L23/30H Mk2 Instruction Manual - Marinemaytau.ut.edu.vn/userfiles/files/L27-30H-MK2.PART3.pdfL23/30H Mk2 Instruction Manual - Marine Four-stroke GenSet Fuel oil system 514/614 Internal

L23/30H Mk2Instruction Manual - MarineFour-stroke GenSet

Fuel oil system

514/614

Internal fuel oil system

Figure 1: Internal fuel oil diagram

Pipe description

A3 Waste opil outlet DN15

A1 Fuel oil inlet DN20

A2 Fuel oil outlet DN20

Table 1: Flange connections are as standard according to DIN2501

General

The internal built-on fuel oil system as shown in fig 1consists of the following parts:

▪ the high-pressure injection equipment

▪ an internal nozzle cooling system

▪ a waste oil system

Fuel oil system

The fuel oil is delivered to the injection pumpsthrough a safety filter.

The safety filter is a duplex filter of the split type witha filter fineness of 50 my. The filter is equipped witha common three-way cock for manual change ofboth the inlet and outlet side.

Fuel injection equipment

Each cylinder unit has its own set of injection equip-ment, comprising injection pump, high-pressurepipe and injection valve.

The injection equipment and the distribution supplypipes are housed in a fully enclosed compartmentthus minimizing heat losses from the preheated fuel.

This arrangement reduces external surface temper-atures and the risk of fire caused by fuel leakage.

Fuel oil injection pump

The fuel oil injection pump is installed on the rollerguide housing directly above the camshaft, and it isactivated by the cam on the camshaft through rollerguides fitted in the roller guide housing.

The injection amount of the pump is regulated bytransversal displacement of a toothed rack in theside of the pump housing.

By means of a gear ring, the pump plunger with thetwo helical millings, the cutting-off edges, is turned.Hereby the length of the pump stroke is specifiedwhen the plunger closes the inlet holes until the cut-ting-off edges again uncover the holes.

MAN Diesel & Turbo

DescriptionPage 1 (2) Internal fuel oil system

514.01Edition 21

L23/30H

2012.08.31 - ES1 - INC

The release of high pressure through the cutting-offedges presses the oil with great force against thewall of the pump housing. At the spot, twoexchangeable plug screws are mounted.

The amount of fuel injected into each cylinder unit isadjusted by means of the governor.

It maintains the engine speed at the preset value bya continuous positioning of the fuel pump racks, viaa common regulating shaft and spring-loaded link-ages for each pump.

The injection valve is for "deep" building-in to thecentre of the cylinder head.

Fuel oil injection valve

The joint surface between the nozzle and holder ismachine-lapped to make it oil-tight.

The fuel injector is mounted in the cylinder head bymeans of the integral flange in the holder and twostuds with distance pieces and nuts.

A bore in the cylinder head vents the space belowthe bottom rubber sealing ring on the injectionvalve, thus preventing any pressure build-up due togas leakage, but also unveiling any malfunction ofthe bottom rubber sealing ring for leak oil.

Fuel oil high pressure pipe

The high-pressure pipe between fuel injection pumpand fuel injector is a shielded pipe with coned pipeends for attachment by means of a union nut, and anipple nut, respectively.

The high-pressure pipe is led through a bore in thecylinder head, in which it is surrounded by a shield-ing tube, also acting as union nut for attachment ofthe pipe end to the fuel injector.

The shielding tube has two holes in order to ensurethat any leakage will be drained off to the cylinderhead bore. The bore is equipped with drain channeland pipe.

The shielding tube is supported by a sleeve, moun-ted in the bore with screws.

The sleeve is equipped with O-rings in order to sealthe cylinder head bore.

Internal nozzle cooling system

The nozzles of the injection valves on HFO-enginesare temperature controlled by means of a circuitfrom the engines lubricating oil system.

The system maintains a nozzle surface temperaturelow enough to prevent formation of carbon trum-pets on the nozzle tips during high load operationand high enough to avoid cold corrosion duringidling or low-load operation.

Waste oil system

Waste and leak oil from the comparements, fuelvalves is led to a fuel leakage alarm unit.

The alarm unit consists of a box with a float switchfor level monitoring. In case of a larger than normalleakage, the float switch will initiate alarm. The sup-ply fuel oil to the engine is lead through the unit inorder to keep this heated up, thereby ensuring freedrainage passage even for high-viscous waste/leakoil.

Optionals

Besides the standard components, the followingstandard optionals can be built-on:

▪ Pressure differential alarm high

– PDAH 43-40 Fuel oil, inlet and outlet filter

▪ Pressure differential transmitting

– PDT 43-40 Fuel oil, inlet and outlet filter

▪ Pressure alarm low

– PAL 40 Fuel oil, inlet fuel oil pump

▪ Pressure transmitting

– PT40 Fuel oil, inlet fuel oil pump

▪ Temperature element

– TE40 Fuel oil, inlet fuel oil pump

MAN Diesel & Turbo514.01

Edition 21Internal fuel oil system Description

Page 2 (2)

L23/30H

2012.08.31 - ES1 - INC

Safety precautions

Engine stoppedShut-off starting airShut off cooling waterShut off fuel oilShut-off cooling oilStop lub. oil circulationPress Blocking - Reset

Short Description

Dismounting, inspection/overhaul and mounting offuel injection pump. Inspection of fuel injectionpipe.

Starting PositionCover for fuel injection pump has been dismoun-ted.

Related Procedure

Inspection of roller guide for fuelinjection pump

508-01.05

Qualified Manpower

Duration in h : 4Number : 1

Data

Data for pressure and tolerance (Page 500.35)Data for tightening torque (Page 500.40)Declaration of weight (Page 500.45)

Special tools

Plate No. Item No. Note52014 013 52014 025 52014 204 52014 253 52006 261 20-120 Nm52006 273 80-360 Nm

Hand ToolsRing and open end spanner, 13 mmRing and open end spanner, 14 mmRing and open end spanner, 17 mmRing and open end spanner, 19 mmAllen key, 8 mm, 10 mmPlier for lock ringTools for cleaningClean kerosene or gas oilClean lubricating oilAntiseizure product (Copaslip, Molykote GN Plusor similar)

Replacement and wearing parts

Plate No. Item No. Quantity

51401 189 1/pump51401 190 1/pump51401 236 1/pump51401 248 1/pump

MAN Diesel & Turbo

Work CardPage 1 (4) Fuel injection pump and fuel injection pipe

514-01.05Edition 12

L23/30H

2008.01.14.

Dismounting of fuel injection pump

Warning!

Use protective gloves!

1) Dismount the fuel injection pipe pos. 1 fig 1 andthe fuel inlet pipe pos 2.

2) Separate the spring loaded lever from the regu-lating rod on the fuel injection pump.

Figure 1: View from control side

3) Remove the pipe for lub.oil and drain.

4) Remove the screws in the bottom flange (4pieces) and take the fuel injection pump away.

Separation of fuel injection pump

1) If necessary, clean the exterior of the injectionpump.

2) Mount the injection pump in the clampingbracket PYO-W020 (see plate 52014 item 037),on the test pump.

3) Press the thrust cap (N) fig. 2 downwards andremove the securing ring (P). Remove the thrustcap (N) with lower spring plate (O) and plunger(M). Be sure not to damage the plunger.

4) Take out the plunger spring (L), upper springplate (K) and pinion (J). If necessary remove thelock ring (R) and guide pin (I) and dismount theregulating rod (H) as well as the cap screw inthe opposite end of the regulating rod (H).

2 O-ring inside dia. 37 mmx 3




Figure 2: Cross section of fuel injection pump

5) Unscrew the four screws (A) and remove theconnecting piece (B). Take out the valve spring(D) and the non-return valve (F).

6) Loosen and remove the four screws (C) andtake out the barrel (E).

7) Remove all the O-rings from the injection pump.

8) All parts must be cleaned, using kerosene orgas oil and a hand brush (not a steel brush).Blow through the holes for sealing oil in thepump houses and the barrel (E).

MAN Diesel & Turbo514-01.05Edition 12

Fuel injection pump and fuel injection pipe Work CardPage 2 (4)

L23/30H

2008.01.14.

Inspection of fuel injection pump

1) Insert plunger (M) and non-return valve (F) intothe barrel (E) after wetting with clean gas oil.Plunger and non-return valve must slide into thebarrel by their own weight.

2) The axial clearance between lower spring plateand plunger foot must not exceed 0.25 mm.The clearance between lower spring plate andplunger foot is 0.05 to 0.1 mm when new. Seefig 3.

1 Plunger (M) 2 Spring (L)

3 Lower spring plate (O) a Max 0.25 mm

Figure 3: Clearance between lower spring plate and plunger

3) Check the cavitation plugs (G) for wear andrenew if necessary.

4) Barrel (E), plunger (M) and non-return valve (F)are manufactured to very close tolerances. Anyattempt to refinish these parts causes altera-tions of the tolerances and must therefore NOTbe carried out. If during the visual inspection of the parts, heavyabrasion symptoms or damage can beobserved, the part in question must bereplaced.

Assembling of fuel injection pump

1) When assembling the injection pump, proceedin the reverse order to disassembling. Payattention to the following: A. At initial tightening up of new parts the fol-lowing (C) for barrel (E). Tighten screws to

55-65 Nm. B. Renew all sealing rings. For placing of therings, see fig 2. C. Coat all the threads with an anti seize prod-uct. D. Wipe dry with paper plane sealing surface onbarrel (E) and connecting piece (B). E. Before inserting the pinion (J), the easymotion of the plunger (M) in the barrel (E) mustbe checked. F. When assembling the pinion (J), ascertainthat the tooth (recognizable by the chamfer) willenter the space of the regulating rod (H) markedby two sings, see fig 4. G. The marking on the guide cam of the plunger(M), must be in line with the marking in the slotsof the pinion (J). (Not shown on fig 4).

1 Marking on regulating rod 2 Tooth with chamfer

3 Marking on pinion

Figure 4: Mounting of regulating rod mechanism

2) After assembling, the easy motion of the regu-lating rod (H), must be checked and the plunger(M) must be moved from the no-load stop tofull-load stop.

MAN Diesel & Turbo

Work CardPage 3 (4) Fuel injection pump and fuel injection pipe

514-01.05Edition 12

L23/30H

2008.01.14.

Mounting of fuel injection pump

Warning!


1) Before mounting the fuel injection pump, cleanthe roller guide spring and washer for spring inthe roller guide housing.

2) Reconnect the regulating rod (H) to the springloaded lever and all the pipes to the fuel pump.

Fuel injection pipe

By normal working conditions the fuel injection piperequire very little maintenance except replacementof O-rings and gasket in connection with the normaloverhaul of fuel injection equipment.


Fuel injection pump and fuel injection pipe Work CardPage 4 (4)

L23/30H

2008.01.14.

Safety precautions


Short Description

Dismounting, overhaul, pressure testing andmounting of fuel injection valve.

Starting Position

Top cover on the cylinder headand front cover on the fuel injec-tion pump have been dismounted.

For dismounting of fuel injectionpipe

514-01.05

Related Procedure

Qualified Manpower


Data


Special tools

Plate No. Item No. Note52006 261 20-120 Nm52014 013 52014 108 52014 204 52014 300 Extra tools52014 361 52014 407

Hand ToolsRing and open end spanner, 12 mmRing and open end spanner, 24 mmSocket spanner, 24 mmet spanner, 30 mmTools for cleaningClean kerosene or gas oilAntiseize product (Copaslip, Molykote GN Plus orsimilar)



51402 116 3/valve (L'Or-ange)

51402 224 3/valve (Nico)

MAN Diesel & Turbo

Work CardPage 1 (4) Fuel injection valve

514-01.10Edition 02

L23/30H

2011.07.11.

Fuel injection valve

The fuel injection valve is the single component thathas the greatest influence on the diesel engine con-dition. Various forms of operation and quality of fueloil affect the overhaul intervals. In some cases itmay be necessary to shorten the prescribed inter-vals.

Dismounting and cleaning

Warning!


1) Dismount the fuel injection valve from the cylin-der head by means of the special tool as shownin fig. 1.

Figure 1: Dismounting of fuel injection valve from cylinder head

2) Mount the fuel injection valve into the clampingbracket VTO-W020 (see plate 52014, item 025)on the pressure testing pump, and loosen thelock nut (B) fig 2. Unstress the nozzle spring by turning theadjusting screw (D).

3) Clean the lower part of the nozzle (J) from car-bonized oil deposits before dismantling the noz-zle nut (H). Remove the nozzle nut (H) and thenozzle (J).

B Lock nut C Sealing ring

D Adjusting screw E Sealing ring

F Nozzle spring G Spring spindle

H Nozzle nut J Nozzle

Figure 2: Fuel injection valve

Attention! Do not damage the lapped surface.

4) The nozzle spring (F) and the spring spindle (G),are to be taken out by loosening the adjustingscrew (D), completely.

5) All parts must be cleaned with kerosene or gasoil and a hard brush (not a steel brush).


Fuel injection valve Work CardPage 2 (4)

L23/30H

2011.07.11.

6) Clean the nozzle holes of charred coke bymeans of the supplied special drill (see plate52014-01H item 108) with holder.

7) Clean the cooling chamber and the coolingducts in the nozzle guide and injector body byplacing these in a cleaning liquid and then blowthrough the parts with dry working air.

Injection of the parts

1) Nozzles are matched by lapping and are there-fore only interchangeable as units. Insert nozzleneedle with gas oil in the needle guide. It mustbe controlled whether the nozzle needle slidesdown by its dead weight on its seat.

2) If the holes are oval worn, which is checkedwith of a magnifying glass, the nozzle must bescrapped.

3) The best way, however, to check if the holesare worn out is to control the flow rate of thenozzle which, in general, only can be made atthe manufacturer's works on a special teststand.

4) Every effort to refinish will result in alterations ofthese values and malfunction of the nozzle. Ifheavy abrasion symptoms, respectively dam-ages are observed at the visual inspection ofthe parts, the parts in question must bereplaced.

Reassembling

1) When all parts have been overhauled, found ingood order and carefully cleaned, assemble thefuel injection valve again.

2) When assembling the injection valve, proceed inthe opposite order compared to the disassem-bly. Pay attention to the following: A. Lubricate the threads on the adjusting screw(D) with lub. oil, and the threads of the nozzleholder for the nozzle nut. The shoulder of thenozzle which is in contact with the nozzle nut,must be lubricated with an antiseizure product. B. The sealing plane surface of body and nozzlemust be wiped dry with paper. C. Renew the sealing rings (C) and (E). D. Tighten torque for nozzle nut (see page500.40.)

Pressure testing of fuel injection valve

1) The most effective checking of the fuel valves isobtained through pressure testing, preferablycarried out after each overhaul and also in caseof irregularities in operation. The pressure test-ing is carried out in the following way by meansof the pressure testing apparatus supplied.

2) Mount the fuel injection valve in the bracketVTO-W020 (see plate 52014 item no. 25) again.The bracket to be in such a position that thenozzle of the injector is pointing downwards.

3) For test of the injection pressure and atomizingmount the test pipe VTO-W021 (see plate52014 item 049), increase pressure by meansof the lever on the test pump, and adjust theopening pressure to 320 bar (8 holes nozzle)/350 bar (10 holes nozzle), by the adjustingscrew (D), see fig 2, then tighten lock nut (B)and check opening pressure again. Do not expect chattering, but make sure thatthe nozzle spray from all holes in the sameangle. The nozzle might chatter if the lever isworked very fast, actually by hitting it. Do not expect a nozzle tip with more than 1000running hours to perform like a new nozzle inthe test pump. Then increase the pressure to300 bar and keep the pressure by working thelever slowly downwards. When the pressure iskept at 300 bar, there should be no more thanone drip from the nozzle tip for approx. 3-5 sec.

WARNING: Keep out of the fuel jets as they will penetratethe skin. Fuel which has penetrated the skin cancause painful inflammations (blood poisoning).

MAN Diesel & Turbo

Work CardPage 3 (4) Fuel injection valve

514-01.10Edition 02

L23/30H

2011.07.11.

Mounting of the fuel injection valve incylinder head

Figure 3: Grinding tools for seat and liner for fuel injection valve

1) Before mounting the fuel valve, clean andinspect the valve sleeve in the cylinder head. Ifnecessary, grind the seating face with the grind-ing tool (see fig 3).

2) Coat the O-rings and the lower part of the valvewith an antiseizure product, place the valve inthe cylinder head and press it down to the seat.

3) Mount the high pressure pipe before tighteningthe nuts then it is easier to fit the threads.

4) Put on the distance pieces, fit the nuts andtighten up with a torque spanner (for torquemoment, see page 500.40).

Figure 4: Grinding tools for fuel injection valve (extra tools)


Fuel injection valve Work CardPage 4 (4)

L23/30H

2011.07.11.

Safety precautions


Short Description

Disassembly, cleaning and assembly of fuel oilsplit filter

Starting Position

Related Procedure

Qualified Manpower

Duration in h : 1/2Number : 1

Data


Special tools

Plate No. Item No. Note

Hand ToolsRing and open end spanner, 13 mmRing and open end spanner, 17 mmKerosene, gas oil similar



MAN Diesel & Turbo

Work CardPage 1 (2) Fuel oil split filter

514-01.15Edition 01

L23/30H

1991.02.18.

Fuel oil split filter

1) During normal operation both filters should be inoperation, single operation only to be usedwhen dismantling one of the filters for manualcleaning or inspection.

2) Normally the filters are cleaned during operationby turning the handle, (1) see fig 1, on the filterhousing top a couple of turns. (clockwise).

Simultaneously with turning of the handle, the draincock, (2) in bottom of the filter housing should beopened in order to drain of the dirt being scraped ofthe filter element, (3).

Figure 1: Fuel oil split filter

3) Position of three way cock, see fig 2.

A Left filterThis position is only forcleaning of the right filter,not for continuous operat-ing

B Both filters in operation

C Right filterThis position is only forcleaning of the left filter,not for continuous operat-ing

Figure 2: Fuel oil split filter (top view)

Note: Shut-off fuel oil, before dismantling filter ele-ment.

4) If no drainage occurs when the drain cock isopened, the filter housing should be dismantledfor manual cleaning. Remove the nuts (5), andtake out the filter element (3).

5) Clean the filter element in kerosene gas oil orsimilar and blow it dry with working air.

6) Mount the filter element again.

7) The filter element itself should never be disman-tled, but has to be replaced if damage or malfunction is experienced.


Fuel oil split filter Work CardPage 2 (2)

L23/30H

1991.02.18.

Safety precautions


Short Description

Check of fuel oil piping system.

Starting Position

Engine is running.

Related Procedure

Qualified Manpower

Duration in h : ½Number : 1

Data


Special tools


Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (2) Check of Fuel Oil Piping System

514-01.90Edition 01

L23/30H, V28/32S

1992.01.20. - ES0

Health Risk!

Warning!

Health Risk!

Due to vibrations during engine operation, espe-cially in awkward positions!

Fuel Oil System

1 Venting pipe

Figure 1: Cross section of cylinder head

1) Dismount the covers to the injection pumps.Blow through drain pipes from the pump bed.

2) Examine the piping system for leaks.

3) Retighten all bolts and nuts in the piping sys-tem.

4) Move all valves in the piping system. Lubricatevalve spindles with graphite or similar.

5) Check flexible connections for leaks and dam-ages.

It is important that the flexible connections are freefrom paint and grease and in healthy condition.

6) Check for any leak of the O-ring for the fuelinjection pipe.

Concerning fuel oil condition, see section 504.


Check of Fuel Oil Piping System Work CardPage 2 (2)

L23/30H, V28/32S

1992.01.20. - ES0

Safety precautions


Short Description

Disassembly, overhaul and assembly of fuel oilfeed pump. Adjustment of fuel oil pressure.

Starting PositionAll pipe connections to the feed pump have beendisconnected and the feed pump is removed fromthe engine

Related Procedure

Qualified Manpower


Data


Special tools


Hand ToolsAllen key, 8 mm, 10 mm, 22 mmRing and open end spanner, 17 mmRing and open end spanner, 46 mmBig screwdriverAdjustable spannerPullerHard brushGas oil



51410 049 1/pump51410 050 4/pump51410 108 1/pump51410 265 1/pump

MAN Diesel & Turbo

Work CardPage 1 (3) Fuel oil feed pump

514-10.00Edition 01

L23/30H

1996.06.24.

Fuel oil feed pump

Disassembly:

1) Remove the coupling part (14), see fig. 1, bymeans of a puller.

2) Remove screws (12) and dismount the cover(11) with locking ring, sealing ring, o-ring androtating packing (9).

3) After removal of the screws (4) (6 pcs.) thecover (3) is dismantled and the gear wheels (5and 7) are pulled out.

4) Dismounting of the spring loaded adjustable by-pass valve.

Remove the cap nut (21), nut (20), spring housing(19), spring (18) and the cylinder (23). If the piston(17) cannot be pulled out from the same side theplug screw (15) can be removed and the piston canbe pressed from this side with a screw driver or thelike.

Overhaul:

5) Clean all the parts with gas oil and a hardbrush.

Warning: Never use a steel brush.

The parts are blown clean with working air.

6) If the bearing bush are to be removed the exist-ing bearing bush is plugged out, the bores arecleaned and new bearing bush is mounted, seefig. 2.

Before the gear wheels can be mounted the bearingbush must be adjusted with a reamer or a bearingscraper, so that the gear wheel can run easily whenthe pump is assembled.

7) Renew the sealing ring in cover (11).

8) Inspect all other parts for wear and damage,and renew, if necessary.

Assembly:

9) Mount the gear wheel (5 and 7), coat the seal-ing lip with silastene or similar and mount thecover (3).

10) Mount the rotating packing (9) and the cover(11) with sealing ring, o-ring, locking ring andcoupling (14).

11) Mount the spring loaded by-pass valve, nut(20), gasket (16), cap nut (21) and plug screw(15).

12) Mount the feed pump on the engine and con-nect all the pipes.

Figure 1: Fuel oil feed pump


Fuel oil feed pump Work CardPage 2 (3)

L23/30H

1996.06.24.

Figure 2: Mounting of bearing bush

Adjusting of fuel oil pressure

1) The outlet pressure of the feed pump, can beadjusted by means of an adjusting screw in theby-pass valve.

Remove the cap nut (21) and loosen the nut (20).

By turning the spring housing clockwise the pres-sure is raised and reverse the pressure is loweredby turning the spring housing (19) anti-clockwise.When the correct pressure is reached, see page500.30, the spring housing (19) is locked with nut(20) and finally the gasket (16) and cap nut (21) aremounted.

MAN Diesel & Turbo

Work CardPage 3 (3) Fuel oil feed pump

514-10.00Edition 01

L23/30H

1996.06.24.

MAN Diesel & Turbo

98.28 - EO0

Fuel Injection Pump - NICO 51401-03HPlatePage 1 (2)

L23/30H

MAN Diesel & Turbo

98.28 - EO0

Fuel Injection Pump - NICO51401-03H

Designation BenævnelseBenævnelseDesignation

577

589

590

600

612

624

636

648

661

673

685

697

707

719

720

732

744

756

768

781

793

803

815

827

839

840

852

Item No.

Qty.

Qty.

Item No.

O-ring

O-ring

O-ring

Deflector

Gasket

Washer

Pointer

Nut

Control rack

Pump housing,complete

Gasket

Plug

Snap ring

Rack stopper

Control sleeve

Spring seat

Spring : Plunger

Spring seat

Guide : Plunger

Snap ring

Bolt

Case : Delivery valve

Ring

Spring :Delivery valve

Bolt

Plunger, complete

O-ring

O-ring

O-ring

O-ring

Deflektor

Pakning

Skive

Viser

Møtrik

Reguleringstandstrang

Pumpehus, komplet

Pakning

Prop

Låsering

Stop for tandstang

Kontrolbøsning

Fjederplade (øverste)

Fjeder

Fjederplade(nederste)

Styr

Låsering

Bolt

Hus for ventil

Ring

Fjeder

Bolt

Stempel, komplet

O-ring

PlatePage 2 (2)

L23/30H

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./P = Qty./PumpQty./C = Qty./Cylinder

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/P = Antal/PumpeAntal/C = Antal/Cylinder

1/P

1/P

1/P

2/P

2/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

4/P

1/P

1/P

1/P

4/P

1/P

1/P

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel & Turbo

10.23 - ES0, L'Orange

Fuel Injection Pump 51401-10HPlatePage 1 (2)

L23/30H

057/374

069/386

069/386

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel & Turbo

10.23 - ES0, L'Orange

Fuel Injection Pump51401-10H


021

033

045

057

069

070

082

094

104

116

128

141

153

165

177

189

190

200

212

224

236

248

261

273

285

297

Item No.

Qty.

Qty.

Item No.

Pump housing

Screw

Packing ring

Fuel injection pump,complete (HFO)

Plunger and barrelincl. non-return valve (HFO)

Joint washer

Washer

Screw

Circlip

Regulating rod

Guide pin

Upper spring plate

Spring

Lower spring plate

Thrust cap

O-ring

O-ring

Circlip

Spring

Connecting piece

O-ring

O-ring

Pointer

Nut

Screw

Cap screw

Pumpehus

Skrue

Pakningsring

Fuel indsprøjtnings-pumpe, komplet (HFO)

Stempel og cylinderinkl. kontraventil (HFO)

Pakning

Skive

Skrue

Låsering

Reguleringsstang

Styretap

Øverste fjederplade

Fjeder

Nederste fjederplade

Trykhætte

O-ring

O-ring

Låsering

Fjeder

Forbindelsesstykke

O-ring

O-ring

Viser

Møtrik

Skrue

Hætteskrue

PlatePage 2 (2)

Securing ring

Gear rim

Screw

Packing ring

Screw

Fuel injection pump,complete (Low sul-phur fuel, WC/C)

Plunger and barrelincl. non-return valve (Low sul-phur fuel, WC/C)

+ Are not included in fuel injection pump, complete

Beskyttelsesring

Tandkrans

Skrue

Pakningsring

Skrue

Fuel indsprøjtnings-pumpe, komplet (Svovl-fattig brændstof, WC/C)

Stempel og cylinderinkl. kontraventil (Svovl-fattig brændstof, WC/C)

+ Indgår ikke i fuel ind-sprøjtningspumpe,komplet

L23/30H

307

319

344+

356+

368

374

386


* = Only available as part of a spare parts kit.Qty./P = Qty./PumpQty./C = Qty./Cylinder


* = Kun tilgængelig som en del af et reservedelssæt.Antal/P = Antal/PumpeAntal/C = Antal/Cylinder

1/P

2/P

2/P

1/C

1/P

1/P

2/P

4/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

4/P

1/P

1/P

1/P

1/P

1/P

2/P

1/C

1/P

MAN Diesel & Turbo

L23/30H

Fuel Injection Valve 51402-29PlatePage 1 (2)

12.03 - ES0, L'Orange, Cooled

* When ordering, please state IMO-17.02

021*

116

033*

045

057

141

189

104

189

094

177

082

069

MAN Diesel & Turbo


Fuel Injection Valve PlatePage 2 (2)51402-29

L23/30H

Item No.

Qty.

Qty.

Item No.

