
- •500 Engine Data
- •500.00 Main Data for GenSets
- •500.01(01H) Introduction
- •500.02(01H) Safety
- •500.05(01H) Cross Section
- •500.10(01H) Key for Engine Designation
- •500.11(01H) Designation of Cylinders
- •500.12(01H) Engine Rotation Clockwise
- •500.20(01H) Code identification for Instruments
- •500.35(01H) Data for Pressure and Tolerance
- •500.35(11H) Data for Pressure and Tolerance
- •500.40(01S) Data for Torque Moment
- •500.45(01H) Declaration of Weight
- •500.50(01H) Ordering of Spare Parts
- •500.55(01H) Service Letters
- •500.60(01H) Conversion Table
- •500.65(01H) Basic Symbols for Piping
- •501 Operation of Engine
- •501.01(01H) Operating
- •501.05(01H) Out-of Service
- •501.10(01H) Starting-up after Out of Service Periods
- •501.15(02H) Guidelines for Longterm Low-Load Operation on HFO
- •501.25(01H) Operating a Diesel Engine at Low Frequency
- •502 Engine Performance and Condition
- •502.01(01H) Engine Performance and Condition
- •502.05(01H) Condensate Amount
- •502-01.00(01H) Engine Performance Data
- •503 Trouble Tracing
- •503.01(01H) Starting Failures
- •503.01(02H) Starting Failures
- •503.02(01H) Faults in Fuel Oil System
- •503.03(01H) Disturbances during Running
- •503.04(01H) Ignition in Crankcase
- •503.06(01H) Trouble Shooting Guide for Turbine Starter
- •503.09(01H) Trouble Shooting for Cooling Water System
- •503.10(01H) Trouble Shooting for Lubricating Oil Cooler
- •504.01(01H) Lubricating Oil Specification
- •504.01(05H) Lubricating Oil Specification
- •504.03(01H) Maintenance of Lubricating Oil Condition
- •504.05(01H) Lubricating Points
- •504.06(01H) Lubricating Oil in Base Frame
- •504.06(04H) Lubricating Oil in Base Frame
- •504.20(02H) Fuel Oil Specification
- •504.20(04H) Fuel Oil Specification
- •504.25(01H) Fuel Oil Quality
- •504.26(01H) Nomogram for Determination of CCAI
- •504.26(02H) Nomogram for Determination of CCAI
- •504.27(01H) Analysis Data
- •504.30(01H) Fuel Oil Cleaning
- •504.40(01H) Fresh Water System Treatment
- •504.40(02H) Freshwater System Treatment
- •505 Cylinder Head
- •505.01(01H) Cylinder Head
- •505-01.00(01H) Dismantling of Cylinder Head
- •505-01.05(01H) Inspection of Inlet Valve, Exhaust Valve and Valve Guide
- •505-01.15(01H) Valve Rotator
- •505-01.20(01H) Replacement of Valve Guide
- •505-01.26(01H) Indicator Valve
- •505-01.30(01H) Replacement of Sleeve for Fuel Injector
- •505-01.35(01H) Replacement of Valve Seat Ring
- •505-01.40(01H) Mounting of Cylinder Head
- •505-01.45(01H) Inspection of Cylinder Head Cooling Water Space
- •50501-01H Cylinder Head
- •50502-01H Valve Spindles and Valve Gear
- •50508-01H Indicator Valve
- •50510-01H Cylinder Head, Top Cover
- •506 Piston, Connecting Rod and Cylinder Liner
- •506.01(01H) Piston, Connecting Rod and Cylinder liner
- •506-01.05(01H) Separation of Piston and Connecting Rod
- •506-01.10(01H) Piston
- •506-01.15(01H) Connecting Rod
- •506-01.25(01H) Tightening and Check of Connecting Rod Screws
- •506-01.30(01H) In-situ Inspection of Connecting Rod Big-end Bearing
- •506-01.35(01H) Inspection and Honing of Cylinder Liner
- •506-01.40(01H) Replacement of Cylinder Liner
- •50601-01H Piston and Connecting Rod
- •507 Camshaft and Camshaft Drive
- •507.01(01H) Camshaft and Camshaft Drive
- •507-01.00(01H) Check of Camshaft and Camshaft Drive
- •507-01.05(01H) Inspection and Replacement of Camshaft Bearing
- •507-01.20(01H) Adjustment of Camshaft
- •50701-01H Intermediate Wheel
- •50705-01H Camshaft and Camshaft Bearing
- •50705-07H Camshaft and Camshaft Bearing
- •508-01.00(01S) Inspection of Valve Roller Guides
- •50801-01H Roller Guide and Push Rods
- •509.01(01H) Control and Safety Systems
- •509.05(01H) Instruments and Automatics
- •509.10(02H) Lambda Controller
- •509.35(01H) Starting Box
- •509-01.05(01H) Functional Test and Adjustment of Overspeed Trip
- •509-05.00(01S) Adjustment and Test of ON/OFF Pressostate
- •509-05.01(01S) Adjustment and Test of ON/OFF Thermostate
- •50903-01H Overspeed Device
- •50905-03H Prelubricating Oil Alarm (LAL 25)
- •50905-04H Instrument Panel
- •50907-02H Thermometer
- •50908-01H Pick-up
- •50910-01H Lambda Controller
- •50935-01H Starting Box
- •510 Crankshaft and Main Bearings
- •510.01(01H) Crankshaft and Main Bearings
- •510-01.00(05H) Checking of Main Bearings Alignment (Autolog)
- •510-01.05(01H) Inspection of Main Bearing Shells
- •510-01.10(01H) Inspection of Guide Bearing Shells
- •51001-01H Crankshaft
