% - 75% -100% -75%
For any load between 20% and 100% of the sum of the rated of all generators, the load on any
generator is not differ more than 15% of the rated output in kilowatt of the largest generator.
6) Others
- Crankshaft defl eciton
- Torsional i bra t ion One(1) engine / project
Doosan Engine Co. ,Ltd

Instruction Manual For Diesel Generator DOOSAN MAN DIESEL 5L23 30H 720RPM

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Instruction Manual For Diesel Generator DOOSAN MAN DIESEL 5L23 30H 720RPM

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Volume 1

Index for Maintenance Manual

500 Main Data for Engine

'n J~ta for Engine 500.00

(Marine engines an/y)

! is impartant that aII Diesel engines are oper-

In accordance with Chapter 1I,e Code Federal

CyI. Nos. available 5-6-7-8

Power range 650-1280 kW (885-1740 )

Stroke/bore ratio 1.33:1

Piston area per cyI. 398 cm'

Swept volume per cyI. 11.91Ir.

Compression ratio 13:1

Max. combustion pressure 130 bar'

urbocharging principle Constant pressure system and intercooling

Fuel qualiIy acceptance HFO up 700 cStJ50 C (BSMA 100-9)

Speed rpm 720 750 90

Mean effective presSlIre bar 18.2 18.1 17. 9

Max. combustion pressure bar 130 130 13

Power per cylinder kW/cyl. 130 135 16

Over!oad rating ( 10 1%) allowable 1 houl' for cvery 12 hours

Power per cylinder

The book is a basic instruction manual the particu-

The first v seclios (500-504) the book serve

The last section (520) comprises tools.

The engine is divided a number main com-

Each these sections starts with technical de-

In particular, welding work which causes the

Fire Opening cocks may cause discharge hot liquids

Hand tools should be placed 10 be easily accessible Crankcase Work

FeeIing Over Turning

Engine Type Identification

MCR Maximum continuous rating

Front end Flywheel end

Exhaust side Right side

Direction "Clockwise" of diesel engine seen from flywheel end

(40T')~"""'- Measuring device

Iemperature Jj,larm High

Refer standard location and instruments on the following pages.

Specilication letter code lor measuring devices

V Viscosity S Switching, Stop

Charging Alr System

Fuel 011 System

Nozzle Cooling System

Exhaust Gas System

General The Iront page indicates the lollowing:

The maintenance system is divided 2 main

overhauls and inspections the engine.

the works be carried ! by the personnel

The stated recommended intervals are only 3 .

Working Cards Fig. 1 Instrction guide for working cards.

Each the working cards can be divided : a

Time Between Overhaul

Readings data engine and alternor, wl -

/n/et and ehaust va/ve - overhaul and regrinding

Cylinder head cooling water space - inspection ............ . 11 505-01.45

Piston, Connec!ing Aod and Cylinder Liner:

Inspection pistO/1 ..................................................... . 506-01.1

Piston pin and bush cO/1necting rod - checl<

Connecting rod - retightening ........................................ .. 200 liII 506-01.25

Camshafl and Camshaft Drie:

Camshaft - inspection gear wheels, bolts, connections

Lubrication camshaft bearing - check ........................ .. 507-01.00

Lubricating operating gear - checl< ______ . _ -- liI 508-01,00

Salety, alarm and monitoring equipment ________ . _ _ 509-01 _00

Lambda controller - adjustmen. _ . ,, .- .--. 509-10,00

Vibration damper - check the condition _________ , _ 510-04,00