021

033

045

057

069

082

094

104

116

141

177

189

1/V

1/V

2/V

1/V

1/V

1/V

1/V

1/V

3/V

1/V

1/C

2/V

Injector housing, please state IMO-17.02

Nozzle, completeplease state IMO-17.02

Dowel pin

Screw cap

Thrust spindle

Spring

Adjusting screw

Nut

O-ring

Cap nut

Fuel injection valve,complete

Washer

Ventilhus, venligst oplys IMO-17.02

Forstøver, komplet ven-ligst oplys IMO-17.02

Styrestift

Omløber

Trykspindel

Fjeder

Justeringsskrue

Møtrik

O-ring

Hættemøtrik

Brændselsventii,komplet

Skive


* = Only available as part of a spare parts kit.Qty./V = Qty./ValveQty./C = Qty./Cylinder.


* = Kun tilgængelig som en del af et reservedelssæt.Qty./V = Qty./VentilQty./C = Qty./Cylinder.


MAN Diesel & Turbo

L23/30H




021*

116

033*

045

057

141

189

104

189

094

177

082

069

MAN Diesel & Turbo



L23/30H

Item No.

Qty.

Qty.

Item No.

021

033

045

057

069

082

094

104

116

141

177

189

1/V

1/V

2/V

1/V

1/V

1/V

1/V

1/V

3/V

1/V

1/C

2/V

Injector housing, plea-se state IMO-17.06

Nozzle, completeplease state IMO-17.06

Dowel pin

Screw cap

Thrust spindle

Spring

Adjusting screw

Nut

O-ring

Cap nut


Washer


Forstøver, komplet, ven-ligst oplys IMO-17.06

Styrestift

Omløber

Trykspindel

Fjeder

Justeringsskrue

Møtrik

O-ring

Hættemøtrik


Skive






MAN Diesel & Turbo

L23/30H


12.03 - ES0, Nico, Uncooled


221*

224

248*

236

261

273

285

297

325

319

320

307

MAN Diesel & Turbo



L23/30H

Item No.

Qty.

Qty.

Item No.

221

224

236

248

261

273

285

297

307

319

320

325

1/V

3/V

2/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

Injector body, please state IMO-17.02

O-ring

Dowel pin

Atomizer, completeplease state IMO-17.02

Nozzle nut

Cap nut

Nut

Adjusting screw

O-ring

Spring

Spindle

Fuel Injection Valve, Complete

Brændstofsventil, ven-ligst oplys IMO-17.02

O-ring

Styrestift

Forstøver, komplet ven-ligst oplys IMO-17.02

Forstøver

Hættemøtrik

Møtrik

Justeringsskrue

O-ring

Fjeder

Spindel

Brændstofsventil, komplet





12.03 - ES0, Nico, Uncooled

MAN Diesel & Turbo

L23/30H


12.03 - ES0, Nico, Cooled


221*

224

248*

236

261

273

285

297

325

319

320

307

MAN Diesel & TurboMAN Diesel & Turbo



L23/30H

Item No.

Qty.

Qty.

Item No.

221

224

236

248

261

273

285

297

307

319

320

325

1/V

3/V

2/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

Injector body, please state IMO-17.02

O-ring

Dowel pin

Atomizer, complete, please state IMO-17.02

Nozzle nut

Cap nut

Nut

Adjusting screw

O-ring

Spring

Spindle

Fuel Injection Valve, Complete

Brændstofsventil, ven-ligst oplys IMO-17.02

O-ring

Styrestift


Forstøver

Hættemøtrik

Møtrik

Justeringsskrue

O-ring

Fjeder

Spindel

Brændstofsventil, komplet





12.03 - ES0, Nico, Cooled

MAN Diesel & Turbo

L23/30H


12.03 - ES0, L'Orange, Cooled, Low sac


021*

116

033*

045

057

141

189

104

189

094

177

082

069

MAN Diesel & Turbo



L23/30H

Item No.

Qty.

Qty.

Item No.

021

033

045

057

069

082

094

104

116

141

177

189

1/V

1/V

2/V

1/V

1/V

1/V

1/V

1/V

3/V

1/V

1/C

2/V

Injector housing, plea-se state IMO-17.06

Nozzle, complete, please state IMO-17.06

Dowel pin

Screw cap

Thrust spindle

Spring

Adjusting screw

Nut

O-ring

Cap nut


Washer



Styrestift

Omløber

Trykspindel

Fjeder

Justeringsskrue

Møtrik

O-ring

Hættemøtrik


Skive





12.03 - ES0, L'Orange, Cooled, Low sac

MAN Diesel & Turbo

L23/30H

Fuel Oil Filter Duplex 51403-06H Plate

Page 1 (2)

09.28

A

A

326338351363

292280

279267

255243

302314

015

MAN Diesel & Turbo

09.28


Fuel Oil Filter Duplex PlatePage 2 (2)51403-06H

L23/30H

Item No.

Qty.

Qty.

Item No.

015

243

255

267

279

280

292

302

314

326

338

351

363

1/E

2/F

2/F

2/F

4/F

2/F

1/F

1/F

1/F

2/F

2/F

2/F

2/F

Fuel oil filter duplex,complete

Lock screw

Gasket

O-ring

Nut

Filter element

O-ring

Gasket

Fixing screw

Lock screw

Gasket

Bushing

O-ring

Brændselsoliespalte-filter, komplet

Låseskrue

Pakning

O-ring

Møtrik

Filterelement

O-ring

Pakning

Fastspændingsskrue

Låseskrue

Pakning

Bøsning

O-ring


* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./Engine.Qty./F = Qty./Filter.


* = Only available as part of a spare parts kit.Qty./E = Qty./Engine.Qty./F = Qty./Filter

MAN Diesel & Turbo

L23/30H

Fuel Injection Pipe 51404-01HPlatePage 1 (2)

94.22 - ES0S

178010

130

130

237

250

262

142

166

154

178

262

142

154

166

095

213

201

225

MAN Diesel & Turbo

94.22 - ES0S

Fuel Injection Pipe PlatePage 2 (2)51404-01H

L23/30H


Item No.

Qty.

Qty.

Item No.

010

095

130

142

154

166

178

201

213

225

237

250

262

1/C

1/C

2/C

2/C

4/C

2/C

2/C

2/C

2/C

1/C

1/C

1/C

4/C

Fuel injection pipe, complete

Sleeve

O-ring

Flange

Screw

Sealing ring

O-ring

Sleeve in 2/2

Wire lock ring

Nut

Screwed socket

Nut

Locking washer

Højtryksrør,komplet

Styrebøsning

O-ring

Flange

Skrue

Tætningsring

O-ring

Bøsning 2-delt

Wire låsering

Møtrik

Gevindmuffe

Møtrik

Låseskive


* = Only available as part of a spare parts kit.Qty./C = Qty./Cylinder.


* = Kun tilgængelig som en del af et reservedelssæt.Qty./C = Qty./Cylinder.

MAN Diesel & Turbo

General

Fuel Oil Filter Duplex 51415-11PlatePage 1 (2)

13.07 - ES0, 25 my

002

004

006

010011

014015 012

013

018

019

024025026027

020021022023

028

031032033034035

029030 036

037038039

040041042043

044045

003

007

005

016017

070072073

075076077078079

MAN Diesel & Turbo

51415-11


Qty.

Qty.

002

003

004

005

006

007

010

011

012

013

014

015

016

017

018

019

020

021

022

023

024

025

026

027

028

029

2/F

2/F

2/F

2/F

2/F

2/F

6/F

6/F

2/F

2/F

2/F

2/F

6/F

6/F

1/F

1/F

2/F

2/F

2/F

2/F

1/F

1/F

1/F

1/F

1/F

2/F

Screw plug

Gasket

Screw plug

Gasket

Screw plug

Gasket

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50, DN 65

Cover, DN 25, DN 32

Cover, DN 40, DN 50, DN 65

O-ring, DN 25, DN 32

O-ring, DN 40, DN 50, DN 65

Nut, DN 25, DN 32

Nut, DN 40, DN 50, DN 65

Ball valve

Cock


O-ring, DN 40

O-ring, DN 50

O-ring, DN 65

Circlip ring, DN 25, DN 32

Circlip ring, DN 40

Circlip ring, DN 50

Circlip ring, DN 65

Plug key

Gasket, DN 25, DN 32

Propskrue

Pakning

Propskrue

Pakning

Propskrue

Pakning

Bolt, DN 25, DN 32


Dæksel, DN 25, DN 32

Dæksel, DN 40, DN 50, DN 65



Møtrik, DN 25, DN 32

Møtrik, DN 40, DN 50, DN 65

Kugleventil

Hane


O-ring, DN 40

O-ring, DN 50

O-ring, DN 65

Sikringsring, DN 25, DN 32

Sikringsring, DN 40

Sikringsring, DN 50

Sikringsring, DN 65

Prop

Pakning, DN 25, DN 32


* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./EngineQty./F = Qty./Filter


* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./F = Qty./Filter

General

Fuel Oil Filter Duplex PlatePage 2 (2)

13.07 - ES0, 25 my

Item no

Item no

030

031

032

033

034

035

036

037

038

039

040

041

042

043

044

045

070

072

073

075

076

077

078

079

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

8/F

8/F

8/F

8/F

8/F

8/F

2/F

2/F

2/F

1/E

1/E

1/E

1/E

1/E

Gasket, DN 40, DN 50, DN 65

Filter element, DN 25






Gasket, DN 40

Gasket, DN 50

Gasket, DN 65

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50

Bolt, DN 65

Nut, DN 25, DN 32

Nut, DN 40, DN 50

Nut, DN 65

Screw

Nut

Spring washer

Fuel oil filter duplex, DN 25, complete





Pakning, DN 40, DN 50, DN 65

Filterelement, DN 25






Pakning, DN 40

Pakning, DN 50

Pakning, DN 65

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50

Bolt, DN 65



Møtrik, DN 65

Skrue

Møtrik

Fjederskive

Brændselsoliespaltefil-ter, DN 25, Komplet





MAN Diesel & Turbo

General


13.07 - ES0, 25 my

002

004

006

010011

014015 012

013

018

019

024025026027

020021022023

009

028

031032033034035

029030 036

037038039

040041042043

044045

003

007

005

016017

070072073

075076077078079

MAN Diesel & Turbo

51415-12


Qty.

Qty.

002

003

004

005

006

007

009

010

011

012

013

014

015

016

017

018

019

020

021

022

023

024

025

026

027

028

2/F

2/F

2/F

2/F

2/F

2/F

1/F

6/F

6/F

2/F

2/F

2/F

2/F

6/F

6/F

1/F

1/F

2/F

2/F

2/F

2/F

1/F

1/F

1/F

1/F

1/F

Screw plug

Gasket

Screw plug

Gasket

Screw plug

Gasket

Differential pressure indicator

Bolt, DN 25, DN 32


Cover, DN 25, DN 32




Nut, DN 25, DN 32

Nut, DN 40, DN 50, DN 65

Ball valve

Cock


O-ring, DN 40

O-ring, DN 50

O-ring, DN 65


Circlip ring, DN 40

Circlip ring, DN 50

Circlip ring, DN 65

Plug key

Propskrue

Pakning

Propskrue

Pakning

Propskrue

Pakning

Differential trykindikator

Bolt, DN 25, DN 32








Kugleventil

Hane


O-ring, DN 40

O-ring, DN 50

O-ring, DN 65


Sikringsring, DN 40

Sikringsring, DN 50

Sikringsring, DN 65

Prop





General


13.07 - ES0, 25 my

Item no

Item no

029

030

031

032

033

034

035

036

037

038

039

040

041

042

043

044

045

070

072

073

075

076

077

078

079

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

8/F

8/F

8/F

8/F

8/F

8/F

2/F

2/F

2/F

1/E

1/E

1/E

1/E

1/E









Gasket, DN 40

Gasket, DN 50

Gasket, DN 65

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50

Bolt, DN 65

Nut, DN 25, DN 32

Nut, DN 40, DN 50

Nut, DN 65

Screw

Nut

Spring washer














Pakning, DN 40

Pakning, DN 50

Pakning, DN 65

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50

Bolt, DN 65



Møtrik, DN 65

Skrue

Møtrik

Fjederskive






MAN Diesel & Turbo

General


13.07 - ES0, 25 my

002

004

006

010011

014015 012

013

018

019

024025026027

020021022023

028

031032033034035

029030 036

037038039

040041042043

044045

003

007

005

016017

070072073

075076077078079

008

MAN Diesel & Turbo

51415-13


Qty.

Qty.

002

003

004

005

006

007

008

010

011

012

013

014

015

016

017

018

019

020

021

022

023

024

025

026

027

028

2/F

2/F

2/F

2/F

2/F

2/F

1/F

6/F

6/F

2/F

2/F

2/F

2/F

6/F

6/F

1/F

1/F

2/F

2/F

2/F

2/F

1/F

1/F

1/F

1/F

1/F

Screw plug

Gasket

Screw plug

Gasket

Screw plug

Gasket

Oil Pan

Bolt, DN 25, DN 32


Cover, DN 25, DN 32




Nut, DN 25, DN 32

Nut, DN 40, DN 50, DN 65

Ball valve

Cock


O-ring, DN 40

O-ring, DN 50

O-ring, DN 65


Circlip ring, DN 40

Circlip ring, DN 50

Circlip ring, DN 65

Plug key

Propskrue

Pakning

Propskrue

Pakning

Propskrue

Pakning

Bundkar

Bolt, DN 25, DN 32








Kugleventil

Hane


O-ring, DN 40

O-ring, DN 50

O-ring, DN 65


Sikringsring, DN 40

Sikringsring, DN 50

Sikringsring, DN 65

Prop





General


13.07 - ES0, 25 my

Item no

Item no

029

030

031

032

033

034

035

036

037

038

039

040

041

042

043

044

045

070

072

073

075

076

077

078

079

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

8/F

8/F

8/F

8/F

8/F

8/F

2/F

2/F

2/F

1/E

1/E

1/E

1/E

1/E









Gasket, DN 40

Gasket, DN 50

Gasket, DN 65

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50

Bolt, DN 65

Nut, DN 25, DN 32

Nut, DN 40, DN 50

Nut, DN 65

Screw

Nut

Spring washer














Pakning, DN 40

Pakning, DN 50

Pakning, DN 65

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50

Bolt, DN 65



Møtrik, DN 65

Skrue

Møtrik

Fjederskive






MAN Diesel & Turbo

General


13.07 - ES0, 25 my

002

004

006

010011

014015 012

013

018

019

024025026027

020021022023

009

028

031032033034035

029030 036

037038039

040041042043

044045

003

007

005

016017

070072073

075076077078079

008

MAN Diesel & Turbo

51415-14


Qty.

Qty.

002

003

004

005

006

007

008

009

010

011

012

013

014

015

016

017

018

019

020

021

022

023

024

025

026

027

2/F

2/F

2/F

2/F

2/F

2/F

1/F

1/F

6/F

6/F

2/F

2/F

2/F

2/F

6/F

6/F

1/F

1/F

2/F

2/F

2/F

2/F

1/F

1/F

1/F

1/F

Screw plug

Gasket

Screw plug

Gasket

Screw plug

Gasket

Oilpan

Differential pressure indicator

Bolt, DN 25, DN 32


Cover, DN 25, DN 32




Nut, DN 25, DN 32

Nut, DN 40, DN 50, DN 65

Ball valve

Cock


O-ring, DN 40

O-ring, DN 50

O-ring, DN 65


Circlip ring, DN 40

Circlip ring, DN 50

Circlip ring, DN 65

Propskrue

Pakning

Propskrue

Pakning

Propskrue

Pakning

Bundkar

ifferential trykindikator

Bolt, DN 25, DN 32








Kugleventil

Hane


O-ring, DN 40

O-ring, DN 50

O-ring, DN 65


Sikringsring, DN 40

Sikringsring, DN 50

Sikringsring, DN 65





General


13.07 - ES0, 25 my

Item no

Item no

028

029

030

031

032

033

034

035

036

037

038

039

040

041

042

043

044

045

070

072

073

075

076

077

078

079

1/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

8/F

8/F

8/F

8/F

8/F

8/F

2/F

2/F

2/F

1/E

1/E

1/E

1/E

1/E

Plug key









Gasket, DN 40

Gasket, DN 50

Gasket, DN 65

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50

Bolt, DN 65

Nut, DN 25, DN 32

Nut, DN 40, DN 50

Nut, DN 65

Screw

Nut

Spring washer






Prop









Pakning, DN 40

Pakning, DN 50

Pakning, DN 65

Bolt, DN 25, DN 32

Bolt, DN 40, DN 50

Bolt, DN 65



Møtrik, DN 65

Skrue

Møtrik

Fjederskive






0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.17 - ES0

Butterfl y Valve with Actuator 51425-03H

General

052

064

088

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Butterfl y Valve with Actuator PlatePage 2 (2)51425-03H

General

052

064

076

088

Item no Benævnelse

Actuator

Kugleventil

Reservedelssæt

Kugleventil med actua-tor komplet

Designation

Actuator

Butterfl y valve

Spare parts kit

Butterfly valve with actuator complete

Qty

1/Q

1/Q

1/Q

1/Q


* = Kun tilgængelig som en del af et reservedelssæt.Qty/Q = Qty/Anlæg


* = Only available as part of a spare parts kit.Qty/Q = Qty/Plant

07.17 - ES0

Item no BenævnelseDesignationQty

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.17 - ES0

Ball Valve with Actuator 51425-04

General

A

Seen from A

015

027 039

040

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Ball Valve with Actuator PlatePage 2 (2)51425-04

General

015

027

039

040

Item no Benævnelse

Magnetventil

Actuator

Grænseafbryder

Kugleventil

Designation

Solenoid valve

Actuator

Limit switch

Ball valve

Qty

1/Q

1/Q

1/Q

2/Q




* = Only available as part of a spare parts kit. Qty/Q = Qty/Plant

07.17 - ES0


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.18

Butterfl y Valve with Actuator 51425-06H

General

052

064

088

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Butterfl y Valve with Actuator PlatePage 2 (2)51425-06H

General





* = Only available as part of a spare parts kit.Qty/Q = Qty/Plant

07.18


052

064

076

088

Actuator

Kugleventil

Reservedelssæt

Kugleventil med actua-tor komplet

Actuator

Butterfl y valve

Spare parts kit

Butterfly valve with actuator complete

1/Q

1/Q

1/Q

1/Q

MAN Diesel & Turbo

PlatePage 1 (3)

12.49 - ESO

Pipes on Cylinder Section 51430-27

L23/30H

A

A

742

646658671

538

168181193203

730

073

252

335

097107119120

012024036048

754766778791

264276288311

418431443455

480492502514

347359360372

396

479

MAN Diesel & Turbo

A-A

599609610622

252

240

156 227 144

406

239

683695705717

085

551252

575

563

Pipes on Cylinder Section PlatePage 2 (3)51430-27

12.49 - ESO

L23/30H

MAN Diesel & Turbo

Pipes on Cylinder SectionPlatePage 3 (3) 51430-27

012024036048

073

085

097107119129

144

156

168181193203

227

239

240

252

264276288311

335

347359360372

396

Brændselsolieforde-lingsrør5 cyl.6 cyl.7 cyl.8 cyl.

Stikrør cylindersection

Ligeforskruning

Brændselsoliedrænrør5 cyl.6 cyl.7 cyl.8 cyl.


Forskruning

Brændselsoliedrainrør5 cyl.6 cyl.7 cyl.8 cyl.

Rør fra brændselsolie-pumpedræn

Højtryksbrændsels-oliedrænrør

Ligeforskruning

Ligeforskruning

Køleolierør5 cyl.6 cyl.7 cyl.8 cyl.


Køleolierør5 cyl.6 cyl.7 cyl.8 cyl.


Fuel oil distributor pipe5 cyl.6 cyl.7 cyl.8 cyl.

Branch pipe cylinder section

Straight male stud coupling

Fuel oil return pipe5 cyl.6 cyl.7 cyl.8 cyl.


Screwed connection

Fuel oil drain pipe5 cyl.6 cyl.7 cyl.8 cyl.

Pipe from fuel pump drain

High pressure fuel pipe drain



Cooling oil pipe5 cyl.6 cyl.7 cyl.8 cyl.


Cooling oil pipe5 cyl.6 cyl.7 cyl.8 cyl.


1/E1/E1/E1/E

1/C

1/C

1/E1/E1/E1/E

1/C

1/C

1/E1/E1/E1/E

1/C

1/C

1/C

4/C

1/E1/E1/E1/E

1/C

1/E1/E1/E1/E

1/C

12.49 - ESO

L23/30H

BenævnelseDesignationQty.Item No.

Item No. Qty. Designation Benævnelse

* = Only available as part of a spare parts kit. Qty./E = Engine Qty./C = Qty./Cylinder

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = MotorAntal/C = Antal/Cylinder

Restriktion

Smøreolie fordelingsrør for vippearm5 cyl.6 cyl.7 cyl.8 cyl.


Spærreoliefordelingsrør

5 cyl.6 cyl.7 cyl.8 cyl.


Ligeforskruning

Rør fra brændselsolie-pumpedræn

Banjoforskruning

Beslag5 cyl.6 cyl.7 cyl.8 cyl.

Holder

Fjederlås

Møtrik

Beslag5 cyl.6 cyl.7 cyl.8 cyl.

Beslag

Beslag

Højtryksrør5 cyl.6 cyl.7 cyl.8 cyl.

Restriction

Lub. oil distrubution pipe for rocker arms5 cyl.6 cyl.7 cyl.8 cyl.


Sealing oil distribu-tion pipe5 cyl.6 cyl.7 cyl.8 cyl.



Pipe from fuel pump drain

Banjo coupling

Bracket5 cyl.6 cyl.7 cyl.8 cyl.

Clamp

Spring locks

Nut

Bracket5 cyl.6 cyl.7 cyl.8 cyl.

Bracket

Bracket

Fuel injection pipe5 cyl.6 cyl.7 cyl.8 cyl.

406

418431443455

479

480492502514

538

551

563

575

599609610622

646

658

671

683695705717

730

742

754766778791

1/C

1/E1/E1/E1/E

1/C

1/E1/E1/E1/E

1/C

1/C

1/C

1/C

4/E5/E6/E7/E

2/C

4/C

4/C

4/E5/E6/E7/E

1/E

1/E

1/C1/C1/C1/C

Lubricating oil system

515/615

MAN Diesel

DescriptionPage 1 (5) Internal Lubricating Oil System

L23/30H

07.47 - ES0

Fig 1 Diagram for internal lubricating oil system.

Flange connections are as standard according to DIN 2501

Pipe description for connection at the engine

DN25

DN25

DN65

DN65

DN20

DN50

DN50

DN25

Lubricating oil from separator

Lubricating oil to separator

Lubricating oil from separate fi lter

Lubricating oil to separate fi lter

Back-fl ush from full-fl ow fi lter

Oil vapour discharge*

Lubricating oil overfl ow

Lubricating oil supply

C3

C4

C7

C8

C9

C13

C15

C16

* For external pipe connection, please see section for crankcase ventilation.

General

As standard the lubricating oil system is based on wet sump lubrication.

All moving parts of the engine are lubricated with oil circulating under pressure in a closed built-on system.

The lubricating oil is furthermore used for the purpose of cooling the pistons.

The standard engine is equipped with built-on:

– Engine driven lubricating oil pump – Lubricating oil cooler – Lubricating oil thermostatic valve – Duplex full-fl ow depth fi lter – Pre-lubricating oil pump

Governordrive

Drain fromoil vapourdischarge

C13

LAL28

LAH28

TE29

TE29

TE29

TE29

TE29

PI21-22

PDAH21-22

PDT21-22

PT22

TE22

PAL22

TAH22

PSL22

LAL25

TI22

TE20

TI20

PI23

TAH20

Standard

Optionals

Cyl. 1

C3C16 C15

Lub. oil cooler

Filter

Hand wing pump

El. Driven pre-lub. oil pump

Prelub.oil inlet

TC

Centri-fugalfilter

Topiston

To pumpdrive

To main bearing

Engine drivenlub. oil pump

C4 C9

Boring incamshaft

Forced oil

To rocker arms

Tocamshaftdrive

Separate full flow filter

A

B

A When full flow filter

B 1 piece for 5-6 cyl. engines, 2 pcs. for 7-8 cyl. engines

C8C7

515.01Edition 11H

MAN Diesel

07.47 - ES0

DescriptionPage 2 (5)Internal Lubricating Oil System

L23/30H

Oil Quantities

The approximate quantities of oil necessary for a new engine, before starting up are given in the table, see "B 12 01 1 / 504.06 Lubricating Oil in Base Frame" (max. litre H3)

If there are connected external, full-fl ow fi lters etc., the quantity of oil in the external piping must also be taken into account.

Max. velocity recommendations for external lub ri ca-ting oil pipes:

– Pump suction side 1.0 - 1.5 m/s – Pump discharge side 1.5 - 2.0 m/s

Lubricating Oil Consumption

The lubricating oil consumption is 0.6 - 1.0 g/kWh, see "Specifi c Lubricating Oil Consumption - SLOC, B 12 15 0 / 504.07"

It should, however, be observed that during the run-ning in period the lubricating oil consumption may exceed the values stated.

Quality of Oil

Only HD lubricating oil (Detergent Lubricating Oil) should be used, characteristic stated in "Lubricating Oil Specifi cation B 12 15 0 / 504.01".

System Flow

The lubricating oil pump draws oil from the oil sump and presses the oil through the cooler and fi lter to the main lubricating oil pipe, from where the oil is distri buted to the individual lubricating points. From the lubricating points the oil returns by gravity to the oil sump.

The main groups of components to be lubricated are:

1 – Turbocharger

2 – Main bearings, big-end bearing etc.

3 – Camshaft drive

4 – Governor drive

5 – Rocker arms

6 – Camshaft

1) For priming and during operation, the tur bo char-ger is connected to the lubricating oil circuit of the engine, the oil serves for bearing lubrication and also for dissipation of heat.

The inlet line to the turbocharger is equipped with an orifi ce in order to adjust the oil fl ow and a non-return valve to prevent draining during stand-still.

The non-return valve has back-pressure func-tion requiring a pressure slightly above the prim-ing pres sure to open in normal fl ow direction. In this way overfl ooding of the turbocharger is prevented during stand-still periods, where the pre-lubricating pump is running.

2) Lubricating oil for the main bearings is sup-plied through holes drilled in the engine frame. From the main bearings it passes through bores in the crankshaft to the connecting rod big-end bea rings.

The connecting rods have bored channels for supply of oil from the big-end bearings to the small-end bearings, which has an inner circum-ferential groove, and a pocket for distribution of oil in the bush itself and for supply of oil to the pin bosses and the piston cooling through holes and channels in the piston pin.

From the front main bearings channels are bored in the crankshaft for lubricating of the pump drive.

3) The lubricating oil pipes, for the camshaft drive gear wheels, are equipped with nozzles which are adjusted to apply the oil at the points where the gear wheels are in mesh.

4) The lubricating oil pipe, and the gear wheels for the governor drive are adjusted to apply the oil at the points where the gear wheels are in mesh.

515.01Edition 11H

MAN Diesel

07.47 - ES0

Internal Lubricating Oil System

L23/30H

DescriptionPage 3 (5)

5) The lubricating oil to the rocker arms is led through pipes to each cylinder head. It con-tinuous through bores in the cylinder head and rocker arm to the movable parts to be lubricated at rocker arms and valve bridge. Further, lubricating oil is led to the movable parts in need of lubrication.

6) Through a bore in the frame lubricating oil is led to the fi rst camshaft bearing and through bores in the camshaft from where it is distributed to the other camshaft bearings.