- •51002-02H Resilient Gear Wheel
- •51003-02H Flywheel with Gear Rim
- •511S Engine Frame and Base Frame
- •511.01(01H) Engine Frame and Base Frame
- •511-01.00(01H) Functional Test of Crankcase Safety Relief Valves
- •51101-02H Frame with Main Bearings
- •51102-02H Mounting of Pumps
- •51106-02H Covers on Frame
- •51106-03S Covers on Frame
- •512 Turbocharger System
- •512.01(01H) Turbocharger System
- •512-01.00(01H) Overhaul of Charging Air Cooler
- •512-15.00(01H) Water Washing of Turbine Side
- •51202-01S Exhaust Pipe Arrangement
- •51203-03H Turbocharging Arrangement
- •513 Compressed Air System
- •513.01(01S) Compressed Air System
- •513.01.30(01H) Overhaul, Test and Inspection of Turbine Starter
- •513-01.40(01H) Main Starting Valve
- •513-01.90(01H) Check of Compressed Air Piping System
- •51309-01H Turbine Starter
- •51310-01H Main Starting Valve
- •51314-01S Starting Valve
- •51315-03H Main Stop Valve
- •51316-03H Air Strainer
- •51319-02H Safety Valve
- •51320-01H ON-OFF Valve for Jet System
- •51321-01H Air Filter
- •514 Fuel Oil System
- •514.01(01H) Internal Fuel Oil System
- •514-01.05(01H) Fuel Injection Pump and Fuel Injection Pipe
- •514-01.10(02H) Fuel Injection Valve
- •514-01.15(01H) Fuel Oil Split Filter
- •514-01.90(01H) Check of Fuel Oil Piping System
- •514-05.01(01H) Adjustment of The Maximum Combustion Pressure
- •51401-01H Fuel Injection Pump
- •51402-01H Fuel Injection Valve
- •51403-01H Fuel Oil Filter Duplex
- •51404-01H Fuel Injection Pipe
- •51430-01H Pipes on Cylinder Section
- •515 Lubricating Oil System
- •515.01(01H) Internal Lubricating Oil System
- •515.06(01H) Lubricating Oil Cooler
- •515-01.00(01H) Lubricating Oil Pump, Engine Driven
- •515-01.10(01H) Lubricating Oil Filter
- •515-01.20(01H) Lubricating Oil, Thermostatic Valve
- •515-01.90(01H) Check of Lubricating Oil Piping System
- •515-06.00(02H) Lubricating Oil Cooler
- •51501-03H Lubricating Oil Pump (Gear Driven)
- •51502-01H Lubricating Oil Filter (Type A)
- •51502-02H Lubricating Oil Filter (Suppl. for Plate 51502-01H)
- •51504-01H Prelubricating Pump
- •51506-01H Lubricating Oil Cooler
- •51525-01H Hand Wing Pump
- •51530-01H Lubricating Oil Separator
- •516 Cooling Water System
- •516.01(01H) Cooling Water System
- •516.04(01H) Cooling Water Thermostatic Valve
- •516-01.90(01H) Check of Cooling Water System
- •516.04-00(01H) Cooling Water, Thermostatic Valve
- •51604-01H Cooling Water Thermostatic Valve
- •51610-01H High Temperature Fresh Water Pump
- •51625-01H Pipes on Cylinder Head
- •51635-01H Preheater - Fresh Water
- •517 Special Equipment
- •518 Driven Machinery
- •519 Specific Plant Information
- •519.03(01S) Resilient Mounting of Generating Sets
- •519-03.00(01S) Fitting Instructions for Resilient Mounting of GenSets
- •519-03.00(02S) Fitting Instructions for Resilient Mounting of GenSets
- •519-03.00(03S) Fitting Instructions for Resilient Mounting of GenSets
- •519-03.05(01S) Replacement of Conicals
- •519-03.10(01S) Replacement of Conicals
- •520 Tools
- •520.01(01H) Introduction to Spare Part Plates for Tools
- •520-01.05(01H) Application of Hydraulic Tools
- •520-01.10(01H) Maintenance of Hydraulic Tools
- •520-01.15(01H) Tightening with Torque Spanner

Description |
Ignition in Crankcase |
503.04 |
Page 1 (1) |
Edition 01H |
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L23/30H |
Cause |
1. Stop the Engine |
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08028-0D/H5250/94.08.12
During running the atmosphere in the crankcase contains the same gases (N2-O2-CO2) in the same proportions as in the ambient air, but an intense spray of coarse oil drops is flung around everywhere. If undue friction, and thus heating, arise between sliding surfaces, or heat is transmitted otherwise to the crankcase, the heated surface will cause evaporation of the lubricating oil splashed onto it. When the oil vapours condense they form a multitude of minute drops suspended in the atmosphere, i.e. a milky white oil mist is formed, able to nourish and spread a flame if ignited. Such ignition may be caused by the same "hot spot" which produced the oil mist. If a large quantity of oil mist has developed before ignition, the burning may cause considerable pressure rise in the crankcase, forcing the relief valves to open. In a few cases, presumably when the whole crankcase has been filled with oil mist, a subsequent explosion has thrown off crankcase doors and caused fire in the engine room.