Lubricating Oil Pump

The lubricating oil pump, which is of the gear wheel type, is mounted on the front end of the engine and is driven by means of the crankshaft through a cou-pling. The oil pressure is controlled by an ad just able spring- loaded relief valve built-on the oil pump.

Thermostatic Valve

The thermostatic valve is designed as a T-piece with the inlet in the cover (A) under which the thermostatic elements are located.

The outlet to the engine (by-passing cooler) is marked (B) and outlet to the cooler is marked (C). In the warming up period, the oil is by-passing the cooler. When the oil from the engine reaches the normal temperature see "Operation data & set points 500.30" a controlled amount af oil passes through the cooler.

The thermostatic elements must be replaced if the temperature during normal operation deviates es-sential from the one stated in the test report.

The valve cannot be set or adjusted, and it requires no maintenance.

Built-on Full-fl ow Depth Filter

The lubricating oil fi lter is a double fi lter which is generally used with only one fi lter chamber being in operation, the other fi lter chamber being stand-by.

If the fi lter chamber in operation needs to be servi-ced, the operation can be switched to the other fi lter chamber without any interruption in lubricating oil supply to the engine.

Servicing is generally restricted to replacing of the paper cartridges, cleaning of the radial mesh insert and inspection of sealings, the latter to be replaced if damages observed.

Each fi lter chamber is equipped with 1 or 2 replaceable paper cartridges of fi neness 10-15 microns.

In the centre of each fi lter chamber a fi lter basket (central element) is situated. This fi lter basket is acting as a safety fi lter, having a fi neness of about 60 microns.

During operation an increased pressure drop across the fi lter will be observed as dirt particles will deposit on the fi ltration surfaces of the paper cartridges and thus increase the fl ow resistance through the fi lter.

If the pressure drop across the fi lter exceeds 2.0 bar, a release valve will open and by-pass the 10-15 microns fi lter element, and the engine will run with only the 60 microns safety fi lter.

To ensure safe fi ltering of the lubricating oil, none of the by-pass valves must open during normal service and the elements should be replaced at a pressure drop across the fi lter of 1.5 bar.

515.01Edition 11H

C B

A

Fig 2 Thermostatic Valve

MAN Diesel


07.47 - ES0

L23/30H

Servicing is essential the exchange of the paper cartridges.

When exchanging cartridges, it is advisable to release any old oil remaining in the fi lter housing by means of the drain plug provided for this purpose, and to wipe out the housing with a cloth.

The fi lter chambers can be serviced successively du-ring operation or when the engine is at standstill.

It is essential to follow the instructions in work card 515-01.10 closely when replacing fi lter cartridges.

Filter cartridges must under no circumstances be cleaned and used again.

Pre-lubricating

As standard the engine is equipped with an electric-driven pre-lubricating pump mounted parallel to the main pump. The pump must be arranged for automatic operation, ensuring stand-still of the pre-lubricating pump when the engine is running, and running dur-ing engine stand-still in stand-by position.

Running period of the pre-lubricating pump is prefer-ably to be continuous. If intermittent running is requi-red for energy saving purpose, the timing equipment should be set for shortest possible intervals, say 2 minutes of running, 10 minures of stand-still, etc. Further, it is recommended that the pre-lubricating pump is connected to the emergency switch board thus securing that the engine is not started without pre-lubrication.

Draining of the Oil Sump

It is recommended to use the separator suction pipe for draining of the lubricating oil sump.

Crankcase Ventilation

The crankcase ventilation is not to be directly con-nected with any other piping system. It is preferable that the crankcase ventilation pipe from each engine is led independently to the open air. The outlet is to be fi tted with corrosion resistant fl ame screen separately for each engine.

However, if a manifold arrangements is used, its arrangements are to be as follows:

1) The vent pipe from each engine is to run indepently to the manifold, and be fi tted with corrosion resistant fl ame screen within the manifold.

2) The manifold is to be located as high as practi-cable so as to allow substantial length of piping separating the crankcase.

3) The manifold is to be vented to the open air, such that the vent outlet is fi tted with corrosion resistant fl ame screen, and the clear open area of the vent outlet is not less than the aggregate area of the individual crankcase vent pipes entering the manifold.

4) The manifold is to be provided with drainage arrangement.

The ventilation pipe should be designed to eliminate the risk of water condensation in the pipe fl owing back into the engine and should end in the open air:

– The connection between engine (C13) and the ventilation pipe must be fl exible.

– The ventilation pipe should be continuously inclined (min. 5 degrees).

– A continuous drain has to be installed near the engine. The drain must not be lead back to the engine.

– Dimension of the fl exible connection DN50. – Dimension of the ventilation pipe after the fl ex-

ible connection min. DN65.

Optionals

Besides the standard components, the following optionals can be built-on:

– Level switch for low/high level in oil sump (LAL/LAH 28) – Centrifugal by-pass fi lter (standard for stationary engines) – Hand wing pump Pressure differential transmitting – PDT 21-22 Lubricating oil inlet across fi lter

515.01Edition 11H

MAN Diesel

Temperature alarm high – TAH 20 Lubricating oil inlet before cooler

Pressure transmitting – PT 22 Lubricating oil inlet after cooler

Temperature element – TE 20 Lubricating oil inlet before cooler

Temperature element – TE 22 Lubricating oil inlet after cooler

Temperature element – TE 29 Lubricating oil inlet main bearings

Branches for:

– External fi ne fi lter – External full/fl ow fi lter

Branches for separator is standard.

07.47 - ES0


L23/30H


515.01Edition 11H

MAN Diesel & Turbo

DescriptionPage 1 (4) Internal Lubricating Oil System

L23/30H

11.47 - ES0 - Tier II - Stationary - INC

Fig 1 Diagram for internal lubricating oil system.

Flange connections are as standard according to DIN 2501

Pipe description for connection at the engine

DN25

DN25

DN65

DN65

DN20

DN50

DN50

DN25

Lubricating oil from separator

Lubricating oil to separator

Lubricating oil from separate filter

Lubricating oil to separate filter

Back-flush from full-flow filter

Oil vapour discharge*

Lubricating oil overflow

Lubricating oil supply

C3

C4

C7

C8

C9

C13

C15

C16

* For external pipe connection, please see "Crank-case Ventilation, B 12 00 0/515.31"

General

As standard the lubricating oil system is based on wet sump lubrication.

All moving parts of the engine are lubricated with oil circulating under pressure in a closed built-on system.

The lubricating oil is furthermore used for the purpose of cooling the pistons.

The standard engine is equipped with built-on:

– Engine driven lubricating oil pump – Lubricating oil cooler – Lubricating oil thermostatic valve – Duplex full-flow depth filter – Pre-lubricating oil pump

515.01Edition 14

Governordrive

Drain from oilvapour discharge(see combustionair diagram)

C13

LAL28

LAH28

TE29

TE29

TE29

TE29

TE29

PI21-22

PDAH21-22

PDT21-22

PT22

TE22

PAL22

TAH22

PSL22

LAL25

TI22

TE20

TI20

PI23

TAH20

StandardOptionals

Cyl. 1

C3C16 C15

Lub. oil cooler

Filter

Hand wing pump

El. Driven pre-lub. oil pump

Prelub.oil inlet

TC

Centri-fugalfilter

Topiston

To pumpdrive

**

**Lube oil pipeto internalnozzle cooling

To main bearing

Engine drivenlub. oil pump

C4 C9

Boring incamshaft

Forced oil

To rocker arms

Tocamshaftdrive

Separate full flow filter

A

B

A When full flow filter

B 1 piece for 5-6 cyl. engines, 2 pcs. for 7-8 cyl. engines

C8C7

MAN Diesel & Turbo



L23/30H

Oil Quantities

The approximate quantities of oil necessary for a new engine, before starting up are given in the table, see "B 12 01 1 / 504.06 Lubricating Oil in Base Frame" (max. litre H3)

If there are connected external, full-flow filters etc., the quantity of oil in the external piping must also be taken into account.

Max. velocity recommendations for external lub ri-ca ting oil pipes:

– Pump suction side 1.0 - 1.5 m/s – Pump discharge side 1.5 - 2.0 m/s

Lubricating Oil Consumption

The lubricating oil consumption, see "Specific Lubri-cating Oil Consumption - SLOC, B 12 15 0 / 504.07"

It should, however, be observed that during the run-ning in period the lubricating oil consumption may exceed the values stated.

Quality of Oil

Only HD lubricating oil (Detergent Lubricating Oil) should be used, characteristic stated in "Lubricating Oil Specification B 12 15 0 / 504.01".

System Flow

The lubricating oil pump draws oil from the oil sump and presses the oil through the cooler and filter to the main lubricating oil pipe, from where the oil is distri buted to the individual lubricating points. From the lubricating points the oil returns by gravity to the oil sump.

The main groups of components to be lubricated are:

1 – Turbocharger

2 – Main bearings, big-end bearing etc.

3 – Camshaft drive

4 – Governor drive

5 – Rocker arms

6 – Camshaft

1) For priming and during operation, the tur-bo char ger is connected to the lubricating oil circuit of the engine, the oil serves for bearing lubrication and also for dissipation of heat.

The inlet line to the turbocharger is equipped with an orifice in order to adjust the oil flow and a non-return valve to prevent draining during stand-still.

The non-return valve has back-pressure func-tion requiring a pressure slightly above the prim-ing pres sure to open in normal flow direction. In this way overflooding of the turbocharger is prevented during stand-still periods, where the pre-lubricating pump is running.

2) Lubricating oil for the main bearings is sup-plied through holes drilled in the engine frame. From the main bearings it passes through bores in the crankshaft to the connecting rod big-end bea rings.

The connecting rods have bored channels for supply of oil from the big-end bearings to the small-end bearings, which has an inner circum-ferential groove, and a pocket for distribution of oil in the bush itself and for supply of oil to the pin bosses and the piston cooling through holes and channels in the piston pin.

From the front main bearings channels are bored in the crankshaft for lubricating of the pump drive.

515.01Edition 14

MAN Diesel & Turbo



L23/30H


3) The lubricating oil pipes, for the camshaft drive gear wheels, are equipped with nozzles which are adjusted to apply the oil at the points where the gear wheels are in mesh.

4) The lubricating oil pipe, and the gear wheels for the governor drive are adjusted to apply the oil at the points where the gear wheels are in mesh.

5) The lubricating oil to the rocker arms is led through pipes to each cylinder head. It con-tinuous through bores in the cylinder head and rocker arm to the movable parts to be lubricated at rocker arms and valve bridge. Further, lubricating oil is led to the movable parts in need of lubrication.

6) Through a bore in the frame lubricating oil is led to the first camshaft bearing and through bores in the camshaft from where it is distributed to the other camshaft bearings.

Lubricating Oil Pump

The lubricating oil pump, which is of the gear wheel type, is mounted on the front end of the engine and is driven by means of the crankshaft through a cou-pling. The oil pressure is controlled by an ad just able spring- loaded relief valve built-on the oil pump.

Thermostatic Valve

The thermostatic valve is designed as a T-piece with the inlet in the cover (A) under which the thermostatic elements are located.

The outlet to the engine (by-passing cooler) is marked (B) and outlet to the cooler is marked (C). In the warming up period, the oil is by-passing the cooler. When the oil from the engine reaches the normal temperature see "Operation data & set points 500.30" a controlled amount af oil passes through the cooler.

The thermostatic elements must be replaced if the temperature during normal operation deviates es-sential from the one stated in the test report.

The valve cannot be set or adjusted, and it requires no maintenance.

Built-on Full-flow Depth Filter

The lubricating oil filter is a double filter which is generally used with only one filter chamber being in operation, the other filter chamber being stand-by.

If the filter chamber in operation needs to be servi-ced, the operation can be switched to the other filter chamber without any interruption in lubricating oil supply to the engine.

Servicing is generally restricted to replacing of the paper cartridges, cleaning of the radial mesh insert and inspection of sealings, the latter to be replaced if damages observed.

Each filter chamber is equipped with 1 or 2 replaceable paper cartridges of fineness 10-15 microns.

In the centre of each filter chamber a filter basket (central element) is situated. This filter basket is acting as a safety filter, having a fineness of about 60 microns.

During operation an increased pressure drop across the filter will be observed as dirt particles will deposit on the filtration surfaces of the paper cartridges and thus increase the flow resistance through the filter.

515.01Edition 14

C B

A

Fig 2 Thermostatic Valve

MAN Diesel & Turbo



L23/30H

If the pressure drop across the filter exceeds 2.0 bar, a release valve will open and by-pass the 10-15 microns filter element, and the engine will run with only the 60 microns safety filter.

To ensure safe filtering of the lubricating oil, none of the by-pass valves must open during normal service and the elements should be replaced at a pressure drop across the filter of 1.5 bar.

Servicing is essential the exchange of the paper cartridges.

When exchanging cartridges, it is advisable to release any old oil remaining in the filter housing by means of the drain plug provided for this purpose, and to wipe out the housing with a cloth.

The filter chambers can be serviced successively du-ring operation or when the engine is at standstill.

It is essential to follow the instructions in work card 515-01.10 closely when replacing filter cartridges.

Filter cartridges must under no circumstances be cleaned and used again.

Pre-lubricating

As standard the engine is equipped with an electric-driven pre-lubricating pump mounted parallel to the main pump. The pump must be arranged for automatic operation, ensuring stand-still of the pre-lubricating pump when the engine is running, and running dur-ing engine stand-still in stand-by position.

Running period of the pre-lubricating pump is prefer-ably to be continuous. If intermittent running is requi-red for energy saving purpose, the timing equipment should be set for shortest possible intervals, say 2 minutes of running, 10 minures of stand-still, etc. Further, it is recommended that the pre-lubricating pump is connected to the emergency switch board thus securing that the engine is not started without pre-lubrication.

Draining of the Oil Sump

It is recommended to use the separator suction pipe for draining of the lubricating oil sump.

Optionals

Besides the standard components, the following optionals can be built-on:

– Level switch for low/high level in oil sump (LAL/LAH 28) – Centrifugal by-pass filter (standard for stationary engines) – Hand wing pump Pressure differential transmitting – PDT 21-22 Lubricating oil inlet across filter

Temperature alarm high – TAH 20 Lubricating oil inlet before cooler

Pressure transmitting – PT 22 Lubricating oil inlet after cooler

Temperature element – TE 20 Lubricating oil inlet before cooler

Temperature element – TE 22 Lubricating oil inlet after cooler

Temperature element – TE 29 Lubricating oil inlet main bearings

Branches for:

– External fine filter – External full/flow filter

Branches for separator is standard.

515.01Edition 14

MAN Diesel

DescriptionPage 1 (1) Lubricating Oil Cooler 515.06

Edition 01H

96.26 - ES0U-G

L23/30H

Principle of the Plate Heat Exchanger

The built-on lubricating oil cooler is a plate heat exchanger.

The plate heat exchanger consist of a number of cold pressed plates which are compressed between a frame plate (head) and the pressure plate (follow) by means of tie bolts.

The plates are made with special corrugations, which ensures turbolent fl ow and high heat transfer coffi cients.

Plates

After clamping of the plate pack, the plates - which are fi tted gaskets - ensure an effective seal between fl uids and atmosphere. In addition, intermixing of the fl uids is eliminated by a double gasket seal around the inlet ports.

Every second plate is turned through 180°. This means that the double gasket seal occurs around every second inlet to the channels between the plates.

The plate pack now forms a series of parallel fl ow channels in which the fl uids fl ow in a counter cur-rent regime.

Description

The centrifugal filter is a by-pass filter mounteddirectly at the engine base frame.

The centrifugal filter is a supplement to the main fil-ter. During service, a part of the lubricating oil sup-plied from the engine driven lubricating oil pumpenters the centrifugal filter and returns to the oilsump in the base frame.

The centrifugal filter relies on the centrifugal forceand can therefore remove high density, sub-micronparticles.

Principle of operation

Oil enters the base of the filter and depresses thecut-off valve (A) which has a pre-set pressure valve.The cut-off valve is fitted to ensure that at low pres-sure and flow conditions the entire oil pump outputis supplied to the engine working parts. Havingdepressed the cut-off valve the oil travels up thecentre of the spindle. Through holes at the top (B)and enters the rotor (C) at the maximum heightabove the stand tube. The oil completely fills thecleaning chamber (D) and travels through thestrainer (E) into the drive chamber (F), leaving underpressure via diametrically opposed tangential noz-zles in the bottom of the rotor.

The reaction of the oil leaving the nozzles providesthe driving force causing the rotor to spin about thespindle at high speed. The oil leaving the nozzles isthen allowed to drain back to the sump, by gravityat atmospheric pressure.

The centrifugal force field within the spinning rotorforces the contaminants to travel to the inner wall ofthe rotor, where they form a dense rubber-likesludge which is easily removed.

For proper filtration, it is important that the rotor isalways correctly balanced.

An out-of-balance condition can occur as a result ofan uneven built-up of sludge or as a result of exces-sive bearing or spindle wear.

A Cut-off valve B Top

C Rotor D Cleaning chamber

E Strainer F Drive chamber

Figure 1: Diagram showing principle of operation

MAN Diesel & Turbo

DescriptionPage 1 (1) Centrifugal by-pass filter 515.15

Edition 01

L23/30H, V28/32S, L28/32DF

1996.01.15

Crankcase ventilation

The crankcase ventilation is not to be directly con-nected with any other piping system. It is preferablethat the crankcase ventilation pipe from eachengine is led independently to the open air. The out-let is to be fitted with corrosion resistant flamescreen separately for each engine.

Figure 1: Crankcase ventilation

However, if a manifold arrangement is used, itsarrangements are to be as follows:

1) The vent pipe from each engine is to run inde-pendently to the manifold and be fitted with cor-rosion resistant flame screen within the mani-fold.

2) The manifold is to be located as high as practi-cable so as to allow a substantial length of pip-ing, which separates the crankcase on the indi-vidual engines.

3) The manifold is to be vented to the open air, sothat the vent outlet is fitted with corrosion resist-ant flame screen, and the clear open area of thevent outlet is not less than the aggregate areaof the individual crankcase vent pipes enteringthe manifold.

4) The manifold is to be provided with drainagearrangement.

The ventilation pipe must be designed to eliminatethe risk of water condensation in the pipe flowingback into the engine and should end in the open air:

▪ The connection between engine (C13 / C30)and the ventilation pipe must be flexible.

▪ The ventilation pipe must be made with continu-ous upward slope of minimum 5°, even whenthe ship heel or trim (static inclination).

▪ A continuous drain must be installed near theengine. The drain must be led back to thesludge tank.

Engine Nominal diameter ND (mm)

A B C

L16/24 50 65

L21/31 65 40 80

L23/30H 50 - 65

L27/38 100 - 100

L28/32H 50 - 65

V28/32H 100 - 125

L32/40 125 50 125

V28/32S 100 - 125

Table 1: Pipe diameters for crankcase ventilation

▪ Dimension of the flexible connection, see pipediameters Fig 2.

▪ Dimension of the ventilation pipe after the flexi-ble connection, see pipe diameters Fig 2.

MAN Diesel & Turbo

DescriptionPage 1 (2) Crankcase ventilation

515.31Edition 03

L16/24, L23/30H, V28/32S, L21/31, L27/38

2012.01.16 - ES1

The crankcase ventilation flow rate varies over time,from the engine is new/major overhauled, until it istime to overhaul the engine again.

The crankcase ventilation flow rate is in the range of3.5 – 5.0 ‰ of the combustion air flow rate [m³/h]at 100 % engine load.

If the combustion air flow rate at 100 % engine loadis stated in [kg/h] this can be converted to [m³/h]with the following formula (Tropic Reference Condi-tion) :

Example :

Engine with a mechanical output of 880 kW andcombustion air consumption of 6000 [kg/h] corre-sponds to :

The crankcase ventilation flow rate will then be inthe range of 19.2 – 27.4 [m³/h]

The maximum crankcase backpressure measuredright after the engine at 100 % engine load must notexceed 3.0 [mbar] = 30 [mmWC].


Edition 03Crankcase ventilation Description

Page 2 (2)

L16/24, L23/30H, V28/32S, L21/31, L27/38

2012.01.16 - ES1

Safety precautions


Short Description

Disassembly, overhaul and assembly of lubricatingoil pump, engine driven. Adjustment of lub. oilpressure.

Starting PositionAll pipe connections to the lub. oil pump havebeen disconnected, and the lub. oil pump isremoved from the engine.

Related Procedure

Qualified Manpower

Duration in h : 6-8Number : 1

Data


Special tools

Plate No. Item No. Note52005 273 80-360 Nm

Hand Tools



51501 234 1/Pump51501 055 5/Pump51501 151 1/Pump

MAN Diesel & Turbo

Work CardPage 1 (2) Lubricating oil pump

515-01.00Edition 01

L23/30H

1996.06.24

Disassembly

1) Remove the coupling part or gear wheel (1), seefig. 2, by means of a puller or a soft hammer.

2) Remove screws (2) and dismount the cover (3).

3) Dismount the locking ring (4), screws (5) andremove 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 piston(14) cannot be pulled out from the same side, theplug screw (15) can be removed and the piston canbe pressed out from this side with a screw driver orthe like.

Figure 1: .

Overhaul

6) Clean all the parts with gas oil and a hardbrush, (never use a steel brush). The parts areblown clean with working air.

7) If the bearing bush is to be removed the existingbearing bush is plugged out by means of amandrel, the bores are cleaned and new bear-ing bush is mounted, see fig. 1.

Before the gear wheels (7 and 8) can be mountedthe bearing bush must be adjusted with a reamer ora bearing scraper, so that the gear wheel can runeasily when the pump is assembled.

8) Inspect all other parts for wear and damage,and renew, if necessary.

Figure 2: .

Assembly

9) Mount the gear wheel (7 and 8).

Coat the sealing lip with silastene or similar andmount the cover (6) with gear wheel and lockingring (4).

10) Mount the cover (3) with gasket.

11) Mount the gear wheel or coupling part (1).

For tightening the nut for gear wheel, see page500.40.

12) Mount the spring loaded by-pass valve, nut (10)with gasket, cap nut (9) and plug screw (15).

Adjusting of Lub. Oil Pressure

13) The outlet pressure of the lub. oil pump, can beadjusted by means of a adjusting screw in theby-pass valve.

Remove the cap nut (9) and loosen the nut (10).

By turning the spring housing clockwise the pres-sure is raised and reverse the pressure is loweredby turning the spring housing (11) anti-clockwise.When the correct pressure is reached , see page500.30, the spring housing (11) is locked with nut(10) and finally the gasket and cap nut (9) aremounted.


Lubricating oil pump Work CardPage 2 (2)

L23/30H

1996.06.24

Safety precautions


Short Description

Replacement of paper filter element(s). Cleaning ofsafety filter and filter housing.

Starting Position

Related Procedure

Qualified Manpower


Data


Special tools


Hand ToolsRing and open end spanner, 22 mmRing and open end spanner, 24 mmRing and open end spanner, 27 mmAdjustable spanner



51502 013 see plate51502

51502 290 1/Filter

MAN Diesel & Turbo

Work CardPage 1 (3) Lubricating oil filter

515-01.10Edition 01

L23/30H

1991.11.04

Description

The lubricating oil filter is dimensioned so that eachof the two filter parts has sufficent capacity to treatthe amount of lubricating oil delivered by the pump.

The three-way valve positioned is determiningwhether the left hand or the right hand filter cham-ber is in operation, and also gives the possibility ofhaving both filter chambers in operation simultane-ously.

The three-way valve is marked with flow directionsand the figure indicates the operation modesaccording to valve positions.

Figure 1: Three-way valve positions

Service Procedure

Warning!

Use protective gloves, safety glasses

1 Left hand filter camber 2 Right hand filter chamber

3 Inlet 4 Outlet

5 Vent screw 6 Three-way valve/ switchvalve

7 Fill-up valve 8 Drain plug

Figure 2: Lubricating oil filter

1) Turn the three-way valve, see fig. 2, into theposition setting the stand-by filter chamber inoperation and the filter chamber requiring serv-ice out of operation.

2) Open the vent screw (5) on the top of the filterto get the pressure out of the filter half.

3) Open the drain plug (8) under the filter housingand drain off oil.

4) Filter housing cap is dismantled.

5) Remove the inner safety element. Clean the ele-ment with detergent. Check that it is intact.

6) Remove the outer element(s). Filter element is ofdisposable type. It change always to new origi-nal filter.


Lubricating oil filter Work CardPage 2 (3)

L23/30H

1991.11.04

7) Clean the filter housing and the cap. Be carefulof not to let the oil from the dirty side to go intothe clean oil channel in the middle of bottom.

8) Check the seal on the bottom of the filter hous-ing and in the cap. Change if needed.

9) Assemble the filter in opposite order.

Figure 3: Fill-up valve position

10) Let the air valve be open and fill the filter hous-ing with oil by means of the slow fill-up valve (7)in position FILL, see fig. 3. This valve is insidethe three-way valve and by using it, the fillingcan be made so slowly that the pressure on theother part of the filter does not drop too much.

11) Close the vent screw (5) after the housing is fil-led up with oil.

12) Open the three-way valve (6) and close the fill-up valve (7) by turning it to position CLOSED,see fig. 3.

13) The filter just serviced is now ready to be set inoperation.

Inspect for oil leakages in order to ascertain all seal-ings to be tight.

Check that pressure drop across filter is correct.

Clean the other side of the filter correspondingly.

MAN Diesel & Turbo

Work CardPage 3 (3) Lubricating oil filter

515-01.10Edition 01

L23/30H

1991.11.04

Safety precautions

Engine stopped

Shut-off starting air

Shut off cooling water

Shut off fuel oil

Shut-off cooling oil

Stop lub. oil circulation

Press Blocking - Reset

Short Description

Inspection of thermostatic valve and replacementof elements.

Starting Position

Lubricating oil drained fromengine (if necessary).

Related Procedure

Qualified Manpower


Data


Special tools


Hand ToolsRing and open end spanner, 24 mmCopaslipTools and cleaning preparation for cleaning



61503 020 2/engine61503 044 2/engine61503 093 3/engine

MAN Diesel & Turbo

Work CardPage 1 (2) Lubricating oil, thermostatic valve

515-01.20Edition 01

L23/30H, L28/32DF

2014.03.18

Thermostatic valve

The thermostatic valve cannot be adjusted andunder normal working conditions maintenance isnot required. However, in some cases it is neces-sary to replace the elements in the thermostaticvalve.

1 Nut 2 Washer

3 Element 4 O-rings sealing

5 Gasket

Figure 1: Thermostatic valve

Replacement of elements

Warning!

Use protective gloves

1) Remove nuts (1) and washers (2), 4 or 6 pcs.See fig. 1.

2) Disconnect upper and lower part of the hous-ing.

3) Remove the assembled elements (3) and theelements O-ring sealing.

4) Remove the gaskets between the upper andlower part of the housing.

5) The upper and lower part of the housing arethoroughly cleaned inside and on the gasketsurfaces.

6) The sealing rings (4) for the elements in thehousing are replaced and lubricated with a thinlayer of copaslip.

7) Remount the assembled elements in the hous-ing by wriggling these somewhat over side.

8) Upper and lower part of the housing areassembled with a new gasket (5), the nuts (1)are mounted and tightened "cross-wise".

Note: After inspection or replacement of the ele-ments the temperature is checked to ensure thatthe elements are working correctly.