Every precaution should therefore be taken to (A) avoid "hot spots" and (B) discover oil mist in time.
A."Hot spots" in Crankcase
Overheating of bearings is a result of too bad or failing lubrication possibly caused by pullution of the lubricating oil.
It is therefore important that the lubricating oil filtration equipment is in perfect condition. Filter cartridges must not be used again, if they have been removed from the filter. Check of the oil condition by analysis is recommended.
B Oil Mist in Crankcase
Presence of oil mist may by noted at the vent pipe, which is usually fitted to the top of the engine frame.
Measures (in case of white oil mist).
Warning: Keep away from doors and relief valves on crankcase. Do not stay unnecessarily in doorways near doors of the engine room casing.
2. Leave the engine room. Shut doors and keep away from them. Make ready fire-fighting equipment.
Warning: Do not open crankcase until 10 minutes after stopping the engine. When opening up, keep clear of possible flames. Do not use naked light and do not smoke.
3. Take off all doors on one side of the crankcase. Cut off starting air. Engage turning gear, if fitted.
4. Locate the hot spot. Powerful lamps should be employed at once (in explosion-proof fittings). Feel over all sliding surfaces (bearings, liners, pistons, roller guides, etc.).
Look for squeezed-out bearing metal and discoloration by heat (blistered paint, burnt oil, heated steel).
5. Prevent further heating, preferably by making a permanent repair. Special attention should be given to ensure lubricating oil supply and satisfactory condition of the frictional surfaces involved. It is equally important to replace filter elements in time.
6. Start electrically driven lubricating oil pump and check oil flow from all bearings and splash pipes in crankcase while turning the engine through at least two revolutions. Section 502, Check 1.
7. Stop and feel over. Look out for oil mist.
Especially the frictional surfaces that caused the heating should be felt over (5-15-30 minutes after starting, and again when full load is obtained). Section 501.10, Point 2.
8. In case it has not been possible to locate the hot spot, point 8 should be intensified and repeated until the cause of the oil mist has been found and remedied. In very rare cases oil mist could be due to "atomization" of lubricating oil by the action of an air jet (for instance blow-by, or blow-by through cracked piston).
96.37 - ES0U-G

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Description |
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Trouble Shooting Guide for Turbine Starter |
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503.06 |
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Page 1 (2) |
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Edition 01H |
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L23/30H |
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Trouble |
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Possible Cause, see working card |
Trouble Shooting |
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Motor will not run. |
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No air supply. |
Check for blockage or damage to air |
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supply lines or tank. |
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Damaged motor assembly (12). |
Inspect motor assembly and power |
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train and repair power train or |
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replace motor assembly, if |
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necessary. |
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Foreign material in motor and/or |
Remove motor assembly and piping |
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piping. |
and remove the blockage. |
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Blocked exhaust system. |
Remove housing exhaust cover (1) |
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and check for blockage. |
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Defective control or relay valve. |
Replace control valve or relay valve. |
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Loss of power. |
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Low air pressure to starter. |
Check air supply. |
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Restricted air supply line. |
Check for blockage or damage to air |
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lines. |
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Relay valve malfunctioning. |
Clean or replace lines or relay valve. |
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Lubricate relay valve. |
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Exhaust flow restricted. |
Check for blocked or damaged |
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piping. Clean or replace piping. |
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Check for dirt or foreign material and |
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clean or remove. Check for ice build- |
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up. Melt ice and reduce moisture |
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build-up to starter. |
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Damaged motor assembly. |
Replace motor assembly. |
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Drive (57) will not engage. |
No pressure to drive housing port. |
Check air supply. |
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Internal drive housing ports blocked. |
Remove blockage. |
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Fluid in drive unit components. |
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Remove fluid. |
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Damaged or worn piston assembly |
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0D/H5250/94.08.12-08028 |
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(54), O-rings or seals. |
Replace damaged or worn parts. |
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O-rings and seals dry. |
Relubricate O-rings and seals. |
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Motor runs, pinion engages, but |
Damaged or broken drive train. |
Disassemble drive train and replace |
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does not rotate flywheel. |
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worn or damaged parts. |
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Excessive butt engagement. |
Damaged drive pinion (63) or |
Inspect drive pinion and flywheel |
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flywheel. |
and replace, if necessary. |
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Damaged starter drive (57) |
Inspect drive components and |
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components. |
replace worn or damaged parts. |
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Cont. .... |
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96.38 - ES0U-G

503.06 |
Trouble Shooting Guide for Turbine Starter |
Description |
Edition 01H |
Page 2 (2) |
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L23/30H
Trouble |
Possible Cause, see working card |
Trouble Shooting |
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Low air pressure. |
Check air supply. |
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Wrong drive pinion. |
Replace with proper drive pinion. |
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Oil blowing out of exhaust. |
Oil in air supply line. |
Inspect air line and remove source |
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of oil. |
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Splash deflector retaining screw (5) |
Install splash deflector retaining |
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or pipe plug missing. |
screw or pipe plug. |
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Worn or damaged rotor seals or |
Replace static seals on outside of |
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static O-rings. |
motor or send motor to Ingersoll |
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Rand to be rebuilt. |
Oil leaking from gear case (28). |
Worn or damaged O-rings. |
Replace O-rings. |
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Loose joints. |
Make sure that joints fit properly and |
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starter assembly cap screws are |
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tightened to 60 ft-lb (81 Nm) torque. |
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Make sure all seals and O-rings fit |
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and seal properly at their perimeters. |
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If they do not replace with new seals |
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and O-rings. |
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Excessive high-speed operation. |
Operate according to recommen- |
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dations. |
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High number of start cycles. |
Replace worn components. |
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Loose or leaking pipe plugs (10) or |
Tighten or replace pipe plugs using |
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(11). |
Ingersoll-Rand No SMB-441 pipe |
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sealant. |
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Splash deflector retaining screw |
Tighten splash deflector retaining |
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loose or pipe plug missing. |
screw or replace pipe plug. |
Air or gas leakage. |
Loose joints. |
Make sure that joints fit properly and |
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starter assembly cap screws are |
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tightened to 60 ft-lb (81 Nm) torque. |
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Make sure all seals and O-rings fit |
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and seal properly at their perimeters. |
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If they do not, replace with new |
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seals and O-rings. |
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Excessive high-speed operation. |
Operate according to recommen- |
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dations. |
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High number of start cycles. |
Replace worn components. |
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Loose or leaking pipe plugs. |
Tighten or replace pipe plugs. |
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Splash deflector retaining screw |
Tighten splash deflector retaining |
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loose or pipe plug missing. |
screw or replace pipe plug. |
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08028-0D/H5250/94.08.12
96.38 - ES0U-G

Description |
Trouble Shooting for Cooling Water System |
503.09 |
Page 1 (1) |
Edition 01H |
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Description
The built-on fresh water pump in the high tempera-ture (HT) circuit is of the centrifugal type and is mounted on the front cover of the engine and is driven through a gearing.
L23/30H
The pump bearings are lubricated automatically with oil from the lubricating oil system of the engine.
If the pump leaks and the shaft sealing rings are worn, it is recommended to replace the shaft seal, see working card 516-02.00.
08028-0D/H5250/94.08.12
Trouble |
Possible Cause |
Trouble Shooting |
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The pump does not work after |
Pump draws in air at suction side. |
Check packings and pipes for |
start. |
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tightness. |
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The system is not filled-up. |
Check the level in the expansion |
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tank. |
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Air cannot escape on delivery side. |
Vent the system. |
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Leaking shaft seal. |
Check the shaft seal. |
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Pump capacity drops after |
Air leakages of shaft seal. |
Overhaul the shaft seal. |
normal operation. |
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Fouled impeller. |
Clean the impeller. |
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Pump does not give maximum |
Suction valve not fully open. |
Open the suction valve. |
delivery. |
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Defective seals. |
Replace the seals. |
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Worn impeller and worn wear rings. |
Overhaul the pump. |
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Note! Running troubles with the pump, apart from mechanical faults, are most often due to leaks in the suction line. It is essential, therefore, that all packings and gaskets are in order and that they are renewed when necessary. Even a tiny hole in the suction line will reduce the pump capacity.
96.02 - ES0U-G