Lubricating oil, thermostatic valve Work CardPage 2 (2)

L23/30H, L28/32DF

2014.03.18

Safety precautions


Short Description

Check and examination of the lubricating oil pipingsystem.

Starting Position

Engine running.

Related Procedure

Qualified Manpower


Data


Special tools


Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (2) Check of lubricating oil piping system

515-01.90Edition 01

L23/30H

1992.01.20

Health Risk!

Warning!

Health Risk!


Checks to be carried out



3) Move all valves and cocks in the piping system.Lubricate valve spindles with graphite or similar.

4) Blow-through drain pipes.

5) Check flexible connections for leaks and dam-ages.

6) Check manometers and thermometers for pos-sible damages.

For lubricating oil condition, see section 504.


Check of lubricating oil piping system Work CardPage 2 (2)

L23/30H

1992.01.20

Safety precautions


Short Description

Separation, cleaning and assembling. Replace-ment of plates and gaskets.

Starting PositionCooling water and lube oil have been drained fromcooler/engine. All external pipes are disconnected.

Related Procedure

Qualified Manpower


Data


Special tools


Hand ToolsRing and open end spanner, 10 mmRing and open end spanner, 55 mmRing and open end spanner, 30 mmAdjustable spanner



51506 111/279 4/cooler

MAN Diesel & Turbo

Work CardPage 1 (4) Lubricating oil cooler

515-06.00Edition 02

L23/30H

1996.09.23

Introduction

Cleaning of the cooler must take place, when thepressure drop on the oil and water side exceeds anallowable value and/or if oil cannot be sufficientlycooled.

Separation

Cooling and pressure relief

Before opening the plate heat exchanger, it must becooled down to below 40° C and be without pres-sure!

The cooling must not exceed 10° C per minute. The pressure drop must not exceed 10 bar perminute.

Note!

If these norms are exceeded, the guarantee willcease to be valid.

Separation of edge-clamped frame

Upon completion of the procedure “Cooling andPressure Relief”, separate the frame by retainingtwo or four diagonally placed bolts.

Note!

Take care that the pressure plate does not tilt!

Loosen the bolts uniformly and diagonally (max. 10mm at a time), then push the pressure platetowards the end support. When the pressure plateis not tight anymore, the plates can be removed.

Note!

When using plate heat exchangers on board ships,the pressure plate have to be secured in order toavoid danger during the movements of the ship.

Cleaning

The capacity and corrosion resistance of the plateheat exchangers depend on the cleanness of theplates. Any coating on the plates can be removedmanually.

Manual cleaning

Clean the plates with a soft brush and a suitabledetergent. In case of dense coating of scale ororganic materials, the plates must be put in a bathwith detergent.

Note!

Never use a steel brush, metal scraper or the like.

A high-pressure cleaner can be used with care,however, never with sand or other abrasives added.

Detergents

A detergent is suitable, if it will removes any coatingon the plates without causing any damage to platesand gaskets.

Note!

It is of great importance that decomposition of theprotective film on the stainless steel does not takeplace - the film preserves the corrosion resistanceof steel.

Do not use chlorine-containing agents such ashydrochloricacid (HCI)!

Oil and fats are removed by using a water emulsify-ing oil solvent, e.g. BP-system cleaner.

Organic and greasy coatings are removed by usingsodium hydroxide (NaOH):

▪ max. concentration 1.5% (1.5% concentration corresponds to 3.75 l 30%NaOH per 100 l water).

▪ max. temperature 85° C.

Stone and lime/calcareous deposits are removedby using nitric acid (HNO3):


Lubricating oil cooler Work CardPage 2 (4)

L23/30H

1996.09.23

▪ max. concentration 1.5% (1.5% concentration corresponds to 1.75 l 62%HNO3 per 100 l water).

▪ max. temperature 65° C.

Note!

The nitric acid has an important constructive effecton the protective film of stainless steel.

Control of cleaning fluid concentrations

Sodium hydroxide (NaOH) solution is tritrated with0.1 n hydro-chloric acid (HCI) with methyl orange ormethyl red as indicator.

Nitric acid (HNO3) solution is titrated with 0.1 nsodium hydroxide (NaOH) with phenolphtalin as anindicator.

The concentration of the cleaning fluid in % can becalculated from the titration result using the follow-ing formula:

a : ml cleaning fluid taken out for titration

b : ml titration fluid used as cover

n : the molecular concentration of titration fluid

m : The molecular weight of the cleaning fluid(NaOH) molecular weight 40, HNO3 molecularweight 63)

Replacement of plates and gaskets

Marking

The plates are marked with material codes and ref-erence numbers at each end, plus codes for non-glued gaskets, if any, and stamped with the letter Vand H at either end (Fig 1).

When facing the gasket, the plate is designated asa left plate, when letter V turns upwards - and as aright plate when letter H turns upwards. Inlets andoutlets of the V-plates are taking place through thecorner holes Nos 1 and 4. Inlets and outlets of theH-plates take place through corner holes Nos 2 and3.

Replacement of plates

Before mounting a spare plate in the plate stack,please make sure that the spare plate is identicalwith the faulty one.

Note!

The same corner holes must be opened and lettersV and H must be placed properly.

Replacement of glued gaskets

On Plate 51506 stated are gasket and glue quan-tity.

Please use a degreasing agent on the new gaskets.

The first plate after the end cover and the connectorgrid must have gaskets in all grooves. The gasketsmust be cut according to the existing gaskets.

Loosen the glued gaskets by heating the plate inwater at 100° C. Clean the plates and remove thecoatings, if any.

Cleaning of new gaskets and plates

New gaskets and gasket grooves of the plates arecleaned with a cloth moistened with degreasingagent. The glue surfaces must be absolutely clean -without finger prints etc.

Please use our cleaning fluid, which conforms tosuppliers recommendations.

Alternatively, please use:

▪ Trichloroethylene

▪ Chlorothene VG

▪ Acetone

▪ Methyl ethyl ketone

▪ Ethylacetat

It is important that all degreasing agent has evapo-rated, before the glue is applied. This will normallytake approx. 15 min. at 20° C.

Clean the new gaskets on the glued surfaces withfine-grained sandpaper instead of the degreasingagent supplied.

Gluing

Pliobond 25, which is a solvent-based nitrile rubberglue (25% solids). The glue is applied with a brushin a thin layer on the backs of the gaskets and thegaskets must be dried in a clean place free of dust.

MAN Diesel & Turbo

Work CardPage 3 (4) Lubricating oil cooler

515-06.00Edition 02

L23/30H

1996.09.23

Apply a thin layer of glue on the gasket grooves ofthe plates and press the gaskets down into the gas-ket grooves.

The insertion of the gaskets starts at both ends ofthe plate - and continues with the straight sectionsalong the edges.

The gluing process is most easily performed byplacing the gaskets and the plates on a table. Afterpressing the gaskets into the grooves of the plate, itis stacked.

The plates with the gaskets are mounted in theframe which is lightly clamped. In the case of usingrubber grooves, they are assembled to the mini-mum measure stated on the engine sign plus 0.2mm per plate.

Heat up the plate heat exchanger to 90-100° C bymeans of water or steam.

Please note

▪ The temperature must be kept for 1½-2 hours.

▪ The liquid pressure must be kept as low as pos-sible.

If there is no possibility of heating the plate heatexchanger, it must be placed in a place as warm aspossible with connections dismounted.

At 20° C the drying time will be approx. 48 hours.At 40° C, the drying time is approx. 24 hours.

Assembling

If the plates are dismounted, they must be properlyassembled according to plate item numbers.

The fixed cover has number 1 and serial numbersfor the subsequent plates, and intermediate frames,if any, are numbered 2, 3, 4, 5 etc.

Serial numbers are stamped in the right top cornerof the plates. Further, please note that the gasketside must face the fixed cover.

Figure 1: .

Fastening

Fasten the plate heat exchanger until the movablecover touches the duct spacers.


Lubricating oil cooler Work CardPage 4 (4)

L23/30H

1996.09.23

Safety precautions


Short Description

Cleaning procedure, cleaning intervals. Mainte-nance intervals and procedures.

Starting Position

Isolate the filter for lub. oil inlet

Related Procedure

Qualified Manpower


Data


Special tools


Hand ToolsBig adjustable spannerTools for cleaning



51515 398 1/Filter51515 408 1/Filter51515 421 1/Filter

MAN Diesel & Turbo

Work CardPage 1 (3) Centrifugal bypass filter

515-15.00Edition 08

L23/30H

2013.01.22

Cleaning procedure

1) Isolate the filter by closing the valve for lubricat-ing oil inlet to the filter.

Warning!


2) Slacken cover clamp ring (266). Unscrew coverfixing nut and lift off cover (038).

3) Lift off rotor assembly having allowed oil to drainfrom nozzles. The rotor should be removed andreplaced on the spindle with extreme care inorder to ensure that the bearings are not dam-aged.

4) Unscrew rotor cover nut (026) and separaterotor.

026 Cover nut 038 Cover

075 Stand tube 266 Cover clamp ring

Figure 1: Centrifugal bypass filter

5) Remove stand tube (075) and clean.

6) Remove sludge from inside the rotor by meansof a spatula and wipe clean. Ensure that allrotor components are throughly cleaned andfree from deposits of dirt before reassemblingthe rotor.

Note!

Failure to do so could cause an out-of-bal-ance condition which will accelerate bearingand spindle wear.

7) Clean nozzle with brass wire. Examine top andbottom bearings in tube assembly. If damagedor worn - replace tube assembly complete.Examine O-ring and renew if damaged.

8) Replace paper insert (if mounted)

9) Reassemble rotor complete and tighten top nut.

Note!

Ensure that rotor cover and rotor body arealways matched by balance number and pinlocation. Do not interchange rotor cover.

10) Examine spindle journals. If damaged or worn -replace with body assembly complete.

11) Reassemble filter complete checking that rotorrevolves freely. Then replace filter body coverTighten cover nut and secure safety clamp. Theclamp ring should be securely fitted at all timesand the filter should not be run without theclamp ring fitted.

12) Open for lubricating oil.

13) With filter running, check all joints for leakage. Check for excessive vibration.

Maintenance - Bearings and spindles

All rotors are correctly balanced before leaving thefactory. An out-of-balance condition can occur as aresult of an uneven build up of sludge in the rotor oras a result of excessive bearing or spindle wear.


Centrifugal bypass filter Work CardPage 2 (3)

L23/30H

2013.01.22

Dependent on the conditions, wear will eventuallytake place on the spindle and bearings and theseshould be replaced with factory fitted assembliesonly.

To check bearing clearances

This is most easily done by applying a dial gauge tothe outside of the rotor opposite each bearing inturn and measuring the total play, thus:

14) Apply dial gauge and measure play.

15) Turn rotor 90° and repeat measurement.

16) Re-apply dial gauge at 90° to previous positionand repeat.

17) Turn rotor 90° and repeat.

The highest reading is the play in the bearing.

The maximum clearances when new are 0.08 mmat top and 0.06 mm at bottom bearing. If the clear-ance exceeds 0.25 mm top or 0.2 mm bottom thencheck the sizes of the individual components andreplace as necessary.

Spindle top journal diameter 14.98 mm Min

Spindle bottom journal diameter 21.63 mm Min

Top bearing bore diameter 15.06 mm Max

Bottom bearing bore diameter 21.69 mm Max

The spindle and body assembly and the rotor bear-ing tube assembly are factory assembled items andshould only be replaced with complete assemblies.

MAN Diesel & Turbo

Work CardPage 3 (3) Centrifugal bypass filter

515-15.00Edition 08

L23/30H

2013.01.22

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Central driven) 51501-01HPlatePage 1 (2)

94.22 - ES0S

13

163234

175

234187 210

199

330

209

366

258

138

126

114

092126

151

295354

317

018

079

067

234

222

329

305

271

055

031

043

246

055

283

342080102

5-6-7L23/30H 720/750 RPML23/30H-900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Central driven) PlatePage 2 (2)51501-01H

94.22 - ES0S


* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./P = Qty./Pump


* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe


Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

187

199

209

210

222

234

246

258

271

283

295

305

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

Pump housing

Shaft with gearwheel, long

Shaft with gearwheel, short

Bush

Coupling

Dog

Cog wheel

Cog wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Adjusting screw

Spring

Piston

Cylinder

Plug screw

Gasket

Cylindrical pin

Pin

Key

Screw

Screw

Guide pin

Pumpehus

Aksel med tand-hjul, lang

Aksel med tand-hjul, kort

Bøsning

Kobling

Medbringer

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Justerskrue

Fjeder

Stempel

Cylinder

Propskrue

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Styrestift

6/P

2/P

1/E

1/P

1/P

1/P

317

329

330

342

354

366

Screw

Nut

Lub. oil pump,complete

End cover

Cover

Key

Skrue

Møtrik

Smøreoliepumpe,komplet

Endedæksel

Dæksel

Feder

5-6-7L23/30H 720/750 RPML23/30H-900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Central driven) 51501-02HPlatePage 1 (2)

94.22 - ES0S

13

163234

175

234187 210

199

330

209

366

258

138

126

114

092126

151

295354

317

018

079

067

234

222

329

305

271

055

031

043

246

055

283

342080102

8L23/30H720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Central driven) PlatePage 2 (2)51501-02H

94.22 - ES0S





8L23/30H720/750 RPM


Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

187

199

209

210

222

234

246

258

271

283

295

305

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

Pump housing



Bush

Coupling

Dog

Cog wheel

Cog wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Adjusting screw

Spring

Piston

Cylinder

Plug screw

Gasket

Cylindical pin

Pin

Key

Screw

Screw

Guide pin

Pumpehus



Bøsning

Kobling

Medbringer

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Justerskrue

Fjeder

Stempel

Cylinder

Propskrue

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Styrestift

6/P

2/P

1/E

1/P

1/P

1/P

317

329

330

342

354

366

Screw

Nut


End cover

Cover

Key

Skrue

Møtrik


Endedæksel

Dæksel

Feder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Gear driven) 51501-11HPlatePage 1 (2)

07.01 - ES0

7-8L23/30H-720/750 RPM5-6L23/30H-720/750 RPM (High Capacity)

7-8L23/30H-900 RPM (High Capacity)

079

067

271317

018

234

222

305055

329

043

031

330

366

055

246283

342080102

258138126114126092

151354295

401

175234

234

163

391

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Gear driven) PlatePage 2 (2)51501-11H

07.01 - ES0





7-8L23/30H-720/750 RPM5-6L23/30H-720/750 RPM (High Capacity)

7-8L23/30H-900 RPM (High Capacity)


Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

222

234

246

258

271

283

295

305

317

329

330

342

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

6/P

2/P

1/E

1/P

Pump housing



Bush

Gear wheel

Nut

Cog wheel

Cog wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Plug screw

Gasket

Cylindrical pin

Pin

Key

Screw

Screw

Guide pin

Screw

Nut


End cover

Pumpehus



Bøsning

Tandhjul

Møtrik

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Cylinder

Styrestift

Skrue

Møtrik


Endedæksel

1/P

1/P

1/P

1/P

354

366

391

401

Cover

Key

Gasket

Piston, complete

Dæksel

Feder

Pakning

Trykregulerings- stempel, komplet

MAN Diesel & Turbo

Lubricating Oil Pump (Gear driven) 51501-26PlatePage 1 (2)

13.01 - ES0

L23/30H

079

067

271317

018

234

222

305055

329

043

031

330

366

055

246283

342080102

258138126114126092

151354295

401

175234

234

163

391

MAN Diesel & Turbo

Lubricating Oil Pump (Gear driven) PlatePage 2 (2)51501-26

13.01 - ES0





L23/30H


Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

222

234

246

258

271

283

295

305

317

329

330

342

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

6/P

2/P

1/E

1/P

Pump housing



Bush

Gear wheel

Nut

Cog wheel

Cog wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Plug screw

Gasket

Cylindrical pin

Pin

Key

Screw

Screw

Guide pin

Screw

Nut


End cover

Pumpehus



Bøsning

Tandhjul

Møtrik

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Cylinder

Styrestift

Skrue

Møtrik


Endedæksel

1/P

1/P

1/P

1/P

354

366

391

401

Cover

Key

Gasket

Piston, complete

Dæksel

Feder

Pakning

Trykregulerings- stempel, komplet

MAN Diesel & Turbo

PlatePage 1 (2) Lubricating oil filter P51502-07

L23/30H, L28/32DF, L23/30DF

2014.03.31 - Type A

Item No. Qty Item Designation Item No. Qty Item Designation

When ordering spare parts, see also page 500.50/600.50/Pref-ace.

* = Only available as part of a spare parts kit/notavailable separately

Qty/E = Qty/EngineQty/F = Qty/Filter

013 2/F Paper element

025 2/F Safety element

037 1/F Valve housing, incl. item 074,216+

049 2/F Housing, incl. o-ring

050 2/F Cap complete, incl. item 133,348, 361, 373, 407+

062 1/F Spindle, incl. item 121, 312, 444

074 2/F Thrust ring

086 2/F By-pass code, incl. item 324,336, 385, 432, 493+

108 2/F Vent screw, incl. item 228, 241

121 1/F Fill-up valve

133 4/F Sealing ring

145 12/F Stud

157 12/F Screw

169 4/F Screw

170 12/F Nut

182 4/F Washer

194 24/F Washer

216 5/F Pin

228 6/F Pin

241 2/F Gasket

277 2/F Opening guard, incl. vent screw

289 2/F Drain plug

290 1/F Seal kit, item not shown ongraphic

300 1/E Lub. oil filter complete

MAN Diesel & Turbo

P51502-07 Lubricating oil filter PlatePage 2 (2)

L23/30H, L28/32DF, L23/30DF

2014.03.31 - Type A

MAN Diesel & Turbo

PlatePage 1 (2) Lubricating oil filter P51502-02

L23/30H, V28/32S, L28/32DF

2014.03.28




Qty/F = Qty/Filter

312 1/F Cap

324 2/F By-pass valve seat

336 2/F By-pass valve spool

348 2/F Flange

361 2/F Flange

373 2/F Screw

385 2/F By-pass valve spring

397 8/F Seal

407 2/F Spring

419 2/F Spring

420 6/F Pin

432 2/F Gasket

444 2/F O-ring

456 2/F O-ring

468 2/F O-ring

481 4/F O-ring

493 2/F O-ring

MAN Diesel & Turbo

P51502-02 Lubricating oil filter PlatePage 2 (2)

L23/30H, V28/32S, L28/32DF

2014.03.28

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Lubricating Oil Thermostatic Valve 51503-01HPlatePage 1 (2)

94.23 - ES0S-L

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.23 - ES0S-L


Lubricating Oil Thermostatic Valve PlatePage 2 (2)51503-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

019

020

032

044

056

068

081

093

103

115

4/T

2/T

2/T

2/T

2/T

4/T

16/T

3/T

12/T

1/E

Screw

O-ring

Thermostaticelement

O-ring

Sleeve

Washer

Nut

Gasket

Screw

Thermostaticvalve, complete

Skrue

O-ring

Følerelement

O-ring

Bøsning

Skive

Møtrik

Pakning

Skrue

Termostatventil,komplet


* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/T = Antal/Termostatsventil


* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./T = Qty./Thermostatic valve

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

General

Prelubricating Pump with El-Motor 51504-02HPlatePage 1 (2)

94.23 - ES0S-L

0802

8-0D

/H52

50/9

4.08

.12

94.23 - ES0S-L


Item No.

Qty.

Qty.

Item No.

254

266

278

291

301

313

325

337

349

350

362

374

386

398

408

421

433

445

457

469

470

482

494

504

516

528

1/P

1/P

1/P

1/P

1/P

4/P

2/P

1/P

1/P

2/P

1/P

1/E

1/P

1/P

1/P

1/P

1/P

1/P

2/P

2/P

2/P

1/P

1/E

1/E

1/E

1/E

Driving cover

Gear casing

End cover, complete, incl. item 386, 398, 408, 421, 433, 445, 457, 469 and 470

Driving gear shaft

Gear shaft

Screw

Parallel pin

Retaining ring

Parallel key

O-ring

Rotary shaft seal

Pumpe, completewithout El-motor

End cover

Piston

Spindle

Dome nut

Spring

Pipe nut

Screwed plug

Sealing ring

Sealing ring

Coupling, complete

El-motor, complete

Pre.lub oil pump,complete with el-motor

Ball bearing, rear

Ball bearing, front

Medbringerdæksel

Gearhus

Endedæksel, komplet inkl. item 386, 398, 408, 421, 433, 445, 457, 469 og 470

Drivende gearaksel

Gearaksel

Skrue

Styrestift

Sikringsring

Not

O-ring

Roterende akseltæt-ning

Pumpe, komplet uden el-motor

Endedæksel

Stempel

Spindel

Lukkemøtrik

Fjeder

Rørmøtrik

Propskrue

Tætningsring

Tætningsring

Kobling, komplet

El-motor, komplet

Forsmørepumpe,komplet med el-motor

Kugleleje, bagside

Kugleleje, forside

General

51504-02H Prelubricating Pump with El-Motor PlatePage 2 (2)





MAN Diesel

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Lubricating Oil Cooler 51506-11HPlatePage 1 (2)

07.06 - ES0S-G

027039

015016017

040

B

Note: When orderingplates, please statethe serial numbers ofthe plates. The serialnumbers of the platescan be found in thetop right-hand cornerof the plates. (SeeWorking Card 515-06.00)

Husk: Ved bestillingaf plader angivesserienummeret påpladen. Serienum-meret er stemplet itoppen af pladen tilhøjre. (Se arbejdskort515-06.00)

052

064065066

076077078079080081082

088111123

147159

160

172173174175176177178

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.06 - ES0S-G


Lubricating Oil Cooler PlatePage 2 (2)51506-11H

L23/30H

Item No.

Qty.

Qty.

Item No.

015

016

017

027

039

040

052

064

065

066

076

077

078

079

080

4/K

4/K

4/K

4/K

4/K

1/K

/I

2/K

2/K

2/K

4/K

4/K

4/K

4/K

4/K

Hexagon screw5-6-7-8 cyl. engine(720/750 rpm) and6 cyl. engine (900 rpm)

Hexagon screw7 cyl. engine(900 rpm)

Hexagon screw8 cyl. engine(900 rpm)

Washer

Washer

Pressure plate

Gasket

Guide bar5-6-7-8 cyl. engine(720/750 rpm) and6 cyl. engine (900 rpm)

Guide bar7 cyl. engine(900 rpm)

Guide bar8 cyl. engine(900 rpm)

Distance piece5 cyl. engine(720/750 rpm)




Distance piece6 cyl. engine(900 rpm)

Bolt5-6-7-8 cyl. motor(720/750 rpm) og6 cyl. motor (900 rpm)

Bolt7 cyl. motor(900 rpm)

Bolt8 cyl. motor (900 rpm)

Skive

Skive

Trykplade

Pakning

Styrepind5-6-7-8 cyl. motor(720/750 rpm) og6 cyl. motor (900 rpm)

Styrepind7 cyl. motor(900 rpm)

Styrepind8 cyl. motor (900 rpm)

Afstandsstykke5 cyl. motor(720/750 rpm)




Afstandsstykke6 cyl. motor(900 rpm)


* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./K = Qty./CoolerQty./I = Qty./Individual


* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Antal/KølerAntal/I = Antal/Individuel



Stativplade

Pakning

Skrue

Styrepind(for demontering)

Smøreoliekøler,komplet

Plader5 cyl. motor(720/750 rpm)

Plates6 cyl. motor(720/750 rpm)



Plates6 cyl. motor(900 rpm)





Frame plate

Gasket

Screw

Guide bar(for dismantling)

Lubricating oil cooler,complete

Plates5 cyl. engine(720/750 rpm)




Plates6 cyl. engine(900 rpm)



4/K

4/K

1/K

4/K

2/K

2/K

1/E

/I

/I

/I

/I

/I

/I

/I

081

082

088

111

123

147

160

172

173

174

175

176

177

178

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.23 - ES0S

L23/30H

Centrifugal By-Pass Filter 51515-01HPlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.23 - ES0S

Centrifugal By-Pass Filter PlatePage 2 (2)51515-01H

L23/30H




* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/F = Antal/Filter


Item No.

Qty.

Qty.

Item No.

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

2/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

Rotor, complete incl. item 026, 038, 063, 075, 109, 110, 171, 195 and 205

Cover nut

Rotor cover

Body

O-ring

Stand tube

Pin

Paper insert

Rotor body

Nozzle

Plug (cut off valve)

Spring (cut off valve)

Gasket (cutoff valve)

Shuttle (cutoff valve)

Bearing, completeincl. item 195 and 205

Circlip

Pin

Gasket

O-ring

Spindle

Body, complete incl. item 051, 122, 134, 146, 158, 229, 230 and 242

Cover clamp ring

Cover fi xing nut

Rotor, komplet inkl. item 026, 038, 063, 075, 109, 110, 171, 195 og 205

Dækselmøtrik

Rotordæksel

Sokkel

O-ring

Standrør

Stift

Papirindsats

Rotorsokkel

Dyse

Prop (modtryksventil)

Feder (modtryksventil)

Pakning (modtryks-ventil)

Ventilkegle (modtryks-ventil)

Lejemontering, komplet inkl. item 195 og 205

Låsering

Stift

Pakning

O-ring

Spindel

Sokkel, komplet inkl. item 051, 122, 134, 146, 158, 229, 230 og 242

Dækselspændering

Dækselmøtrik

014

026

038

051

063

075

087

099

109

110

122

134

146

158

171

195

205

229

230

242

254

266

278

291

301

313

325

337

349

350

362

374

386

398

408

421

1/F

1/F

1/F

1/F

1/E2/E

4/F

4/F

1/F

4/F

1/F

1/F

1/F

1/F

O-ring

Circlip

Cover

Body cover, complete incl. item 087, 266, 278, 291, 301 and 313

Centrifugal by-passfi lter, complete5-6 cyl.7-8 cyl.

Nut

Screw

Bracket for mounting

Screw

Gasket

Spare parts kit, incl.item 087, 278, 291 and 301

Spare parts kit, incl.item 122, 134, 146 and 158

Spare parts kit, incl. item 063, 146, 229, 230 and 291

O-ring

Låsering

Dæksel

Dæksel, komplet inkl. item 087, 266, 278, 291, 301 and 313

Centrifugal by-passfi lter, komplet5-6 cyl.7-8 cyl.

Møtrik

Skrue

Konsol for montering

Skrue

Pakning

Reservedelssæt, inkl.item 087, 278, 291 og 301

Reservedelssæt, inkl.item 122, 134, 146 og 158

Reservedelssæt, inkl. item 063, 146, 229, 230 og 291

0802

8-0E

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

94.20 - ES0S-G

Hand Wing Pump 51525-01H

L23/30H

019

0802

8-0E

/H52

50/9

4.08

.12

MAN Diesel

Hand Wing Pump PlatePage 2 (2)51525-01H

L23/30H

019

Item No. Benævnelse

Håndvingepumpe, komplet

Designation

Hand wing pump, complete

Qty.

1/E

Item No. DesignationQty. Benævnelse


* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./Motor


* = Only available as part of a spare parts kit. Qty./E = Qty./Engine

94.20 - ES0S-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.08 - ES0

Lubricating Oil Separator 51530-04HPlatePage 1 (2)

L23/30H

053

041

065

077

089090

100

112

124

136

148

161

219

220

185

173

207

232

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.08 - ES0


Lubricating Oil Separator PlatePage 2 (2)51530-04H

L23/30H

Item No.

Qty.

Qty.

Item No.

041

053

065

077

089

090

100

112

124

136

148

161

173

185

207

219

220

232

1/F

1/F

4/F

8/F

1/F

1/F

1/F

1/F

4/F

1/F

1/F

4/F

1/F

1/F

1/F

4/F

1/E

1/F

Breather withfl ange

Gasket

Screw

Screw

Cover

Gasket

Insert for oilseparator

Housing foroil separator

Screw

Gasket

Bend

Nut

Oil trap

Union

Union

Screw

Oil separator, com-plete, incl item 077, 089, 090, 100, and 112

Gasket

Ånderør medfl ange

Pakning

Skrue

Skrue

Dæksel

Pakning

Indsats forolieudskiller

Hus forolieudskiller

Skrue

Pakning

Bøjning

Møtrik

Olielås

Forskruning

Forskruning

Skrue

Olieseparator, kompletinkl. item 077, 089, 090, 100 og 112

Pakning




* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/F = Antal/Filter

MAN Diesel & Turbo

PlatePage 1 (2) Prelubricating pump arrangement P51535-10

L23/30H

2014.03.13 – Monocoque




Qty/E = Qty/Engine

002 4/E Screw

003 3/E Straight male stud, complete

004 1/E Lub. oil pipe

005 2/E Ball valve

006 1/E Adjustable elbow coupling, com-plete

007 2/E Steel pipe

008 1/E Equal tee coupling, complete

009 2/E Equal elbow coupling

010 1/E Steel pipe

011 1/E Steel pipe

012 1/E Non return valve

013 1/E Steel pipe

014 1/E Guard

MAN Diesel & Turbo

P51535-10 Prelubricating pump arrangement PlatePage 2 (2)

L23/30H

2014.03.13 – Monocoque

MAN Diesel & Turbo

PlatePage 1 (2) Lubricating oil pipe thermostatic valve P51543-01

L23/30H

2014.03.19 – Monocoque, one string




Qty/E = Qty/Engine

010 1/E Lub. o. outl. suct. pipe

030 10/E Packing square

031 4/E Hexagon screw

040 1/E Lub. oil inlet pump


062 32/E Nut

064 16/E Cyl. screw

070 1/E Outl. pump inl. therm. v.

092 3/E Packing ring

100 1/E Outl. therm. v. inl. cool

124 8/E Stud

126 1/E Hexagon nipple

127 1/E Ball valve


129 1/E Plug screw

140 1/E Outl. therm. valve/cooler

160 1/E Inlet lub. oil filter

190 1/E Outlet lub. oil filter

220 1/E Lub. o. distribution pipe

243 7/E Packing, oval





303 1/E Lub. oil pipe

304 1/E Pipe coupling

MAN Diesel & Turbo

P51543-01 Lubricating oil pipe thermostatic valve PlatePage 2 (2)

L23/30H

2014.03.19 – Monocoque, one string

MAN Diesel & Turbo

PlatePage 1 (2) Lubricating oil pipe thermostatic valve P51543-02

L23/30H

2014.03.20 – Monocoque, two string




Qty/E = Qty/Engine

010 1/E Lub. o. outl. suct. pipe

030 10/E Packing square


040 1/E Lub. oil inlet pump


062 32/E Nut

064 16/E Cyl. screw

070 1/E Outl. pump inl. therm. v.


100 1/E Outl. therm. v. inl. cool

124 8/E Stud

126 1/E Hexagon nipple

127 1/E Ball valve


129 1/E Plug screw

140 1/E Outl. therm. valve/cooler

160 1/E Inlet lub. oil filter

190 1/E Outlet lub. oil filter

220 1/E Lub. o. distribution pipe

243 7/E Packing, oval





303 1/E Pipe section

304 1/E Pipe coupling

MAN Diesel & Turbo

P51543-02 Lubricating oil pipe thermostatic valve PlatePage 2 (2)

L23/30H

2014.03.20 – Monocoque, two string

Cooling water system

516/616

MAN Diesel


516.01Edition 01H

96.03 - ES0U-G

L23/30HV28/32S

Description

The cooling water system consists of two separate systems. The low temperature (LT) and the high temperature (HT) circuits.

Low Temperature Circuit

The low temperature circuit is used for cooling of the charge air and the lubricating oil, and the alternator if the latter is water cooled.

High Temperature Circuit

The high temperature circuit is used for cooling of the cylinder units.

Cooling water is led through a distributing pipe to the bottom of the cooling water space between the liner and the frame of each cylinder unit. The water is led out through bores in the top of the frame via the cooling water guide jacket to the bore.

Cooling Water System

MAN Diesel & Turbo

Thermostatic Valve

The thermostatic valve in the high temperature cir-cuit is mainly located imediately after the outlet of the engine, but alternatively in the external cooling system near the fresh water cooler.

The cooling water enters through the cover (A) under which the thermostatic elements are located.

The number of elements depends on the size of the valve.

The outlet to the suction side of the pump is marked (B) and outlet to the cooler is marked (C).

In the warming-up period the cooling water is by-passing the cooler. When the outlet water from the cylinder heads reaches the normal temperature (75-85° C) a controlled amount of water passes through the cooler.

The thermostatic elements must be replaced if the cooling water temperature during normal operation deviates essentially from the one stated in the test report.

DescriptionPage 1 (1) Cooling Water Thermostatic Valve

L23/30HV28/32S

94.26 - ES0S-G

516.04Edition 01H

The thermostatic valve cannot be set or adjusted, and requires no maintenance.

In some plants a corresponding thermostatic valve is installed in the low temperature circuit. The ther-mostatic elements of this valve have an other tem-perature range.

C B

A

Fig. 1 Thermostatic Valve

Safety precautions


Short Description

Check of cooling water system.

Starting Position

Engine is running

Related Procedure

Qualified Manpower


Data


Special tools


Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (2) Check of Cooling Water System

516-01.90Edition 04

L23/30H

2005.10.10.

Health Risk!

Warning!

Health Risk!


Checks to be carried out



3) Move all valves and cocks in the piping system.Lubricate valve spindles with graphite or similar.

4) Check flexible connections for leaks.

5) Check manometers and thermometers for pos-sible damages.

For check of the fresh water condition, see section504.


Check of Cooling Water System Work CardPage 2 (2)

L23/30H

2005.10.10.

Safety precautions


Short Description

Inspection of thermostatic valve and replacementof elements.

Starting Position

Cooling water drained from engine(if necessary)

Related Procedure

Qualified Manpower


Data


Special tools


Hand ToolsRing and open end spanner, 24 mmCopaslipTools and cleaning preparation for cleaning



51604 031 1/E51604 055 2 or 4/E51604 092 3/E

MAN Diesel & Turbo

Work CardPage 1 (2) Cooling Water, Thermostatic Valve

516-04.00Edition 01

L23/30H

1994.07.18.

Thermostatic valve

The thermostatic valve cannot be adjusted andunder normal working conditions maintenance isnot required. However, in some cases it is neces-sary to replace the elements in the thermostaticvalve.

1 Nut 2 Washer

3 Element 4 O-rings sealing

5 Gasket

Figure 1: Thermostatic valve

Replacement of elements

Warning!


1) Remove nuts (1) and washers (2), 4 or 6 pcs.See fig. 1.

2) Disconnect upper and lower part of the hous-ing.

3) Remove the assembled elements (3) and theelements O-ring sealing.

4) Remove the gaskets between the upper andlower part of the housing.

5) The upper and lower part of the housing arethoroughly cleaned inside and on the gasketsurfaces.

6) The sealing rings (4) for the elements in thehousing are replaced and lubricated with a thinlayer of copaslip.

7) Remount the assembled elements in the hous-ing by wriggling these somewhat over side.

8) Upper and lower part of the housing are assem-bled with a new gasket (5), the nuts (1) aremounted and tightened "cross-wise".

Note: After inspection or replacement of the ele-ments the temperature is checked to ensure thatthe elements are working correctly.


Cooling Water, Thermostatic Valve Work CardPage 2 (2)

L23/30H

1994.07.18.

MAN Diesel & Turbo

L23/30H

Cooling Water Thermostatic Valve 51604-01HPlatePage 1 (2)

94.23 - ES0S

MAN Diesel & Turbo

94.23 - ES0S


Cooling Water Thermostatic Valve PlatePage 2 (2)51604-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

4/T

2/T

2/T

2/T

2/T

4/T

16/T

3/T

12/T

1/E

Screw

O-ring

Thermostaticelement

O-ring

Sleeve

Washer

Nut

Gasket

Screw

Thermostaticvalve, complete

Skrue

O-ring

Følerelement

O-ring

Bøsning

Skive

Møtrik

Pakning

Skrue

Termostatventil,komplet


* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/T = Antal/Termostatsventil


* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./T = Qty./Thermostatic valve

MAN Diesel & Turbo

High Temperature Fresh Water Pump 51610-01HPlatePage 1 (2)

01.36 - ES0S

L23/30H720/750 RPM

MAN Diesel & Turbo

01.36 - ES0S

High Temperature Fresh Water Pump PlatePage 2 (2)51610-01H






Item No.

Qty.

Qty.

Item No.

010

022

034

046

058

071

083

095

105

117

129

130

142

154

166

178

191

201

213

225

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

2/P

1/P

1/P

2/P

2/P

1/P

8/P

1/E

1/E

4/E

Pump housing

Bearing housing

Shaft

Impeller

Gear wheel

Self locking nut

Rotating sealing

Sealing ring

Ball bearing

Retaining ring

Key

Locking washer

Self locking nut

Plug screw

Gasket

Ball valve

Screw

Fresh water pump,complete

Gasket

Screw

Pumpehus

Lejehus

Aksel

Løbehjul

Tandhjul

Selvlåsende møtrik

Roterende pakdåse

Tætningsring

Kugleleje

Sikringsring

Feder

Låseskive


Propskrue

Pakning

Kugleventil

Skrue

Ferskvandspumpe,komplet

Pakning

Skrue

L23/30H720/750 RPM

MAN Diesel & Turbo

High Temperature Fresh Water Pump 51610-02HPlatePage 1 (2)

178

010

046

071

129

154-166

201

117

083 191 095 022 034 105 058 130

129 142

L23/30H900 RPM

93.05 - ES0S

MAN Diesel & Turbo

93.05 - ES0S

High Temperature Fresh Water Pump PlatePage 2 (2)51610-02H


Item No.

Qty.

Qty.

Item No.

010

022

034

046

058

071

083

095

105

117

129

130

142

154

166

178

191

201

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

2/P

1/P

1/P

2/P

3/P

1/P

8/P

1/E

Pump housing

Bearing housing

Shaft

Impeller

Gear wheel

Self locking nut

Rotating sealing

Sealing ring

Ball bearing

Retaining ring

Key

Locking washer

Self locking nut

Plug screw

Gasket

Ball valve

Screw


Pumpehus

Lejehus

Aksel

Løbehjul

Tandhjul


Roterende pakdåse

Tætningsring

Kugleleje

Sikringsring

Feder

Låseskive


Propskrue

Pakning

Kugleventil

Skrue






L23/30H900 RPM

MAN Diesel & Turbo

Low Temperature Fresh Water Pump 51610-05HPlatePage 1 (2)

01.36 - ES0S

L23/30H

MAN Diesel & Turbo

01.36 - ES0S

Low Temperature Fresh Water Pump PlatePage 2 (2)51610-05H






Item No.

Qty.

Qty.

Item No.

010

022

034

046

058

071

083

095

105

117

129

142

154

166

178

191

201

213

225

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

2/P

1/P

3/P

3/P

1/P

8/P

1/E

1/E

8/E

Pump housing

Bearing housing

Shaft

Impeller

Gear wheel

Self locking nut

Rotating sealing

Sealing ring

Ball bearing

Retaining ring

Key

Self locking nut

Plug screw

Gasket

Ball valve

Screw


Gasket

Screw

Pumpehus

Lejehus

Aksel

Løbehjul

Tandhjul


Roterende pakdåse

Tætningsring

Kugleleje

Sikringsring

Feder


Propskrue

Pakning

Kugleventil

Skrue


Pakning

Skrue

L23/30H

MAN Diesel & Turbo

Low Temperature Fresh Water Pump 51610-13HPlatePage 1 (2)

07.06 - ES0

L23/30H

178

010

046

071

129

154-166

201 117

213 191 095 022 034 105 058

129 142

083 225

MAN Diesel & Turbo

07.06 - ES0

Low Temperature Fresh Water Pump PlatePage 2 (2)51610-13H






Item No.

Qty.

Qty.

Item No.

010

022

034

046

058

071

083

095

105

117

129

142

154

166

178

191

201

213

225

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

2/P

1/P

3/P

3/P

1/P

8/P

1/E

1/E

8/E

Pump housing

Bearing housing

Shaft

Impeller

Gear wheel

Self locking nut

Rotating sealing

Sealing ring

Ball bearing

Retaining ring

Key

Self locking nut

Plug screw

Gasket

Ball valve

Screw


Gasket

Screw

Pumpehus

Lejehus

Aksel

Løbehjul

Tandhjul


Roterende pakdåse

Tætningsring

Kugleleje

Sikringsring

Feder


Propskrue

Pakning

Kugleventil

Skrue


Pakning

Skrue

L23/30H

MAN Diesel & Turbo

Pipes on Cylinder HeadPlatePage 1 (2)

94.25 - ES0S

51625-01H

L23/30H

MAN Diesel & Turbo

Pipes on Cylinder Head PlatePage 2 (2)51625-01H

L23/30H

012

024

036

048

061

073

085

097

107

119

120

132

144

Item No. Benævnelse

H.T. samlerør,5 cyl.




Pakning, oval

Skrue

Termometerstykke

Pakning, oval

Skrue

Skrue

Møtrik

Pakning, oval

Termometer

Designation

H.T. collecting pipe,5 cyl.




Packing, oval

Screw

Thermometer piece

Packing, oval

Screw

Screw

Nut

Packing, oval

Thermometer

Qty.

1/E

1/E

1/E

1/E

1/C

2/C

1/C

1/C

2/C

2/C

2/C

1/C

1/C

Item No. DesignationQty. Benævnelse

94.25 - ES0S


* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./MotorQty./C = Qty./Cylinder


* = Only available as part of a spare parts kit. Qty./E = Qty./EngineQty./E = Qty./Cylinder

MAN Diesel & Turbo

PlatePage 1 (2) Preheater - Fresh Water

L23/30HV28/32S

07.46 - ES0

51635-04H

MAN Diesel & Turbo


Item No.

Qty.

Qty.

Item No.

353

365*

377*

389*

390*

400*

412*

424*

436*

Rør for forvarmer

Forvarmer5 L23/30H,stationær

Forvarmer6, 7 L23/30H,stationær

Forvarmer8 L23/30H,stationær

Forvarmer5 L23/30H,marine

Forvarme6, 7 L23/30H,marine

Forvarmer8 L23/30H,marine

Forvarmer12 V28/32S

Forvarmer16, 18 V28/32S

* Ved ordre oplyses spænding (V) og ef-fekt (W)

Preheater - Fresh Water

07.46 - ES0

L23/30HV28/32S

PlatePage 2 (2)51635-04H

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

Pipe for preheater

Preheater5 L23/30H,stationary

Preheater6, 7 L23/30H,stationary

Preheater8 L23/30H,stationary

Preheater5 L23/30H,marine

Preheater6, 7 L23/30H,marine

Preheater8 L23/30H,marine

Preheater12 V28/32S

Preheater16, 18 V28/32S

* At ordering please inform of voltage (V) and output (W)





Special equipment

517/617

MAN Diesel & Turbo

KitPage 1 (2)

12.38 - ES0

Kit for Cylinder Unit 51704-12

L23/30H

338

040

052

363

184

037

025

185

220

234

210

024024

264

097

132

075

026

099

116224

178

166

130

130

178

MAN Diesel & Turbo

Kit for Cylinder Unit KitPage 2 (2)51704-12

L23/30H

Item no Designation Where to find in the engine instruction book

021 Kit per cylinder unit

1 O-ring Plate 50501 Item 040

1 Snap ring Plate 50501 Item 052




3 Gasket Plate 50508 Item 025










1 Sealing ring Plate 51203 Item 234




2 Packing Plate 51404 Item 166


1 Packing, oval Plate 51625 Item 097

1 Packing, oval Plate 51625 Item 132

Qty

Please Note that this is a kit supply, and that any exceeding number of parts are not accepted as return goods.

12.38 - ES0

MAN Diesel & Turbo

KitPage 1 (2)

10.16 - ES0

Kit for Rotocap 51705-02

L23/30H

017

524/536

548

585

See working card 505-01.15

Cylinder head,see plate 50501

MAN Diesel & Turbo

Kit for Rotocap KitPage 2 (2)51705-02

L23/30H


017 Kit per rotocap

7 Spring Plate 50502 Item 524

7 Ball Plate 50502 Item 536

1 Spring washer Plate 50502 Item 548

1 Retainer ring Plate 50502 Item 585

Qty


10.16 - ES0

MAN Diesel & Turbo

KitPage 1 (2)

11.48 - ES0

Kit for Covers on Frame 51751-01

L23/30H

FramePlate 51101

237

058

MAN Diesel & Turbo

Kit for Covers on Frame KitPage 2 (2)51751-01

L23/30H


006 Kit per coves on frame



Qty


11.48 - ES0

Specific plant information

519/619

Resilient mounting of generating sets

On resilient mounted generating sets, the dieselengine and the generator are placed on a commonrigid base frame mounted on the ship's/erectionhall's foundation by means of resilient supports,type Conical.

All connections from the generating set to the exter-nal systems should be equipped with flexible con-nections, and pipes, gangway etc. must not be wel-ded to the external part of the installation.

Resilient support

A resilient mounting of the generating set is madewith a number of conical mountings. The numberand the distance between them depend on the sizeof the plant. These conical mountings are bolted tobrackets on the base frame (see fig 1).

The setting from unloaded to loaded condition isnormally between 5-11 mm for the conical mount-ing.

The exact setting can be found in the calculation ofthe conical mountings for the plant in question.

Figure 1: Resilient mounting of generating sets

Figure 2: Support of conicals

MAN Diesel & Turbo

DescriptionPage 1 (3) Resilient mounting of generating sets

519.03Edition 13

L23/30H

2011.10.10

Figure 3: Conical mountingsThe support of the individual conical mounting canbe made in one of the following three ways:

1) The support between the bottom flange and thefoundation of the conical mounting is made witha loose steel shim. This steel shim is adjusted toan exact measurement (min. 40 mm) for eachconical mounting.

2) The support can also be made by means of twosteel shims, at the top a loose shim of at least40 mm and below a shim of approx. 10 mmwhich are adjusted for each conical mountingand then welded to the foundation.

3) The support can be made by means of chock-fast. It is recommended to use two steel shims,the top shim should be loose and have a mini-mum thickness of 40 mm, the bottom shimshould be cast in chockfast with a thickness ofat least 10 mm.

Check the minimum permitted thickness of chock-fast for the load surface of this application withchockfast supplier.


Edition 13Resilient mounting of generating sets Description

Page 2 (3)

L23/30H

2011.10.10

4) Finally, the support can be made by means oftwo steel shims, the top shim of 46 mm andbelow a shim of approx. 99 mm. the shims arethen welded to the foundation. The top shimsare then adjusted and tighten to the lower shim.

Irrespective of the method of support, it is recom-mended to use a loose steel shim to facilitate apossible future replacement of the conical mount-ings.

Check of Crankshaft Deflection

The resiliently mounted generating set is normallydelivered from the factory with engine and alternatormounted on the common base frame.Eventhough engine and alternator have been adjus-ted by the engine builder, with the alternator rotorplaced correctly in the stator and the crankshaftdeflection of the engine (autolog) within the prescri-bed tolerances, it is recommended to check thecrankshaft deflection (autolog) before starting up theGenSet.

MAN Diesel & Turbo

DescriptionPage 3 (3) Resilient mounting of generating sets

519.03Edition 13

L23/30H

2011.10.10

Safety precautions


Short Description

Mounting and adjustment instruction for new Gen-Set and adjustment instruction for existing plants.

Starting PositionThe foundation should be welded and milled off onshim surfaces.

Related Procedure

Check of main bearings alignment(autolog)

510-01.00

Replacement of conicals 519-03.05

Qualified Manpower


Data


Special tools


Hand ToolsRing and open-end spanner, 22 mmRing and open-end spanner, 30 mmAllen key, 6 mmFeeler gauge, 1-2 mmMeasuring toolHydraulic jack (if necessary)



51903 013 1/conicalmounting


MAN Diesel & Turbo

Work CardPage 1 (4) Fitting instructions for resilient mounting of GenSets

519-03.00Edition 27

L23/30H, L27/38

2003.12.08 - Method 1

Mounting and adjustment instructions fornew generating sets (Method 1)

Make ready for adjustment of conicalelements

If the conical elements have not been mounted bythe factory, they must be mounted on the preparedbrackets on the base frame. In case they have beenmounted by the factory, please start with item num-ber 2.

1) Fit the conical elements to the bracket on thebase frame by means of four bolts screwed intothe tapped holes on the top casting (5), see fig1.

2) Remove fixing bolt (7), spring washer (8) andtop lock ring (6) from the conical element, seefig 1.

3) Position the four jacking bolts in the tappedholes (9) see fig 1, in the base casting (1).

4) Position the jacking bolts with a through-goingof minimum 40 mm, see fig 2.

1 Base casting 2 Internal buffer

3 Synthetic bush 4 Rubber element

5 Top casting 6 Top lock ring

7 Fixing bolt 8 Spring washer

9 Tapped hole 10 Protective cap

Figure 1: Conical element

5) Lower the generating set until it rests com-pletely on the foundation.

6) Check that all jacking bolts have full contactwith the foundation.

7) Turn all the internal buffers (2), see fig 1, tocheck that they can move freely.

If all internal buffers Then

Can move freely Let conical elements settlefor 48 hours.

Cannot be moved Turn the four jacking boltsin the base casting clock-wise or anticlockwise torelease the internal buffer.

Adjustment of conical elements after 48hours settling

After the conical elements have been deflectedunder static load for 48 hours, the laden height (H1)see fig 2, should be measured and compared to therecommended laden height.

Figure 2: Conical mounting


Fitting instructions for resilient mounting of GenSets Work CardPage 2 (4)

L23/30H, L27/38

2003.12.08 - Method 1

8) Care must be taken, during levelling of theinstallation, to ensure that individual mountingsare not overloaded. The variation in laden heightshould not exceed 2 mm and should ideally beless. The laden height can be measuredbetween top and base casting at H, on twosides (see fig 1).

If Then

Difference exceeds 2 mm Level the conical elementby adjusting the jackingbolts - commencing withthe conical element withthe largest deviation

Difference does not exceed2 mm

The height of the steel shimcan be measured

The difference between the two sides of a conicalmounting should not be more than 0.6 mm.

Measuring of steel shim

9) Measure the steel shim on several points toobtain the highest possible accuracy duringpreparation.

Fabricating steel shim

10) Make sure that the minimum height of the steelshim is 40 mm to secure a future replacementof the conical element.

Drill the mounting holes in the steel shim accordingto the conical base casting dimensions.

Mounting of the completed steel shim

11) Turn the internal buffer anticlockwise until itcontacts the base casting to secure the ladenheight of each conical element.

12) Lift the generating set with crane or hydraulicjack.

13) Remove all the jacking bolts.

14) Position each completed steel shim.

15) Lower the generating set until it rests com-pletely in itself.

16) Number each steel shim together with eachconical element.

Adjustment of internal buffer

17) Turn the internal buffer clockwise (downwards)until it makes contact with the steel shim orfoundation.

18) Turn the internal buffer anticlockwise (upwards)until it obtains contact with the base casting.

This must be four full turns.

19) Turn the internal buffer two full turns clockwise(downwards) and check with a feeler gaugebetween the base casting of the conical ele-ment and the steel shim that the internal buffer(2), see fig 1, does not touch the steel shim orfoundation.

20) Lock the internal buffer by remounting the toplock ring (6) and turn it to the nearest threadhole - then secure with fixing bolt (7) and springwasher (8), see fig 1.

Mounting of conical elements on thefoundation

21) Drill four mounting holes in the foundation foreach conical element, either

⇨ Mark the positions of the mounting holes onthe foundation through the conical elementand the steel shim.(Re)move the set completely so that themarkings can be reached by drilling withconventional tools.Place the set on its former position by align-ing it with the drilled holes.

or

⇨ Drill the mounting holes in the foundation bymeans of the drilling pattern from the instal-lation drawing.The drilling has to be done on beforehand

MAN Diesel & Turbo


519-03.00Edition 27

L23/30H, L27/38

2003.12.08 - Method 1

and the set must be aligned with the foun-dation holes before the work starts to avoidfurther removal of the set.

22) Fix all the conical elements and the steel shimsto the foundation with four bolts per conical.

Note!

After completion of all works the buffer clearancemust be checked, see points 17, 18, 19 and 20.



L23/30H, L27/38

2003.12.08 - Method 1

Safety precautions


Short Description



Related Procedure


510-01.00


Qualified Manpower


Data


Special tools







MAN Diesel & Turbo


519-03.00Edition 28

L23/30H, L27/38

2003.12.08 - Method 2



If the conical elements have not been mounted bythe factory, they must be mounted on the preparedbrackets of the base frame. In case they have beenmounted by the factory, please start with item num-ber 2.

1) Fit the conical elements to the bracket on thebase frame by means of four bolts screwed intothe tapped holes on the top casting (5), see fig1.

A supporting steel shim with a minimum height of40 mm, to secure a future replacement of the coni-cal element, complete with tapped holes for threejacking bolts and mounting holes drilled accordingto conical base casting dimensions, is required.








3) Position the supporting steel shim as per fig 2and locate the conical element by means ofdowel pins.

4) Position the three jacking bolts in the tappedholes in the supporting steel shim as per fig 2.

5) Position the jacking bolts with a through-goingof minimum 40 mm, see fig 2.

6) Lower the generating set until it rests com-pletely on the foundation.


8) Turn the internal buffer (2), see fig 1 to checkthat it can be moved freely.




L23/30H, L27/38

2003.12.08 - Method 2



Cannot be moved Turn the four jacking boltsin the base casting clock-wise or anticlockwise torelease the internal buffer.




If Then

Difference exceeds 2 mm Level the conical elementby adjusting the jackingbolts - commencing withthe conical element withthe largest deviation


The height of the steel shimcan be measured


Measuring of steel shim

10) Measure the steel shim on several points toobtain the highest possible accuracy duringpreparation.


11) Make sure that the minimum height of the steelshim is 10 mm.

Drill the mounting holes in the steel shim accordingto the mounting holes in the conical base castingand the mounting holes in the supporting steelshim.

Mounting of the completed steel shim

12) Lift the generating set 1 mm totally be means ofthe three jacking bolts.


14) Re-lower the generating set by means of thethree jacking bolts until it rests completely initself.








19) Remove the dowel pins.

20) Drill four mounting holes in the foundation foreach conical element, either

⇨ Mark the positions of the mounting holes onthe foundation through the conical elementand the steel shims. (Re)move the set completely so that themarkings can be reached by drilling with

MAN Diesel & Turbo


519-03.00Edition 28

L23/30H, L27/38

2003.12.08 - Method 2

conventional tools.Place the set on its former position by align-ing it with the drilled holes.

or

⇨ Drill the mounting holes in the foundation bymeans of the drilling pattern from the instal-lation drawing. The drilling has to be done on beforehandand the set must be aligned with the foun-dation holes before the work starts to avoidfurther removal of the set.

21) Fix all the conical elements and the supportingsteel shims/steel shims to the foundation withfour bolts per conical.

22) Weld the lowest steel shim of approx. 10 mmheight to the foundation.

Note!

After completion of all works, the buffer clearancemust be checked, see points 15, 16, 17 and 18.



L23/30H, L27/38

2003.12.08 - Method 2

Safety precautions


Short Description



Related Procedure


510-01.00


Qualified Manpower


Data


Special tools







MAN Diesel & Turbo


519-03.00Edition 29

L23/30H, L27/38

2003.12.08 - Method 3



If the conical elements have not been mounted bythe factory, they must be mounted on the preparedbrackets on the base frame. In case they have beenmounted by the factory, please start with item num-ber 2.

1) Fit the conical elements to the bracket of thebase frame by means of four bolts screwed intothe tapped holes on the top casting (5) see fig1.

A supporting steel shim with a minimum height of40 mm, complete with tapped holes for three jack-ing bolts, four mounting holes and four tappedholes, drilled according to the conical base castingdimension, is required see fig 2.








3) Position the supporting steel shim as per fig 2and locate the conical element by means of fourhold-down bolts.

4) Position the three jacking bolts in the tappedholes in the supporting steel shim as per fig 2.

5) Position the jacking bolts with a through-goingof minimum 10 mm plus permitted thickness,as specified from the chockfast supplier, see fig2.

6) Lowed the generating set until it rests com-pletely on the foundation.


8) Turn the internal buffer (2), see fig 1, to checkthat it can be moved freely.




L23/30H, L27/38

2003.12.08 - Method 3



Cannot be moved Turn the three jacking boltsin the supporting steel shimclockwise, or anticlockwiseand slacken the four hold-down bolts to release theinternal buffer.




If Then

Difference exceeds 2 mm Level the conical elementby adjusting the jackingbolts - commencing withthe conical element withthe largest deviation.


The height of the steel shimand the chockfast can bemeasured.


Measuring of steel shim and chockfast

10) The steel shim should be at least 10 mm high.

Note!

Check the minimum permitted thickness of chock-fast for the load and surface of this application withchockfast supplier.


Make sure that the minimum height of the steelshim is 10 mm.

11) Drill the mounting holes in the steel shimaccording to the mounting holes in the conicalbase casting and in the supporting steel shim.








16) Drill four mounting holes in the foundation foreach conical element according to the support-ing steel shim/steel shim, either

⇨ Mark the positions of the mounting holes onthe foundation through the conical elementand the steel shims. (Re)move the set completely so that themarkings can be reached by drilling withconventional tools.

MAN Diesel & Turbo


519-03.00Edition 29

L23/30H, L27/38

2003.12.08 - Method 3

Place the set on its former position by align-ing it with the drilled holes.

or

⇨ Drill the mounting holes in the foundation bymeans of the drilling pattern. The drilling has to be done on beforehandand the set must be aligned with the foun-dation holes before the work starts to avoidfurther removal of the set.

17) Make sure that the mounting bolts are isolatedfrom the chockfast.

Note!

After completion of all works, the buffer clearancemust be checked, see points 12, 13, 14 and 15.



L23/30H, L27/38

2003.12.08 - Method 3

MAN Diesel & Turbo

Working cardPage 1 (3) Fitting Instructions for Resilient Mounting of GenSets 519-03.00

Edition 30

11.41 - ES0 - Rubber design

Special tools

Plate No Item No Note

Hand tools

Ring and open end spanner, 22 mmRing and open end spanner, 30 mmAllen key, 6 mmFeeler gauge, 1-2 mmMeasurement toolHydraulic jack (if necessary)

Spare and wearing parts

Plate No. Item No. Qty./

51903 013 1/conical mount. 51903 025 4/conical mount.

L23/30H

Safety precautions

Stopped engine Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circulation

Description

Mounting and adjustment instruction for new GenSets, and adjustment instruction for existing plants.

Starting position

The foundation should be welded and milled off on shim surfaces.

Related procedure

Check of main bearings alignment(autolog) 510-01.00Replacement of conicals 519-03.00

Man power

Working hours : 2 HoursCapacity : 2 Men

Data

Data for pressure and tolerance (Page 500.35)Data for torque moment (Page 500.40)Declaration of weight (Page 500.45)

MAN Diesel & Turbo


Mounting and Adjustment Instructions for New Generating Sets (Method 4)

Make Ready for Adjustment of Conical Ele-ments

If the conical elements have not been mounted by the factory, they must be mounted on the prepared brackets on the base frame. In case they have been mounted by the factory, please start with item number 2.

1) Fit the conical elements to the bracket on the base frame by means of four bolts screwed into the tapped holes on the top casting (5), see fig 1. Tighten the bolts with 250 Nm.

2) Remove fixing bolt (7), spring washer (8) and top lock ring (6) from the conical element, see fig 1.

3) Position the four jacking bolts in the tapped holes (9) see fig 1, in the base casting (1).

4) Fit the 49 mm shim and the 99 mm shim to the conical element by means of four bolts screwed into the tapped holes on the lower 99 mm. Position the jacking bolts with a through-going thread of min 50 mm.

5) Lower the GenSet until it rests on the foundation, and adjust the positioning of the GenSet in lon-gitudinal and cross direction to the foundation. Weld the lower 99 mm shim to the foundation.

After the conical elements have been loaded under static load for 48 hours, lift the GenSet by means of the jacking bolts untill it is pos-sible to remove the upper 49 mm shim, adjust the jacking bolt untill the laden height (H1) fig 2. See measurements from "Adjustment of Conicals" from the "Acceptance Test Report".

6) Check that all jacking bolts have full contact with the foundation.

7) Turn all the internal buffers (2), see fig 1, to check that they can move freely.


Can move freely Let conical elements settle for 48 hours.

Cannot be moved Turn the four jacking bolts in the base casting clockwise or anticlockwise to release the internal buffer.

Fig 2 Conical mounting.

7

8

9

2

3

4

5

6

1

Fig 1 Conical element


Fitting Instructions for Resilient Mounting of GenSets

L23/30H

49 m

m

H1

appr

ox. 9

9 m

m

Foundation

Bracket

TopSteel Shim

LowerSteel Shim

519-03.00Edition 30

MAN Diesel & Turbo

Adjustment of Conical Elements after 48 Hours Settling

After the conical elements have been deflected un-der static load for 48 hours, the laden height (H1) see fig 2, should be measured and compared to the recommended laden height.

8) Care must be taken, during levelling of the installation, to ensure that individual mountings are not overloaded. The variation in laden height should not exceed 2 mm and should ideally be less. The laden height can be measured between top and base casting at H, on two sides (see fig 1).

Example:

Average =

If Then

Difference exceeds Level the conical element2 mm. by adjusting the jacking bolts - commencing with the conical element with the largest deviation.

Difference does not ex- The height of the steelceed 2 mm shim can be measured.

The difference between the two sides of a conical mounting should not be more than 0.6 mm.

Measuring of Steel Shim

9) Measure the distance between the foot plate of the conical and the foundation on several points to obtain the highest possible accuracy.

Fabricating Steel Shim

10) Machine the 49 mm steel shim according to the measurements taken. Make sure that the minimum height of the steel is more then 40 mm in order to ensure a future replacement of the conical element.

Mounting of the Completed Steel Shim

11) Turn the internal buffer anticlockwise until it contacts the base casting to secure the laden height of each conical element.

12) Lift the generating set with crane or hydraulic jack.

13) Remove all the jacking bolts.


15) Lower the generating set until it rests completely in itself.

16) Number each steel shim together with each conical element.

17) Tighten the four bolts to the 99 mm shim.

18) Turn the internal buffer clockwise (downwards) until it makes contact with the steel shim or foundation.

19) Turn the internal buffer anticlockwise (upwards) until it obtains contact with the base casting.


20) Turn the internal buffer two full turns clockwise (downwards) and check with a feeler gauge between the base casting of the conical ele-ment and the steel shim that the internal buffer (2), see fig 1, does not touch the steel shim or foundation.

21) Lock the internal buffer by remounting the top lock ring (6) and turn it to the nearest thread hole - then secure with fixing bolt (7) and spring washer (8), see fig 1.

22) After completion of the work, autolog of the crankshaft is to be taken.

Note! After completion of all works the buffer clear-ance must be checked, see points 17, 18, 19 and 20.

H1 + H2 + H3 ----- HN

Number of conical elements


DescriptionPage 3 (3) Fitting Instructions for Resilient Mounting of GenSets

L23/30H

519-03.00Edition 30

Safety precautions


Short Description

Replacement of conicals.

Starting PositionSafety precautions.

Related Procedure

Fitting instructions for resilientmounting.

Qualified Manpower

Duration in h : -Number : 2

Data


Special tools


Hand ToolsRing and open end spanner, 22 mmRing and open end spanner, 30 mmHydraulic jack



MAN Diesel & Turbo

Work CardPage 1 (2) Replacement of conicals

519-03.05Edition 01

L23/30H

1996.01.15

Replacement of conicals

Warning!


A One pair

Figure 1: The conicals must be pairs

1) Loosen all conicals in one side.

2) Mount a jack under the base frame, see fig 2.

3) Lift the GenSet until the steel shim can beremoved. This will give enough space forremoving damaged conical.

4) Mount the GenSet conical.

Note!

Conicals should only be replaced in pairs, seefig 1 and plate 51903.

5) Lower the GenSet again.

6) Repeat items 1-5 for the other side.

7) Adjust the conicals, see Working Card519-03.00 "Fitting Instructions for ResilientMounting of GenSet.

1 Steel shim 2 Foundation

3 Deck 4 Jack

Figure 2: Removal of conicals


Replacement of conicals Work CardPage 2 (2)

L23/30H

1996.01.15

Safety precautions


Short Description

Replacement of conicals.

Starting PositionSafety precautions.

Related Procedure

Fitting instructions for resilientmounting.

Qualified Manpower

Duration in h : -Number : 2

Data


Special tools


Hand ToolsRing and open end spanner, 22 mmRing and open end spanner, 30 mmHydraulic jack



MAN Diesel & Turbo

Work CardPage 1 (2) Replacement of conicals

519-03.05Edition 05

L23/30H

2008.04.21

Replacement of conicals

Warning!


A One pair

Figure 1: The conicals must be pairs

1) Loosen all conicals in one side.

2) Mount a jack under the base frame, see fig 2.

3) Lift the GenSet until the steel shim can beremoved. This will give enough space forremoving damaged conical.

4) Mount the GenSet conical.

Note!

Conicals should only be replaced in pairs, seefig 1 and plate 51903.

5) Lower the GenSet again.

6) Repeat items 1-5 for the other side.

7) Adjust the conicals, see Working Card519-03.00 "Fitting Instructions for ResilientMounting of GenSet.

1 Steel shim 2 Foundation

3 Deck 4 Jack

Figure 2: Removal of conicals


Replacement of conicals Work CardPage 2 (2)

L23/30H

2008.04.21

Safety precautions


Short Description

Control and adjustment of conicals.

Starting Position

Related Procedure

Check of crankshaft deflection(Autolog)

Qualified Manpower


Data


Special tools


Hand ToolsRing and open end spannerFeeler gauge, 1-2 mmHexagon socket key 6 mm



MAN Diesel & Turbo

Work CardPage 1 (2) Maintenance of conicals

519-03.10Edition 01

L23/30H

1996.07.01

Visual check

What to check

Warning!


1) Check for oil deposits on the rubber element.

2) Check for loose mounting bolts.

3) Check for damage in the rubber element.

Result of visual check

If Then

everything is OK continue to next conical

oil deposits on rubber ele-ment are observed

clean rubber element

loose mounting bolts fasten mounting bolts

damage to conicals isobserved

replace conical according toWorking card 519-03.05

Clearance check

What to check

4) Check clearance on all conicals between steelshim and internal buffer through the slot in thebase casting of the conical (see fig 1) with afeeler gauge of approx. 2 mm.

Result of clearance check

If Then

everything is OK check is completed

everything is not OK adjust conicals which do notcomply with the clearancedemands acc. to item 2-3.Recheck all conicals acc. toitem 2.1.

everything is still not OK replace conicals acc. toWorking card 519-03.05

1 Foundation 2 Steel shim


5 Rubber element 6 Top casting

7 Top locking ring 8 Spring washer

9 Fixing bolt 10 Protective cap

Figure 1: Conical

Adjustment of conicals

5) Remove protective cap (No 10).

6) Remove fixing bolt (No 9) and top locking ring(No 7).

7) Turn buffer clockwise until it makes contact withthe steel shim (No 2).

8) Turn buffer anti-clockwise until it makes contactwith the conical base casting (No 3). This mustbe four full rotations.

9) Turn buffer two full rotations clockwise. This willensure full vertical movement for the buffer.

10) Check all conicals again.

11) Replace top locking ring, fixing bolt and protec-tive cap etc.


Maintenance of conicals Work CardPage 2 (2)

L23/30H

1996.07.01

Safety precautions


Short Description

Control and adjustment of conicals.

Starting Position

Related Procedure

Check of crankshaft deflection(Autolog)

Qualified Manpower


Data


Special tools


Hand ToolsRing and open end spannerFeeler gauge, 1-2 mmHexagon socket screw 12 mm



MAN Diesel & Turbo


519-03.10Edition 05

L23/30H

2008.04.21

Visual check

Maintenance of the rubber element should be donein accordance with DIN 7716, to achieve the bestpossible lifetime of the rubber element.

Under normal working conditions and professionallay-out of the mounting system a lifetime expect-ancy of 8 to 12 years of the rubber element is realis-tic. The actual lifetime is influenced by (dynamic)load and environment.

The functional lifetime of the rubber element isdetermined by the vibration behaviour of the sup-ported mass for which the ISO 10816-6 section 6A/B gives a good guidance. The maximum workingdeflection due to nominal load, creep and thermalloads that the mount would accept is stated in thetables below for each individual type and com-pound. The mentioned values are to be measuredat 20° C rubber temperature.

T90 45 51.5 ±0.75 mm 23.0 mm 28.5 mm

T90 50 51.5 ±0.75 mm 21.0 mm 30.5 mm

T90 55 51.5 ±0.75 mm 19.0 mm 32.5 mm

T90 60 51.5 ±0.75 mm 18.0 mm 33.5 mm

T90 65 51.5 ±0.75 mm 17.0 mm 34.5 mm

The environmental influences on the lifetime can beminimised by periodical visual inspection of the rub-ber part for oil contamination and damages. Any oilcontamination should be cleaned with conventionalmild household cleaning agents. Cleaning of the rubber element should be done inaccordance with 7716, to achieve the best possiblelifetime of the rubber element.

Under no circumstance the rubber element can becleaned with solvent cleaning agents, if the directenvironment of the rubber element is cleaned withthese aggresive solvents, the rubber element mustbe cleaned afterwards with the above mentionedcleaning agent.

Rubbersurface temperature of the mounts must bewithin +70° C / -20° C.

Periodical inspection

Visual inspection

1) Inspect the rubber part visually for oil contami-nation, ozon cracking, swelling and mechanicaldamages.

2) Check if the installation is free to move on themounts. No obstructions should be traceablebetween the mounts foundation and the sus-pended machinery.

Note!

The rubber element should be replaced eitherwhen the rubber element is swollen due to con-tamination or cracks and tears in the surface. Incase of replacement of the rubber element, atten-tion is made to the identification number and plateon the mount. When ordering spare parts allwaysmention the stamped numbers and type designa-tion, to allow us to supply an identical product.

Deflection inspection

The resilient mounts are subjected to a constantload and present a deflection determed by theamount of elastic deformation and permanentdeformation in time (creep). This deformation isinfluenced be environmental conditions as tempera-ture, static and dynamic load, etc. For this reasonperiodical inspections are necessary to be regis-tered in the enclosed form (Annex 1), in order toevaluate the deflection of the rubber element.

1) Check the dimensions TB1/2 in unloadedmount condition.

2) Check the dimensions TB1/2 in loaded mountcondition, directly after loading the mounts.

3) Check the dimensions TB1/2 in loaded mountcondition 7-10 days after installation of themounts under the suspended machinery.

4) Check the dimensions TB1/2 in loaded mountcondition after first seatrial.


Maintenance of conicals Work CardPage 2 (3)

L23/30H

2008.04.21

5) Check the dimensions TB1/2 in loaded condi-tion periodically together with the clearance ofthe internal limiter. This should be integrated inthe normal maintenance schedules of the sus-pended machinery. Re-adjustment of the clear-ance according to the installation instructions.

Note!

The resilient mount has to be replaced if thevalues measured at TB1/2 are out of the limitsas set in the maintenance instructions. In caseof replacement of the rubber element, atten-tion is made to the identification number andplate on the mount. When ordering spareparts allways mention the stamped numbersand type designation, to allow us to supply anidentical product.

Clearance check

1) Now the central buffer clearance can be set. Fitthe 12 mm hexagon socket screw to screw posno (8) and turn it up (anticlockwise) until thegreater torque, max. torque = 50 Nm, is felt.From the position the central buffer assemblymust be turned down (clockwise) 2 revolutions.It is adviced to mark the position of screw posno (8) relative to top casting pos no (2) prior toturning it down.

2) Check if the bolt ends pos no (6) do not pro-tude from lock ring pos no (7), correct if neces-sary.

3) Fit lock ring pos no (7) to screw pos no (8) andturn it clockwise until it is in conntact with topcasting pos no (2).

4) Correct the position of screw pos no (8) if nec-essary,

5) Tighten the bolts pos no (6) in 2 steps:

▪ at first handtight starting at a bolt, the next boltto tighten is the direct opposite one, then thethird bolts is found in clockwise direction fromthe last, repeating the same sequence until allbolts are handtight.

▪ Then tighten the bolts in the same sequencewith a torque prescribed in the below table.

Tightening torque

T90 M8-8.8, 24 Nm

6) Fit pos no (9) to the mount, we advice to usewater resistant grease to the contact faces.

7) Insert the foundation bolts though the 4 holes inthe base casting and foundation, use bolt mate-rial quality 8.8 or higher, tightening torques asper below table.

Tightening torque

T90 M20-8.8, 400 Nm

Note!

The rubber element must not be painted, if paintedis carried out on the supported machinery, the rub-ber element must be shielded from the paint.

1 Base casting 2 top casting

3 Element 4 Central buffer

5 Rubber bushing 6 Cylinder head bolt

7 Lock ring 8 Hex. socket set screw

9 Cap

Figure 1: Conical

MAN Diesel & Turbo


519-03.10Edition 05

L23/30H

2008.04.21

MAN Diesel

Item NoDesignationFigure Connection

96.03 - ES0S-G

A3

A7

A8

C3

C4

C9

C11

C12

C15

C16

F3

F5

F6

F7

F15

K1

K2

A1

A2

PlatePage 1 (2) Flexible External Connections 51902-01H

L23/30H

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

187

199

209

210

Waste oil, outlet

Nozzle cooling oil, inlet

Nozzle cooling oil, outlet

Lubricating oil from separator, inlet

Lubricating oil to separator, outlet

Back fl ush from full-fl ow fi lter, inlet

Lub. oil from by pass fi lter, inlet

Lub. oil to by pass fi lter, outlet

Lub. oil overfl ow

Lub. oil supply, inlet

Venting to expansion tank

HT fresh water from preheater, inlet

HT fresh water to preheater, outlet

Fresh water for fi lling/draining

Inlet from expansion tank

Compressed air, inlet

Control air, inlet

Fuel oil, inlet

Fuel oil, outlet

MAN Diesel

Item NoDesignationFigure Connection

Flexible External Connections51902-01H PlatePage 2 (2)

C13

C7

C8

F1

F2

G1

G2

G3

G4

222

234

246

258

271

283

295

305

317

Oil vapour discharge, outlet

Lubricating oil from full-fl ow fi lter, inlet

Lubricating oil to full-fl ow fi lter, outlet

HT fresh water, inlet

HT fresh water, outlet

LT fresh water/raw water,inlet

LT fresh water/raw water, outlet

Seawater, Inlet

Seawater, outlet

96.03 - ES0S-G

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

96.03 - EO0S-G

L23/30H

51903-01H

Conical Element

Note! When ordering be aware that conical elements always should be replaced in pairs. State manufac-turing No of existing conical elements.

Bemærk! Ved bestilling af conicals elementer skalconicals elementer altid udskiftes parvis. Opgiv fabri-kationsnr. på eksisterende conicals elementer.

PlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

96.03 - EO0S-G

51903-01H

PlatePage 2 (2)Conical Element

Item No Qty Designation Benævnelse

Screw

Washer

Conical element

Adjusting screw

Protecting cap

Fixing ring

013

025

037

049

050

062

4/M

4/M

1/M

4/M

1/M

1/M

Skrue

Skive

Konisk understøtning

Justerskrue

Beskyttelseskapsel

Fiksering ring



* = Only available as part of a spare parts kit.Qty/M = Qty/Conical mounting.


* = Kun tilgængelig som en del af et reservedelssæt.Antal/M = Antal/Conical montering.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.10 - EO0

General

51903-06H

Conical Element

Note! When ordering be aware that conical elements always should be replaced in pairs. State manufac-turing No of existing conical elements.

Bemærk! Ved bestilling af conicals elementer skal conicals elementer altid udskiftes parvis. Opgiv fabri-kationsnr. på eksisterende conicals elementer.

PlatePage 1 (2)

[email protected]

MANUF.DATE:

ID.NUMBER:

TYPE:

R

VULKAN

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

General

07.10 - EO0

51903-06H

PlatePage 2 (2)Conical Element


Screw

Washer

Conical element

Adjusting screw

Protecting cap

Fixing ring

013

025

037

049

050

062

4/M

4/M

1/M

4/M

1/M

1/M

Skrue

Skive

Konisk understøtning

Justerskrue

Beskyttelseskapsel

Fiksering ring



* = Only available as part of a spare parts kit.Qty/M = Qty/Conical mounting.


* = Kun tilgængelig som en del af et reservedelssæt.Antal/M = Antal/Conical montering.

Tools

520/620

Description

The contents of these spare part plates with toolsare a summary of STANDARD TOOLS for normalmaintenance and EXTRA TOOLS for reconditioning,which can be supplied by MAN Diesel & Turbo.Thus, the list comprises the total extent of toolsavailable for this engine type.

For each specific plant the amount of tools deliv-ered depends of the contractual specifications.

The tools listed are assembled in sections corres-ponding to the chapters of the instruction book.

However, some tools such as torque spanners,hydraulic tools etc. may also have other applica-tions. Information about the exact use of the toolsappears from the relevant sections in the instructionbook.

Note: The table on the spare part plates is markedwith an S or an E. An S means that the tools aresupplied when ordering Standard tools and an Emeans that the tools are supplied when orderingExtra tools, i.e. Tools for Reconditioning (extra toolsare not standard delivery)

MAN Diesel & Turbo

DescriptionPage 1 (1) Introduction to spare part plates for tools

520.01Edition 01

L23/30H, V28/32S

1996.01.15 - ES0

Safety precautions


Short Description

Safety hints and function of hydraulic tools.

Starting Position

Application of hydraulic tools 520-01.06

Related Procedure

Qualified Manpower

Duration in h : -Number : -

Data


Special tools


Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (6) Function of the Hydraulic Tools

520-01.05Edition 02

L16/24, L23/30H, V28/32S, L21/31, L27/38

1999.10.18. - ES0

Function of the Bolt Tensioning Device

In order to achieve an optimal result with one orseveral devices, some rules have to be considered.We expressly point out that a conscientious han-dling of the device as well as the accessories is ofhighest importance. To ignore these rules or sepa-rate hints means danger to life or danger of injuries!See Safety Hints.

Safety Hints

Beside regarding the general accident-preventionrules, the safe handling of the device and thehydraulic accessories demand especially the con-sideration of the following hints. When disregardingeven single items, you can cause danger to life and/or danger of injuries!

1) When leakages occur during the pressurization,bleed pressure immediately and seal the leak-age or replace defect parts.

2) In case of repair, use exclusively original spareparts. Inexpert substitution of damaged parts bynon-original spare parts is prohibited.

3) All assembly parts are to be handled in corre-spondence to the working cards only. A changein the procedure or another operation of thedevice is not allowed.

4) Make sure that the components to be ten-sioned do not exceed the admissible strain.

5) In order to use the device, the thread has to besufficiently exceeding in order to avoid that theturn of a thread cracks, see item 4.

6) During the pressurization the people involvedhave to remain in an appropriate distance. Stay-ing in direction towards the bolt axis is forbid-den.

7) Tensioning pressures or tensioning forces are tobe given or changed by authorized personnelonly while considering the admissible compo-nent loads, see item 4.

8) The operation and handling of the device are tobe carried out by expert staff only.

9) The given max. operation pressure is not to beexceeded in any case and is to be watched atthe manometer of the pressure generator duringthe complete tensioning or loosening proce-dure. When having achieved the given pressure,stop the pressurization immediately.

10) During the pressurization when tensioning orloosening the bolt connection, always watch theadmissible stroke of the device. Exceeding thisstroke is connected with insufficient generatingof tensioning force because the device is ten-sioned in itselve or the hydraulic pressure isbleeded automaticly.

11) On principle, when connecting high-pressurehoses it has to be taken care that the connec-tions are correct (see also separate hints).

12) The hydraulic hoses have to be installed in away that they are not run over by vehicles orunnecessarily walked over by people. Never layhoses across sharp objects (danger of cuts)and never bend or jam them in.

13) Never hold or transport the device by using thehigh-pressure hoses.

14) An incorrect working manometer that doesn´tshow the right pressure leads to overstressingof the parts and to an incorrect bolt connection.Apart from damaged parts an incorrect boltconnection can also cause conditions that aredanger to life. Therefore take care that the man-ometer shows the right value or the tensioningforce is checked in an other way (for exampleby using a master manometer). Tensioningforces can be checked for example by measur-ing the linear deformation. Damaged manome-ters have to be exchanged immediately.

Working Hints

In order to achieve a bolt connection of high preci-sion, it is vital to consider the following workinghints:

▪ Prior to setting the device, clean all threads andremove possible damages in order to avoide a“freeze on”.

▪ The base plate for the device must be plain andfree of dirt. Further check the squarenesstowards the bolt axis in order to avoid that thebolt has a bending stress during the pressuriza-tion (tensioning).

▪ The stroke of the device may not at any pointbe exceeded.

▪ For transporting the device it is necessary touncouple all high-pressure hoses.

▪ After each pressurization, bring the device backto zero, see also Piston Return Stroke.


Function of the Hydraulic Tools Work CardPage 2 (6)

L16/24, L23/30H, V28/32S, L21/31, L27/38

1999.10.18. - ES0

Turnable Connection Unit

In order to simplify the connection of the hydraulichose, a turnable connection unit is mounted onsome devices.The turnable connection unit consists of the follow-ing components:

▪ bolt nipple

▪ disc

▪ seal

▪ securing ring

Furthermore, an entry guide is available or con-tained in the scope of supply, see fig.1.

Figure 1: Turnable connection unit

Exchange of the Seals

Should leakages show up at the connection unit, itmight be necessary to exchange the seals.For doing so, loosen the securing ring and take thedisc off the bolt nipple. Having removed the seals,clean the components with fluff-free cleaning mate-rial. You can also apply compressed air. Havingchecked the components for damages and oiledthem slightly, apply new seals by help of the entryguide and reassemble the turnable connection unit.

Hint:

▪ For the cleaning, never use aggressive cleaningliquids.

▪ For oiling the parts, use exclusively hydraulic oil.

▪ For replacements, use exclusively new seals.

Coupling of the High-Pressure Hoses

▪ Only couple when the hydraulic system is in apressureless condition.

▪ To produce a high-pressure connection, putone coupling and one nipple into each otherwhile the coupling socket is pulled back. Whenletting the coupling socket go, there is a form fitbarring the connection.

▪ By drawing the hose with a manual force ofabout 100 N make sure that the connection iscorrectly barred.

▪ For decoupling the high-pressure hose in apressureless condition, first pull back the cou-pling socket and then take off the hose.

Figure 2: Coupling of the high-pressure hoses.

Hoses with fast-lock coupling sockets avoid, alsowhen uncoupled, that oil runs out. When the hosesget heated, there can be an inside pressure in theuncoupled condition making a coupling impossible.By loosening one screw connection (see fig. 2) thepressure can be bleeded

▪ To avoid a contamination use protecting capsfor the sockets.

Tensioning Procedure

Prior to the tensioning procedure make sure thatthe components to be tensioned are correctly posi-tioned towards each other. Then screw the deviceonto the bolt.

First put the support sleeve on the bolt and align itcentrically to the bolt axis. When screwing on thedevice take care that the support sleeve at the cyl-inder is correctly centered (consider centeringshoulder).

MAN Diesel & Turbo


520-01.05Edition 02

L16/24, L23/30H, V28/32S, L21/31, L27/38

1999.10.18. - ES0

Screw the device until the support sleeve or thesupport cylinder fits exactly to the flange. The pistonof the device must be at its zero position. Further-more, take care that the hydraulic connector andthe window for the adjusting rod is well accessible.

If necessary, turn back the device, but make surethat the max. admissible stroke of the device is notexceeded. Beside that, it has to be ensured that thecylinder and the support sleeve remain centricallytowards each other (consider centering shoulder).

Having made all hydraulic connections correctly,see fig. 2, start the pressurization for the tensioningprocedure. If the necessary pressure is achievedstop pressurization. The inducted force causes thebolt to extend or an edging of the components tobe tensioned so that the main nut is lifted from theflange. Screw it back to the flange, see fig. 3.Check by help of a feeler gauge leaf whether themain nut really fits tight to the flange. After that,bleed hydraulic pressure. Now the connection istensioned.

Having brought the piston to its zero position, seefig. 4, the hydraulic hoses can be decoupled. Inorder to prevent impurities, it is advisable to closecoupling sockets and coupling nipples at once byprotecting caps. The device can be unscrewedfrom the bolt.

▪ Always consider the safety and working hints!

Loosening Procedure

In order to loosen an existing bolt connection,screw the device onto the bolt. First put the supportsleeve on the bolt and align it centrically to the boltaxis. When screwing on the device take care thatthe support sleeve at the cylinder is correctly cen-tered (consider centering shoulder).

The piston of the device must be at its zero posi-tion. Having screwed the device down until the sup-port sleeve or the support cylinder fits tight to theflange, turn back the device by at least the value (slitmeasure) which the bolt and the componentsspring back elastically during the loosening proce-dure.

Hint:The adjusted slit measure may never exceed theadmissible stroke of the device! Furthermore, takecare that the window for the adjusting rod are wellaccessible.Having made all hydraulic connections correctly,see fig. 2, start the pressurization.

During the pressurization, a slight turn-backmomentum is applied to the main nut with theadjusting rod. At the moment, when the main nutcan be loosened, interrupt the pressurization.Should it not be possible to loosen the main nutwhen achieving the original tensioning pressure,interrupt the pressurization immediately. Find thecause with expert staff.

Having achieved the loosening pressure, turn backthe main nut by the value that the bolt and the com-ponents spring back during the loosening proce-dure. The slit measure, however, must be lowerthan the slit measure adjusted at the device before,see also hint b.

The main nut may never be turned back until it fitsto the piston or the cylinder since then the devicecan be tensioned in itself.

Having turned back the main nut, the pressure canbe bled. The bolt connection is loosened. Beforeunscrewing the device, bring the piston back to itszero position, see fig. 4. After that, the hydraulichoses can be decoupled. In order to prevent impur-ities, it is advisable to close coupling sockets andcoupling nipples at once by protecting caps. Thedevice can be unscrewed from the bolt.

▪ Make sure that no operational forces (e.g. innerpressure) affect the components to be loosenedsince only part of the bolts take over theseforces and thus the bolts, which are not yetloosened, might be overburdened.

▪ The pressure when the main nut can be loos-ened may never exceed the tensioning pressureby help of which the connection was tensioned!Should it not be possible to loosen the main nutwhen reaching the original tensioning pressureinterrupt the pressurization immediately. Findthe cause with expert staff.

▪ Always consider the safety and working hints!

Hint:

1. Should it be impossible to unscrew the deviceafter the depressurization, it has been turnedback by a too low measure prior to the pressur-ization. Pressurize again until the original ten-sioning pressure is reached, turn the main nutand bleed the pressure again (tensioning proce-dure). Now you can turn back the device fur-ther. (Attention: consider the admissible strokeof the device!) Now repeat the loosening proce-dure explained above.



L16/24, L23/30H, V28/32S, L21/31, L27/38

1999.10.18. - ES0

2. Should it be impossible to loosen the main nutafter the depressurization, it has been turnedback by a too low measure prior to the pressur-ization. Pressurize again and turn the main nutfurther back. Bleed the pressure again.

Hint:Never screw the main nut back until it fits to the pis-ton since the device can be tensioned in itself.

Adjustment and Turn Back of the Main Nut

During the pressurization of the device, the bolt isbeing extended by the tensioning force and thecomponents are being edged. The result is that themain nut does no longer fit to the flange.

Having achieved the necessary pressure, adjust themain nut - when tensioning - until it fits to the flangeagain before bleeding the pressure, see TensioningProcedure. When loosening the bolts, turn back themain nut after the pressurization according to thebolt and component deformations, (see LooseningProcedure.

Hint:During the loosening procedure, never turn backthe main nut until it fits to the piston or the cylindersince the main nut sticks after the depressurization.

The main nut is equipped with several radial boreswhere the adjusting rod can be put in. The main nutis accessible through the window in the supportsleeve.

Figure 3: Adjustment and turn back of the main nut.

Piston Return Stroke

After each pressurization it must be ensured thatthe piston of the device is brought back to its zeroposition. On principle, it has to be considered thathydraulic oil is being displaced from the piston area.

In order to enable the oil to flow back to the tank ofthe pressure generator, the corresponding hydraulicconnections must be done.

The piston return stroke is done by a screw-downat the bolt itself before the device is taken off.

Hint:When using fast lock coupling elements, the oil’srunning out and thus a piston return stroke in anuncoupled condition is impossible!

During the piston return stroke, considerable back-pressures can occur in the piston area of the devicesince quite large quantities of oil have to flow backthrough the small cross sections of the high-pres-sure connections.

In order not to unnecessarily increase the force forthe piston return stroke turn the piston slowly. Onprinciple the piston of the device has to be pushedback until it fits to the cylinder again.

Figure 4: Piston return stroke

Exchange of the Seals

Should leakages occur at the piston of the device,an exchange of the seals might be necessary.Drive out the piston by carefully beating with a ham-mer while using a plastic spacer in order to protectthe device from unnecessary damages. Afterremoving the hydraulic connector, you can alsocarefully lead compressed air into the piston area.

Attention: Sudden input of compressed air can lead to the pis-ton’s uncontrolled outlet. After removal of the piston, the seals and thebackup rings can be removed from the piston andthe cylinder.

Carefully clean the components with fluff-free mate-rial and check them for damages. If necessary, usecompressed air for the cleaning, but never aggres-

MAN Diesel & Turbo


520-01.05Edition 02

L16/24, L23/30H, V28/32S, L21/31, L27/38

1999.10.18. - ES0

sive cleaning liquids. After that, slightly oil thesecomponents with hydraulic oil and assemble newbackup rings as well as new seals to the piston andthe cylinder according to the drawing.

Figure 5: Exchange of the seals

As shown in the picture, first assemble the backupring, then put the seal onto the backup ring. Pistonand cylinder can now be assembled again by put-ting the components together. By slightly hammer-ing on the piston (with plastic spacer), it can bedriven in until it fits tightly to the cylinder (piston in itszero position). It is essential that the piston does nottilt during being driven in since this might damagethe seals as well as the components. When assem-bling the piston it has to be taken care that the aircan come out of the piston area.

Maintenance and Storage

Regular maintenance of the device is not neces-sary, but you should consider the following points:

▪ Storage

– After each operation, repair possible dam-ages and clean the device in order for it tobe ready for the next operation immediately.In order to avoid a corrosion it is advisableto oil the device and especially its thread. Allcoupling nipples, coupling sockets and alsoloosened screw connections are to beclosed by protecting caps.

– In addition, check the components of thedevice and its accessories for completion. Keep the device in the tool box also offeringprotection from mechanical damages. The temperature must be between -20 Cand +70 C in order to exclude a damage ofthe seals.

▪ Start-up of the device

– Prior to the device’s operation, repair possi-ble damages and clean the device.

– Check the components of the device andits accessories for completion.

– The operating manual has to be read by allusers.



L16/24, L23/30H, V28/32S, L21/31, L27/38

1999.10.18. - ES0

Safety precautions


Short Description

Application of hydraulic tools for connecting rod

Starting Position

Function of hydraulic tools 520-01.05

Related Procedure

Qualified Manpower


Data


Special tools

Plate No. Item No. Note- - See page 2

Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (2) Application of hydraulic tools

520-01.06Edition 03

L23/30H

2000.05.15 - ES0

Description

This working card gives the information for applica-tion of hydraulic tools, to be used in connection withworking card 520-01.05.

Figure 1: Connecting rod


Application of hydraulic tools Work CardPage 2 (2)

L23/30H

2000.05.15 - ES0

Safety precautions


Short Description

Application of hydraulic tools for cylinder head andmain bearing

Starting Position

Function of hydraulic tools 520-01.05

Related Procedure

Qualified Manpower


Data


Special tools

Plate No. Item No. Note- - See page 2

Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (2) Application of hydraulic tools

520-01.06Edition 04

L23/30H

2000.05.15 - ES0

Description

This working card gives the information for applica-tion of hydraulic tools, to be used in connection withworking card 520-01.05.

Please note: The numbers refer to the plate items in section 520.

Figure 1: Hydraulic tools


Application of hydraulic tools Work CardPage 2 (2)

L23/30H

2000.05.15 - ES0

Safety precautions


Short Description

Application of hydraulic tools.

Starting Position

Related Procedure

Qualified Manpower


Data


Special tools


Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (4) Hand Lever Pump

520-01.07Edition 01

L16/24, L23/30H, V28/32S, L21/31, L27/38

2008.08.25. -ES0

Description

Warning: The hand lever pump is not equipped with a pres-sure relief valve. Never use the pump without a mounted manome-ter. Always pay attention to the given pressure ofthe connected pressure consumers. Do neverexceed this pressure or the max. pressure of thehand lever pump.

Important: Except for hydraulic oil, never use different liquidssuch as petrol, water, diesel oil, alcohol or brake liq-uid, since these can lead to damages or even todestruction of the pump and/or the parts connectedwith it. Choose a place of assembling and operationwhere the pump can always stand safe and firm ona horizontal plain. There should always be sufficientspace for operating the pump. Never handle the pump lever with oiled hands andnever use hand lever extensions. Never expose thepump to great heat, fire or extreme coldness, sincethis leads to damages or even destruction. Protectthe pump from falling objects and avoid hard blowsor pushes.

Attention - Danger to life Check the manometer of the pump for the neededhydraulic pressure, given by an authorized person,not to be exceeded. Make sure that the pressureyou want to generate is also admissible for all con-nection parts.

All pressure connections and connecting elementshave to be clean and undamaged. High-pressureconnections from the pump to the tools have to beestablished correctly prior to any pressurization.Disregard leads to danger to life. Please see work-ing card 520-01.06.

Attention - Danger on injuries Loads being lifted by the pump may never be heldby the pump valves alone. Use additional non-return valves or safety relief valves and secure theload by sufficient support against falling.

Initial Start-up and Venting

In general and venting

Please make sure that all parts of the pump, espe-cially the manometer and the pressure port, are in aperfect condition. Defect parts are to be exchangedagainst new ones immediately.

Turn the carrying handle with counter-clockwiserotation out of his fixing. Then turn it into the handlever of the pump against the stopping face.

Attention: If the carrying handle is not srewed-in into the handlever, it can cause injuries while using the pump.

Open the oil filler cap and check the oil level. If nec-cessary, fill up the tank with hydraulic oil accordingto IS0 VG 32. Never overfill the tank. Close the oilfiller cap. Open the tank breather with the square wrench(included in the scope of supply) by about one turn.Now loosen the breather screw at the pump on theleft side on the pump housing with an allen key SW2,5 by about one turn. Close the depressurizationvalve tightly. Seal the nipple on the pump with ahose and pump at the hand lever until oil flows outof the breather screw bladder-free. Only then areyou allowed to close the breather screw. The pumpis now vented and ready for operation.

After each operation and for the transport, close thetank breather in order to avoid the hydraulic oil’srunning out.

Pressurization

▪ Open the tank breather with the square wrenchapprox. one turn.

Remark: The pump is only to be operated with open tankbreather.

▪ Close the depressurization valve at the pumpwhen turning clockwise by handoperation.

Remark: The depressurization valve is designed for manualoperation. The use of any tools at the depressuriza-tion valve could cause damages of the valve or thevalve seat.

▪ Pump at the hand lever until the wanted pres-sure is achieved. Check the pressurization atthe manometer and take care of possible leak-ages.

Remark: The pump works with two stages. The change fromthe first stage to the second stage happens auto-matical at a system pressure of about 30 bar.


Hand Lever Pump Work CardPage 2 (4)

L16/24, L23/30H, V28/32S, L21/31, L27/38

2008.08.25. -ES0

Attention: The pump is not equipped with an internal pressurerelief valve. The use of a manometer and the controlof the system pressure during pressurization isindispensable.

Attention: Do not stand directly over the moving line of thepump lever. Under arising circumstances the levercan “hit back”. To avoid accidents stand sidewaysthe pump.

Attention - High-pressure hydraulic On principle, tihen leakages occur during the pres-surization, immediately release the hydraulic pres-sure and seal the leakage or renew defect parts.

Depressurization

▪ Open the depressurization valve slowly by aturn to the left.

▪ Make sure that the hydraulic pressure at themanometer has been completely released.Consider the returning time of the hydraulic oil.

Adjustment of change-over pressure fromstage 1 to stage 2

In exeptional case, it can be useful to adjust thechange-over pressure from stage 1 to stage 2 (fac-tory adjusted at approx. 30 bar).

Below of the pressure relief valve is an adjustingscrew with inner hexagon (wrench size 10 mm).Turning out counter-clockwisely the adjusting screwminimizes the change-over pressure, turning inclockwise maximizes the change-over pressure.

Attention: Inside of the adjusting screw is another grub screwwith inner hexagon (wrench size 4 mm) to limit thestroke of the change-over piston inside of the pumpblock. It is absolutely necessary, to screw out thegrub screw approx. 2 times before turning theadjusting screw!

The regulation of the adjusting screw follows gradu-ally in approx. 10° - steps. After everv adjustingstep the grub screw is to screw in until it fits closelyand approx. a l/4 turn to loosen.

Check by carefully pumping if the change-overpressure wanted has been reached. If necessary,repeat the procedure as described above.

Analysis and Correction of Malfunction

Correction of malfunctions In case of malfunctions at the pump, the followingpoints are to help you with the analysis of the prob-lem and correcting it yourself. For this, uncouple or unscrew all consumer andhigh-pressure hoses from the pump.

Malfunction Correction

No pressurization 1. Check the oil level and, ifnecessary, fill it up as descri-bed in chapter maintenanceand storage.

2. Close depressurizationvalve.

3. Visual inspection whetherthere are leakages. If so, sealthem.

4. Vent the pump as descri-bed in chapter initial start-upand venting.

Insufficient pressurization

(prior to any corrections,open de-pressurization valveand release hydraulic pres-sure completely)

1. Check the oil level and, ifnecessary, fill it up, asdescribed in chapter main-teance and storage.


3. Visual inspection whetherther are leakages. If so, sealthem.

4. Vent the pump as descri-bed in chapter initial start-upand venting.

Pressure drop

(prior to any corrections,open de-pressurization valveand release hydraulic pres-sure completely)

1. Visual inspection whetherthere are leakages. If so, sealthem.


If the problem cannot be solved, please contact MAN Die-sel & Turbo

Pressure Port

The pressure port of the pump is produced accord-ing to our customers’ wishes. In addition, there is avariety of possibilities to connect the pump with oneor more pressure consumers.

MAN Diesel & Turbo

Work CardPage 3 (4) Hand Lever Pump

520-01.07Edition 01

L16/24, L23/30H, V28/32S, L21/31, L27/38

2008.08.25. -ES0

Attention - Danger to life Prior to the pump’ s start-up please make sure that,no matter which pressure port you chose, all con-nection elements are in a perfect condition. Con-vince yourself of the fact that these are correctlyconnected and suitable for the necessary pressure.

Attention - High-pressure hydraulic On principle, when leakages occur during the pres-surization, immediately release the hydraulic pres-sure and seal the leakane or renew defect parts.

Maintenance and Storage

The pump should be lubricated frequently at themovable parts. Protect it from contaminationbecause dirt in the oil or in the pressure port canlead to the pump’ s failure. A dry storage avoids thesteel parts’ getting rusty. The storage and transport of the pump shouldalways be done in a horizontal position. Thus, youavoid a possibly necessary venting of the pumpduring its start-up.

For checking the oil level, please open the depres-surization valve and let the oil completely flow backinto the tank. Open the oil filler cap and fill uphydraulic oil according to IS0 VG 32, if neccessary.Do not overcharge the tank. Close the oil filler cap.

The use of the pump in a dirty area requires a regu-lar oil change. Fill the pump with clean hydraulic oiland lubricate all moving parts (hinges) regulary.


Hand Lever Pump Work CardPage 4 (4)

L16/24, L23/30H, V28/32S, L21/31, L27/38

2008.08.25. -ES0

Safety precautions


Short Description

Maintenance of hydraulic tools and pressure test-ing of hoses

Starting Position

Related Procedure

Qualified Manpower


Data


Special tools


Hand ToolsAllen key, 6 mmRing and open end spanner, 22 mmClean lube oil



52021 430 52021 422 52021 299 52021 309

MAN Diesel & Turbo

Work CardPage 1 (2) Maintenance of hydraulic tools

520-01.10Edition 01

L23/30H

1996.01.15 - ES0

Description

1) The hydraulic jacks require no maintenanceexcept replacement of defective sealing rings,each of which consists of an o-ring and a back-up ring fitted in ring grooves in the piston andcylinder.

The piston and cylinder are easily separated by tak-ing out the bleed screw and pressing the partsapart by means of working air.

1 Working air

Figure 1: .

Make sure that there are no marks or scratches onthe sliding surfaces of the parts. The presence ofmetal particles will damage the sealing rings.

2) The sealing rings are to be fitted with the o-rings nearest to the pressure chamber and withthe back-up rings away from the pressurechamber.

1 Compression tool

Figure 2: .

Fit the sealing rings and lubricate with clean lub. oil.The piston and cylinder are pressed together bymeans of the tool supplied. See that the rings donot get stuck between the piston and cylinder.

Pressure Testing of Hoses

To avoid working accidents caused by emission ofpressure oil from the hydraulic hoses, the hosesshould be pressure tested at 1200 bar once a year.

Note!

During the pressure testing the hoses must becovered carefully.


Maintenance of hydraulic tools Work CardPage 2 (2)

L23/30H

1996.01.15 - ES0

Safety precautions


Short Description

Starting Position

Related Procedure

Qualified Manpower


Data


Special tools


Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (2) Tightening with torque spanner

520-01.15Edition 01

L23/30H

1996.01.15 - ES0

Description

1 Scale for torque moment 2 Key for adjusting of torque moment

Figure 1: Torque spanner

1) Before the nuts are screwed on, the threadsand the contact faces should be greased withcopaslip or similar, the tightening torques beingbased on a coefficient of fiction in the threads.

2) The nuts should fit easily on the thread, and itshould be checked that they bear on the entirecontact face.

3) In the case of new nuts and studs, tighten andloosen the nuts 2 or 3 times so that the threadmay assume its difinite shape, thus obviatingthe risk of loose nuts.

4) Nuts secured with a split pin are tightened tothe stated torque and then to the next split-pinhole.

5) The following instructions apply to the use andmaintenance of the torque spanner.

Torque spanner

6) The handle of the torque spanner is providedwith a scale indicating the torque at which thespanner can be set.

7) For setting the spanner at the torque required,there is a ball on a small arm at the end of thehandle.

8) When pulling the ball with the arm outwards, asmall crank handle is formed.

A spring-loaded slide in the handle provided with amark which, when turning the crank handle, can beset at the required torque on the scale.

The torque spanner functions are as follows:

9) The above-mentioned spring activates a pawlsystem in the handle, and when using the span-ner, this pawl system will be released when thepre-set torque has been reached, at whichmoment a small jerk is felt in the spanner and asmall click is heard.

10) The torque spanner must not be used for tor-que higher than those stamped on it, and itmust not be damaged by hammering on it orthe like.


Tightening with torque spanner Work CardPage 2 (2)

L23/30H

1996.01.15 - ES0

Safety precautions


Short Description

Tool combinations for tightening and checkingconnecting rod screws

Starting Position

Related Procedure

Dismounting of piston and con-necting rod

506-01.00

In-situ inspection of connectingrod big-end bearing

506-01.25

In-situ inspection of connectingrod big-end bearing

506-01.30

Qualified Manpower


Data


Special tools

Plate No. Item No. Note52006 273 80-360 Nm52006 320 -52006 381 24 mm52006 415 -

Hand Tools



MAN Diesel & Turbo

Work CardPage 1 (2)

Tool combination of tightening of connecting rodscrews

520-01.20Edition 01

L23/30H

1996.01.15 - ES0

Description

The tightening procedure for connecting rod screwscan be executed with the tools originally deliveredwith the GenSets.

The enclosed pages illustrate tool combinationsapplicable to tightening of connecting rod screws.

It is also acceptable to execute the turning of thescrews through a 60° angle, by means of a pneu-matic impact spanner, with power and dimensions,if available.

Tool combinations for tightening of screws, see fig.1.

1 Torque spanner, 80-360 Nm

2 Ratchet (only for tightening)

3 Socket, 24 mm

Figure 1: Tool combinations for tightening of screws

The 24 mm socket to be used must be a socalledspecially designed for socket use with mechanicalor pneumatic impact tools.

Compared to sockets for manually operated span-ner, the power top has increased dimensions, seefig. 2.

The connecting rod screws are situated veryclosely, leaving only minor space between collarsand hexagonals of the screw heads.

Dependent of the manufactures, it can be neces-sary to adapt the power top to the limited spaceconditions around the screws.

In such case only the absolutely necessary machin-ing should be executed.

1 Connecting rod screw 2 Connecting rod

3 Special socket (power top)

Figure 2: Special socket

MAN Diesel & Turbo

520-01.20Edition 01

Tool combination of tightening of connecting rodscrews

Work CardPage 2 (2)

L23/30H

1996.01.15 - ES0

Safety precautions


Short Description

Operation. Overhaul intervals. Dismantling, over-haul and assembly.

Starting Position

Related Procedure

Qualified Manpower

Duration in h : ½Number : 1

Data


Special tools

Plate No. Item No. Note52005 109 Max. pressure indicator

Hand ToolsAllen key, 3 and 6 mmCopaslip or similar



See plate52005

-

MAN Diesel & Turbo

Work CardPage 1 (3) Max Pressure Indicator

520-01.25Edition 01

L23/30H, V28/32S

1996.01.15. - ES0

Health Risk!

Warning!

Health Risk!


Operation

1) Open the indicator valve and blow throughshortly.

2) Connect the max pressure indicator to the indi-cator valve and open the valve.

3) After 3-5 seconds read the max. pressure onthe gauge.

Attention: The indicator valve has to be open whilereading the max. pressure on the gauge. The meas-uring period should not exceed 30 seconds.

4) Close the indicator valve and open the valvescrew (5), fig 1.

5) Disconnect the max. pressure indicator andclose the valve screw (5), fig 1.

6) Measure the remaining cylinders by followingstep 1 to 5.

Overhaul intervals

1) Dismount and clean the non-return valve after200 measuring periods. If the pressure drop ismore than 5 bar within 60 seconds (test pres-sure 100 bar) it is recommended to relap thenon-return valve.

2) Check the pressure gauge after 1,000 measur-ing periods or after 12 months use.

Attention: Use only exhaust gas or nitrogen gasand never oil for testing the pressure drop and thepressure gauge. By using oil carbon will depositinside the measuring instrument.

Dismantling and Assembly

1) Dismount the valve screw (5), fig 1.

2) Turn the screw (4) into the instrument to enabledismounting of the housing (1).

3) Loosen the screws (2) (4 pieces) for separatingupper and lower part.

1 Housing 2 Allen screw

3 Sealing 4 Screw

5 Valve screw

Figure 1: Pressure indicator

4) After separation of the upper and lower part,take off the non-return valve assembly.

5) Lap the valve and the valve seat.

6) Renew the sealing ring (3) and screws (2), ifnecessary.

7) When mounting the upper and lower part, useonly original screws.

8) Coat the screws (2) with copaslip or similar andtighten to 10 Nm.

9) After assembly the instrument can be usedwithout any new calibration.


Max Pressure Indicator Work CardPage 2 (3)

L23/30H, V28/32S

1996.01.15. - ES0

Check of the Pressure Gauge

10) Testing of the instrument should only be madeby skilled specialists, and it is recommended tosend the instrument to MAN Diesel for calibra-tion.

MAN Diesel & Turbo

Work CardPage 3 (3) Max Pressure Indicator

520-01.25Edition 01

L23/30H, V28/32S

1996.01.15. - ES0

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

S 051

Lifting tool for cylinder head,complete. 139 113 68 014S

Mounting tool for valves,complete. 248 ø72

Max. pressure indicator.

Spare Parts:

Valve screw

Non-return valve, complete incl.seals and housing screws.

Connecting nut incl. wedge formounting

Pressure gauge 0-180 bar.

S 109

110

122

134

146

65

Tools for Cylinder HeadPlatePage 1 (4) 52005-04H

01.17 - ES0

L23/30H


NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Grinding table for cylinder head, with bracket for wall mounting, complete. 254E648426846

301E7441050833

Grinding table for cylinder head, with frame for fl oor mounting, complete.

Extractor for valve seat ring (complete). ø137 290 E 504

52005-04H Tools for Cylinder Head PlatePage 2 (4)

01.17 - ES0

L23/30H


NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Grinding machine for valve seat ring, complete.

Spare Parts:

Stone

Guide

E 350

362

374

408

421

EGrinding machine for valve spindle, complete.

Spare Parts:

Stone

457E315ø78Mounting tool for valve seat rings, complete.

Tools for Cylinder HeadPlatePage 3 (4) 52005-04H

01.16 - ES0

L23/30H


NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

NV17

Tools for grinding of valves. 553Sø110 95

673S110107Hand wheel for indicator valve.

Grinding tool for cylinder headand cylinder liner. 205S470399

52005-04H Tools for Cylinder Head PlatePage 4 (4)

01.17 - ES0

L23/30H


NoA B CDesignation

S/E


MAN Diesel & Turbo

Eye screw for lifting of piston. M12 ø30 20.5 021S

Eye bolt for piston lift at checkof connecting rod big-endbearing.

S 070

S 033Shackle for lifting of piston. 28 60

C

AB

M12 54 410

Tools for Piston , Connecting Rod and Cylinder LinerPlatePage 1 (6) 52006-06H

11.38 - ES0

L23/30H


NoA B CDesignation

S/E


MAN Diesel & Turbo

Back stop for cylinder liner,2 pieces. 094Sø60.3280 75

Guide ring for mounting of pi-ston.

Only for 900 rpm and720/750 Stationary

116S110ø298

52006-06H Tools for Piston , Connecting Rod and Cylinder Liner PlatePage 2 (6)

11.38 - ES0

L23/30H

Guide ring for mounting of pi-ston.

Only for 720/750 rpm Marine

117S85ø275


NoA B CDesignation

S/E


MAN Diesel & Turbo

Testing mandrel for piston ringand scraper ring grooves.

Grooves for piston ring.

Grooves for scraper ring.

S

S

153

165

4.43

7.43

200SPlier for piston pin lock ring.

C

B

A 25550 ø3.5

A


11.38 - ES0

L23/30H

141S260105Piston ring opener.

261

273

S

S

½"

¾"

463

718

Torque spanner 20-120 Nm

Torque spanner 80-360 Nm

A

B


NoA B CDesignation

S/E


MAN Diesel & Turbo

Socket. 24 55 ¾" S 381


11.38 - ES0

L23/30H

Pneumatic impact spanner 415E3/4"

Lifting tool for cylinder liner. 452S370 930


NoA B CDesignation

S/E


MAN Diesel & Turbo

1615ø258 S 511Funnel for honing of cylinderliner.


11.38 - ES0

L23/30H

50140Magnifier (30 x). S 559

B

A

488S850ø228Honing brush incl. woodenbox

Wooden boxL x B x H = 269 x 269 x 250 mm


NoA B CDesignation

S/E


MAN Diesel & Turbo


11.38 - ES0

L23/30H

Grinding tool for cylinder liner 350 503 S 655

Inside micrometer:

Measuring range225-250 mm (cylinder liner)

Measuring range175-200 mm (connecting rod)

E

E

618

631

15

10

20275 80


noA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

S 058

Feeler gauge for inlet valves.

Feeler gauge for exhaust val-ves.

(2 sets of each)

0.5

0.9

0.6

1.0

010

022

S

S

Extractor for thrust piece onroller guide for fuel pump. 49 M24

x1.5ø29.5

PlatePage 1 (1) 52008-04H

98.51 - ES0S

L23/30H

Tools for Operating Gear for Inlet Valves,Exhaust Valves and Fuel Injection Pumps

S 071Distance piece 98.5 ø24.5ø30


NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Spanner for adjusting ofoverspeed stop. 125 ø20 100 016S

52009-02H

01.17 - ES0

L23/30H

Tools for Control and Safety SystemsAutomatics and Instruments

PlatePage 1 (1)


NoA B CDesignation

S/E


MAN Diesel & Turbo

Turning rod. 925 ø42.4 011S

Dismantling tool for mainbearing, 2 pieces. S 106

S 059Crankshaft alignment gauge(autolog). 210 150

ø60 125 M12

01.17 - ES0

Tools for Crankshaft and Main BearingPlatePage 1 (2) 52010-04H

L23/30H


NoA B CDesignation

S/E


MAN Diesel & Turbo

Lifting straps for main and guide bearing cap, 2 pieces. 155SM161000

Dismantling tool for guide bearing shells. 202S250

15

214

226

S

S

51.5

ø2.6

ø50

ø7.9

Tool for upper main bearing.

O-ring.

32

01.17 - ES0

52010-04H Tools for Crankshaft and Main Bearing PlatePage 2 (2)

L23/30H


No.A B CDesignation

S/E


MAN Diesel & Turbo

Pressure testing pump, compl.GOU-G001.

Clamping bracket for fuelinjector, VTO W020.

Clamping bracket for fuelinjection pump, PYO-W017.

Fuel pipe, VTO-W021.

Fuel pipe, VWM-W007.

013

025

037

049

050

S

S

S

S

S

S 108Cleaning tool for fuel injectorconsists of:

1 pc. needles.

1 pc. holder.

1 pc. box.

84 ø22.5

Spanner for fuel injection pump. S 204184

Tools for Fuel Oil System and Injection EquipmentPlatePage 1 (3) 52014-03H

11.03 - ES0

L23/30H


No.A B CDesignation

S/E


MAN Diesel & Turbo

Grinding tool for fuel injectionvalve. 300Eø1825 ø55

Grinding tool for seat for fuelinjection valve. 361Sø18

407S185150Extractor for fuel injector valve. 240

533 ø70

52014-03H Tools for Fuel Oil System and Injection Equipment PlatePage 2 (3)

11.03 - ES0

L23/30H


No.A B CDesignation

S/E


MAN Diesel & Turbo

Measuring device for plunger lift 420S

Tools for Fuel Oil System and Injection EquipmentPlatePage 3 (3) 52014-03H

11.03 - ES0

L23/30H

Dimensions

PlatePage 1 (1) 52015-01H

Illustration of Tools ItemNoA B C

96.03 - ES0S

L23/30H

Designation

S/E


Tools for Lubricating Oil System

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Guide bar for dismantling oflubricating oil cooler. ø30 305 M20 019S


NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Hydraulic ToolsPlatePage 1 (5) 52021-10H

06.25 - ES0

L23/30H

011

023

118

096

059

Pressure pump, complete, with wooden box

Manometer

Gasket for Item 096

Quick coupling

Distributor

S

155

167

179

Distributing piece for cylinder head, complete.

Gasket

Quick coupling

S

Distributing piece for main bea-ring, complete.

Gasket

Quick coupling

S 202

167

179


NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

52021-10H Hydraulic Tools PlatePage 2 (5)

06.25 - ES0

L23/30H

179

275

645

657

669

633

704

716

728

741

753

621

765

777

789

586

790

S

Quick coupling

Venting screw

Ball

Adapter

Stroke indicator band

Hydraulic tools for connecting rod with wooden box, com-plete

Piston for hydraulic jack

Set of O-rings with back-up ring

Adjusting rod

Cylinder for hydraulic jack

Spacer piece

Angle piece complete, incl. item 765, 777, 789, 790

O-ring

Adapter

Coupling socket

Hydraulic jack as item nos. 179, 275, 645, 657, 669, 704, 716, 728, 741, 753

Quick coupling


NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel


06.25 - ES0

L23/30H

179

251

263

275

287

299

309

310

800

334

358

645

657

812

S

Quick coupling

Hydraulic tools for cylinder head with wooden box, complete

Allen key, 7 mm

Venting screw



O-ring


Spacer piece

Tommy bar

Hydraulic jack as Item Nos. 179, 275, 287, 299, 309, 310, 645, 657, 812

Ball

Adapter



NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

52021-10H Hydraulic Tools PlatePage 4 (5)

05.25 - ES0

L23/30H

179

263

275

334

645

657

405

417

429

430

454

466

824

586

574

Quick coupling

Allen key, 7 mm

Venting screw

Tommy bar

Ball

Adapter

Hydraulic tools for mainbearings with wooden box,complete

Spacer piece




Hydraulic jack as Item 179, 275, 429, 430, 454, 645, 657, 824


Disc

Guide

S


NoA B CDesignation

S/E


0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel


06.25 - ES0

L23/30H

501

513

537

549

525

836

ø27

ø27

600

3000

3000

600

Hose for hydraulic tools, 4 pie-ces complete

Hose for hydraulic tools, 1 pie-ces complete

Hose

Quick coupling with protecting cap

Hose

Adapter

S

S

326256367Air-driven high pressure pumpfor hydraulic tools E 608

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

01.17 - ES0-G

L23/30H

Tools for Low Overhaul Height,Piston, Cylinder Liner and Connecting Rod 52050-02HPlate

Page 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

021

033

045

057

Item No Benævnelse

Pull-lift

Løfteværktøj for cylin-derforing, komplet

Halsjern for plejlstang, komplet

Sjækel

Designation

Pull-lift

Lifting tool for cylin-der liner, complete

Collar for connecting rod, complete

Shackle

Qty

2/E

1/E

1/E

2/E

Item No DesignationQty Benævnelse

01.17 - ES0-G

Tools for Low Overhaul Height, Piston, Cylinder Liner and Connecting Rod


* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./Motor.


* = Only available as part of a spare parts kit. Qty/E = Qty/Engine.

52050-02H PlatePage 2 (2)

Operating manual

Test rig GXO-G010a / GXO-G011a

Technical documentation

GXO-D001

Operating manual for test rig

GXO-G010a / GXO-G011a

Die Betriebsanleitung ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Außerhalb dieses Verwendungszwecks darf die Betriebsanleitung ohne unsere vorherige Zustimmung nicht benutzt, vervielfältigt oder Dritten sonstwie zugänglich gemacht werden.

Änderungen bleiben vorbehalten The owner should make this operating manual available to maintenance and operating staff who should follow the instructions it contains to prevent malfunctions or damage during operation. Other than for this purpose, the operating manual may not be reproduced, used or disclosed to third parties by any other means without our prior consent.

Subject to alterations and amendments Änderungsdienst/Amendments service! Falls Sie in den Änderungsdienst von L'Orange aufgenommen werden möchten, können Sie uns das mit einer Postkarte an untenstehende Adresse mit folgenden Angaben mitteilen: If you would like to be included in the L'Orange amendments service, send a postcard to the address below including the following details: Name / Name Betriebsanleitung für GXO-G010a / -G011a

Firma / Company Straße / Street GXO-D001 Postfach / PO Box Operating manual for GXO-G010a / -G011a

PLZ / Postcode / Zip code Ort / City GXO-D001/E Land / Country Betriebsanleitungs-Nr. / Operating manual No.

© 2007 L'Orange GmbH Abteilung KVAM Postfach 40 05 40 70405 Stuttgart Germany


GXO-D001



Contents Section Page1 Structure of the test rig (exterior) .....................................................................................................1

2 Structure of test rig (interior) ............................................................................................................2

3 Handling the test rig.........................................................................................................................5

4 Maintenance ....................................................................................................................................6

5 General safety instructions ..............................................................................................................7

5.1 Use in accordance with purpose.............................................................................................7

5.2 Handling the system ...............................................................................................................7

5.2.1 Hazards in handling the test rig ..........................................................................................7

5.2.2 Safety measures in normal operation .................................................................................7

5.2.3 Hazards from electrical energy ...........................................................................................7

5.2.4 Hazards from hydraulic energy...........................................................................................8

5.2.5 Servicing – Maintenance – Troubleshooting.......................................................................8

5.2.6 Organizational measures....................................................................................................8

5.3 Staff ........................................................................................................................................9

5.3.1 Notes relating to staff..........................................................................................................9

5.3.2 Outside normal operation ...................................................................................................9

5.4 General operating instructions................................................................................................9

5.4.1 How to behave....................................................................................................................9

5.4.2 Rules for operation .............................................................................................................9

6 Commissioning ..............................................................................................................................10

6.1 Transport ..............................................................................................................................10

6.2 Setting up .............................................................................................................................12

6.2.1 General information ..........................................................................................................12

6.2.2 Bench-top mounting (GXO-G011a) ..................................................................................12

6.2.3 Floor mounting (GXO-G010a) ..........................................................................................14

6.3 Commissioning the hydraulic system ...................................................................................16

6.4 Commissioning the electrical system....................................................................................17

6.5 Preparations for commissioning the test rig..........................................................................18

7 Technical data ...............................................................................................................................22

7.1 GXO-G010a (floor-mounted system)....................................................................................22

7.2 GXO-G011a (bench-top system)..........................................................................................22

8 Parts list and exploded drawing.....................................................................................................23


GXO-D001



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1 Structure of the test rig (exterior)

Item Part Item Part Item Part 1.4 Selector switch for mode 5 Relief valve 17.3 Plexiglass tube

(sight glass) 3 Pressure gauge

(pressure display bar/psi) 15.1 Cover

(tray) 17.6 Extraction

(spray container) 4 Hand lever

(hand pump) 15.2 Knurled screw

(to fix cover in position) 17.9 Oil collector

a Rotary receiver

(pump/valve) d Release lever

(rotating mechanism) f Oil sight glass

b Height adjustment e Storage compartments g Switch (extraction)

c Socket (test line)


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2 Structure of test rig (interior)

Item Part Item Part Item Part

1 Booster 4 Hand pump 15.4 Mesh filter a Rotary receiver (pump/valve) b Test oil reservoir c Oil sight glass


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Item Part Item Part Item Part

6 Tube Pump – booster

9 Tube Booster – pressure gauge

13b Hose Oil container – pump

7 Tube Booster – test line connection

13a Hose Relief valve – test oil reservoir

13c Hose Booster – test oil reservoir

8 Tube Booster – relief valve


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The test rig was developed for checking leaks, pressure-testing injection, measuring the pressure drop of injection valves and for assembling/dismantling all L'O devices for medium-speed large diesel engines. There are two versions: GXO-G010a has a base for mounting directly to the floor, whilst GXO-G011a is intended to be fitted to a bench. Both devices have identical functions and operation.

GXO-G010a GXO-G011a The test rig has a safety valve (integrated in the booster) which opens at 900 bar!


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3 Handling the test rig

This operating manual applies primarily to the professional assembly/dismantling of L'O devices, in particular injection pumps and injection valves. The instructions below must be followed. • In the event of malfunctions, the test rig must be professionally examined and repaired

with the utmost care by specialist staff. We therefore recommend that you make use of the fitter service set up by L'Orange or take the test rig to a L'Orange customer service center.

• L'Orange is unable to accept any liability for any damage caused by independent

assembly or repair work performed on the test rig. • In the event of special circumstances requiring immediate work on the test rig, proceed in

accordance with the instructions in Assembly Instruction GXO-D002. • The components of hand pump GCO-G005d are precision-engineered to match and can

consequently only be replaced as an entire unit (paired). • Repair work may only be performed using the tools intended for the purpose. • The test rig serves solely for testing, assembling and dismantling components up to a

maximum weight of 120 kg. All components are to be professionally attached to the receiver and secured against rotation using the locator angle and screws.

• All locator angles for the preceding type (GUO, GXO) will fit the new test rigs without

modification. • The function test (pressure drop time, opening pressure, leak test) of injection valves is

meaningful only up to a needle diameter of Ø 12 mm (e.g. VVO, VWM). The function test on larger injection valves should be performed on test rig GXO-G004.


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4 Maintenance

The test rig is largely maintenance-free. Moving parts are subject to natural wear which experience shows is very limited. However, the wear characteristics of the components depend largely on the test rig being handled and cared for properly. To ensure smooth operation of the test rig in the long term, please note and comply with the following care and maintenance instructions. • Clean the outside of the test rig after every use. • Subject all components to a visual inspection once a month – damaged or worn

components should be replaced by specialist staff if required. • All electrical components should be inspected for damage once a month. Likewise check

monthly that plug connections are tight – damaged components should be replaced by specialist staff if required.

• Check all hydraulic lines and components once a month for pressure loss and damage.

The lines must be located firmly in their screwed connections to prevent them coming loose – damaged components should be replaced by specialist staff if required.

• Check six-monthly that mechanical components have not come loose and are tight – if

required, components should be adjusted and tightened up. • Check once a month that safety devices are working properly. • All moving parts on the device should be greased. The locking bolt and sliding bar on the

spray container should also be oiled occasionally. • Check the oil collector daily. Empty the collector if necessary. Used oil must be disposed

of properly and may not, under any circumstances, be reused.


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5 General safety instructions

5.1 Use in accordance with purpose The test rig is solely for assembling/dismantling injection pumps which do not exceed a total maximum weight of 120 kg (injection pump incl. valve) and for testing injection valves up to size "VVO". The owner of the system is responsible for those setting up, operating or maintaining the device and for third parties following the safety precautions outlined in this operating manual. L'Orange hereby refuses to accept any liability for damage to those operating or setting up the device, to maintenance staff, to the company and/or to other third parties if the system is used in any way not covered by "use in accordance with purpose", unless L'Orange causes such damage deliberately or as a result of gross negligence.

5.2 Handling the system 5.2.1 Hazards in handling the test rig The test rig is built in accordance with the state of the art and satisfies recognized safety regulations. Nevertheless, its use can still present a hazard to the life and limb of the user or of third parties, as well as damage to the system or to other material resources. The system should therefore only be used in accordance with purpose and when it is in a perfectly safe condition. Faults which may impair safety should be eliminated immediately and avoided during operation. 5.2.2 Safety measures in normal operation Operate the test rig only if all the safety devices are fully functional. Check the system for externally visible damage and always check that the safety devices are working before starting operation. Before assembling, dismantling or modifying any circuit: switch off the power supply and depressurize the test rig. Follow the general safety instructions of DIN 58126 and VDE 0100. 5.2.3 Hazards from electrical energy Once maintenance work is complete, check that the safety devices are working properly. Only a professional trained electrician or electronics engineer may perform any work on the electrical supply.


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5.2.4 Hazards from hydraulic energy Keep away from the spray jet during the function test (pressure build-up) – risk of blood poisoning!

Observed the permitted opening pressure for the injection valve in question (see catalogue sheet). 5.2.5 Servicing – Maintenance – Troubleshooting During the warranty period, servicing and maintenance work will be performed within the scope of the maintenance contract. Make sure that the specified setting and servicing work is performed at the prescribed intervals. Secure the hydraulic and electrical systems from being switched on unintentionally. The test rig must be disconnected from the power supply and depressurized for all maintenance, servicing and repair work. Check that all screwed connections undone in the course of maintenance, servicing and repair work are firm. 5.2.6 Organizational measures All safety devices provided are to be checked regularly.


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5.3 Staff 5.3.1 Notes relating to staff • The test rig may only be operated by persons who have received instruction. This applies

to both operation and the safety devices of the test rig. • Wear safety footwear when working on the test rig. • Wear oil-resistant clothing. • Wear safety glasses. • Wear oil-resistant gloves and clothing. • Avoid several people working on maintenance and set-up tasks at the same time. • Naked flames and smoking are forbidden within a radius of 5 m of the test rig! 5.3.2 Outside normal operation Activities involved in maintaining, servicing or repairing the system may be performed only by people with adequate specialist qualifications. 5.4 General operating instructions The test rig demands some rules of operation which must be complied with. If these rules are ignored, it is possible for faults to arise in the testing process and hazards to physical health cannot be ruled out. You are strongly advised to follow the rules below. 5.4.1 How to behave • Naked flames and smoking are absolutely prohibited at the test rig and within a radius of

5 m. • It is prohibited to reach into the spray container (plexiglass tube) during the testing

process. • Stations should be made safe by mechanical means in the event of relatively large groups

of spectators. • It is prohibited to pull out any live cable connection. • Water of any kind is to be kept away from the system. • Test lines should be carefully examined for cracks or leaks before each use. 5.4.2 Rules for operation • The test rig may only be operated by people who have received instruction. • Operation should be in accordance with the operating manual. • Prevent unsupervised operation of any equipment.


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6 Commissioning

6.1 Transport When the test rig is delivered, ensure that it is only transported using suitable transportation equipment. The GXO-G010a weighs approx. 150 kg and the GXO-G011a approx. 75 kg. The routes to be taken should be cleared for transport and be accessible for the transportation equipment. If appropriate, put up warning signs or barrier tape. Take care when opening the transport box, preventing extra components like the test oil supplied from falling out. Once the transport box is open and any additional components have been removed, the test rig can be removed and taken to its final location. Please check that all screwed connections are tight. Vibration during transport may have caused them to come loose. The test rig may not be gripped by its feet and certainly not under the feet – increased risk of crushing or trapping.


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State in which GXO-G010a delivered Canister [b] containing the test oil is in the base of the test rig. The lever for the pump is enclosed with the delivery and needs to be fitted for com-missioning [a].

State in which GXO-G011a delivered

The lever for the pump is enclosed with the delivery and needs to be fitted for com-missioning [a].


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6.2 Setting up 6.2.1 General information The test rig should be screwed to the floor (GXO-G010a) or bench (GXO-G011a) at its intended location. In addition, the workbench should likewise be affixed to the floor to prevent tipping over. A loadbearing/solid floor is a prerequisite for smooth assembly and operation. An appropriate gap should be planned between the test rig and the wall. Keep dust and dirt away from the test rig (cover). 6.2.2 Bench-top mounting (GXO-G011a)

• Remove screw [15.2]. • Remove cover [15.1].

• Fit dismantling aid [a] and hold the body

[15] steady using a crane. • Undo and remove screws [b]. • Carefully lift body [15] using the crane

and place it aside.


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• The baseplate [a] is now in front of you ready for assembly.

• Transfer the bores in the baseplate as shown in the sketch to the workbench and drill into the worktop using a Ø 12 mm bit. Line A represents the edge of the bench!

• Screw the baseplate firmly to the bench

using M10 screws (length depending on the thickness of the workbench). The screws must be pushed in from above and tightened up from underneath with washers and a nut.

• Put body [15] on the baseplate and

attach with screws [b].


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6.2.3 Floor mounting (GXO-G010a)

• Remove screw [15.2]. • Remove cover [15.1].

• Align the test rig and transfer the bore

positions for baseplate [1] to the floor.


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• Fit dismantling aid [a].

• Carefully lift subframe [20] using a crane

and place it aside. • Drill holes in the floor. • Use the crane to return subframe [20] to

its assembly position. • Remove the dismantling aid [a].

• Depending on the substrate, attach the baseplate of the test rig with four screws [a].


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6.3 Commissioning the hydraulic system The owner commissions the rig independently. The procedure required to do so is described below. A prerequisite is that the test rig is already firmly screwed as described in the previous section.

• Remove transport sealing plug [a].

• Fit filter [15.4].

• Pour Fuchs Renotest test oil into the test

oil reservoir to at least oil sight glass [a] (capacity approx. 3.5 liters).


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• Fit cover [15.1] and fix in position with screw [15.2].

• Pump lever [4] until test oil escapes from

connection [a] without bubbles.

6.4 Commissioning the electrical system

• Connect the cable for non-heating appliances supplied to socket [a] and supply with electrical power. Extraction operates at a voltage of 230 V and cannot be switched to 110 V! The fitted plug can be changed if required, but this should be done only by a qualified specialist. The connection for this must be fused at a rating to suit the consumers. To prevent problems in oper-ation, we strongly recommend separate fuse protection for the test rig.


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6.5 Preparations for commissioning the test rig If rotary receiver [1] needs to be swivelled, follow the instructions below.

• 360° rotation The swivel restriction can be released using release lever [b]. If the lever is moved to the right and held there, rotary receiver [a] can be turned through 360°. Warning, risk of injury! The valve can rotate in an uncontrolled manner once the swivel restriction is released.

• 12.5° rotation If lever [b] is moved only briefly to the right and then returned to the left-hand position, rotary receiver [a] can be turned through 12.5°.


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Make the following preparations every time you use the test rig.

• Follow the safety instructions! • Only staff who have received instruction

may operate the test rig. • The test rig must be depressurized com-

pletely using relief valve [5].


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• Use height adjuster [c] to move the spray container right to the bottom and secure the lever in the lowest latching position [b].

• Fit valve receiver on rotary receiver [a]. • Fit valve in receiver.


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• Connect the injection valve to connector [a] of the test rig using the corresponding test line. Tighten screwed connections firmly!

• Use height adjuster [b] to move the spray

container upwards until the injection nozzle of the valve is inside the plexi-glass tube. Secure the lever in one of the latching positions!

• Switch on extraction. • You can now select operating mode.


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7 Technical data

7.1 GXO-G010a (floor-mounted system) Purpose: medium-speed diesel engines Weight: GXO-G010a = 146 kg Dimensions: height: 1130 mm width: 440 mm excl. spray container width: 670 mm incl. spray container depth: 510 mm excl. spray container depth: 560 mm incl. spray container Piston diameter: 8 mm Safety valve: opening pressure = 900 bar Pressure gauge: display up to 1000 bar / 14400 psi Test oil: Fuchs Renotest LO Test oil viscosity: 4.5 cSt/40°C Test oil reservoir: approx. 3.5 liters Test oil line: connecting thread 24 x 1.5 Maximum load: 120 kg (receiver) 7.2 GXO-G011a (bench-top system) Purpose: medium-speed diesel engines Weight: GXO-G011a = 71 kg Dimensions: height: 330 mm excl. spray container height: 1120 mm incl. spray container width: 440 mm excl. spray container width: 670 mm incl. spray container depth: 510 mm excl. spray container depth: 560 mm incl. spray container Piston diameter: 8 mm Safety valve: opening pressure = 900 bar Pressure gauge: display up to 1000 bar / 14400 psi Test oil: Fuchs Renotest LO Test oil viscosity: 4.5 cSt/40°C Test oil reservoir: approx. 3.5 liters Test oil line: connecting thread 24 x 1.5 Maximum load: 120 kg (receiver)


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8 Parts list and exploded drawing

GXO-G011a GXO-G010a

Item Pcs. Part L'O-No. Weight

g Item Pcs. Part L'O-No. Weightg

Test rig GXO-G011a (replacement for all GUO-G...) 71000 15,2 Screw D464-M8x16 10

1 Booster, compl. GXO-U058 13500 15,3 Perforated plate GXO-T133 700

1,1 Booster GXO-U056 12000 15,4 Filter screw GCO-T065 60

1,2 4 Connection piece GXO-T173 30 15,5 Mesh filter FSH-1 5

1,3 2 Screw D912-M10x40-12.9 35 17 Spray container GXO-U065 7150

1,4 Valve actuator GXO-U057 1350 17,1 Cover GXO-U067 1100

3 Gauge FMA-160.1000AH 1100 17,2 Perforated plate GXO-T159 700

4 Hand pump Ø8 GCO-G005d 2700 17,3 Plexiglass tube GXO-T155 1350

5 Relief valve GXO-U059 350 17,5 3 Screw D7380-M8x25 15

6 Tube GXO-T126 110 17,6 Spray container GXO-U066 3900

7 Tube GXO-T127 130 17,8 Screw D7380-M8x20 12

8 Tube GXO-T128 130 17,9 Collector GUO-T041 75

9 Tube GXO-T129 125

10 9 Screw D7380-M6x20 7 Test rig GXO-G010a (replacement for all GXO-G003...) 146000

11 2 Screw D7380-M5x12 5 20 Lower section GXO-U055 57500

12 2 Screw D912-M8x60-12.9 30 20,1 4 Screw D912-M10x20-10.9 25

13 3 Hose GXO-T130 L = 1200 mm 50 20,2 Screw D7380-M8x25 15

15 Body GXO-U062 44150

15,1 Oil tray GXO-U063 2150 06/07not specified items like GXO-G011a

Documents

L23/30H Mk2 Instruction Manual - Marinemaytau.ut.edu.vn/userfiles/files/L27-30H-MK2.PART3.pdfL23/30H Mk2 Instruction Manual - Marine Four-stroke GenSet Fuel oil system 514/614 Internal