- •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
Working Card
Page 1 (3)
Inspection of Valve Roller Guides |
508-01.00 |
|
Edition 01S |
|
|
L23/30H
08028-0D/H5250/94.08.12
Safety precautions:
Stopped engine
Shut-off starting air □ Shut-off cooling water
Shut-off fuel oil
□ Shut-off cooling oil
Stopped lub. oil circul.
Description:
Dismounting. inspection and/or overhaul, and mounting of valve roller guides.
Inspection of roller guide housing.
Starting position:
Top cover for cylinder head and cover for fuel injection pump removed.
Related procedure: |
|
Inspection of fuel injection pump |
|
roller guide, |
508-01.05 |
Control and adjusting of valve |
|
clearance, |
508-01.10 |
Man power: |
|
|
|
Working time |
: |
2 hours |
|
Capacity |
: |
1 man |
|
Data: |
|
|
|
Data for pressure and tolerance |
(Page 500.35) |
||
Data for torque moment |
(Page 500.40) |
||
Declaration of weight |
(Page 500.45) |
||
Special tools: |
|
|
Plate no |
Item no |
Note |
52006 |
261 20 – 120 Nm |
|
Hand tools:
Ring and open end spanner, 19mm. Ring and open end spanner, 24mm. Socket spanner, 19 mm.
Socket spanner, 10 mm. Allen key, 3 mm.
Allen key, 10 mm. Ratchet spanner. Hammer.
Drift.
Replacement and wearing parts:
Plate no |
Item no |
Qty/ |
50801 |
185 |
4/cyl |
50801 |
220 |
2/cyl |
50801 |
232 |
1/cyl |
96.03-ES0S
508-01.00 |
Inspection of Valve Roller Guides |
Edition 01S |
|
|
|
Working Card
Page 2 (3)
L23/30H
Dismounting of Roller Guide.
1)Turn the engine so that the roller, rests on the circular part of the cam.
2)Unscrew the nuts which secure the rocket arm brackets, and lift off the rocker arm with brackets.
3)Remove the push rods (1), see fig 1.
Fig 1.
4)Loosen the lock screw for the push rod protecting tube, see plate 50801, item 207, on the roller guide top cover and lift up and remove the protecting tube (2).
5)Dismount the screws (3) which secure the roller guide top cover, take off the cover, the spring (7) and lift out the roller guide (5).
Disconnect any pipes that may be in the way (lub. oil and fuel oil pipes).
6)If the roller guide housing is to be dismantled, the fuel injection pump and the fuel injection pump roller guide are to be dismounted, see working card 514-01.05 and a number af lubricating oil and fuel oil pipes are also to be disconnected.
The roller guide housing (6) cannot be dismantled with the roller guides fitted.
7)If the event of any marks or scores from seizure, these must be polished away.
8)Inspect the spherical stud for deformations (replace as necessary).
Examine the surface of the roller for marks and other deformations.
Make sure that there is free ply between the roller and the bush and the shaft pin, and replace the bush, if necessary.
Replacement of Roller, Bush and Shaft Pin.
9)Remove the lock screw which secures the roller guide shaft pin and push out the shaft pin.
The roller, shaft pin, and bush can now be replaced as required.
10)Blow through the lubricating ducts in roller guide and roller guide housing, and clean the lubricating grooves.
Mounting of Roller Guide.
11)When assembling the parts, which is carried out in the reverse order to the above care must be exercised not to damage the o-rings when mounting the protecting tube.
12)Adjusting of valve clearance, see working card 508-01.10.
96.03-ES0S
08028-0D/H5250/94.08.12
Working Card
Page 3 (3)
Inspection of Valve Roller Guides |
508-01.00 |
|
Edition 01S |
|
|
L23/30H
13)When the roller guide housing(6) to be replaced into a new part, special care should be done at the mounting checking the contact surface between each cam & roller to give a smooth rolling motion. especially for the alignment of center line between cam shaft and roller guide housing.
08028-0D/H5250/94.08.12
96.03-ES0S
1999.11.16-S.H.B(No. 13) note to be added by S S H1
Working Card
Page 1 (2)
Inspection of Fuel Injection Pump Roller Guide |
508-01.05 |
|
Edition 01S |
|
|
L23/30H
08028-0D/H5250/94.08.12
Safety precautions:
Stopped engine
Shut-off starting air □ Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.
Description:
Dismounting. inspection and/or overhaul, and mounting of roller guide for fuel injection pump.
Starting position:
Cover for fuel injection pump removed. Fuel injection pump has been removed,
Related procedure:
Adjustment and/or check of max.
combustion pressure, |
514-01.20 |
Man power: |
|
|
|
Working time |
: |
1/2 hour |
|
Capacity |
: |
1 man |
|
Data: |
|
|
|
Data for pressure and tolerance |
(Page |
||
|
|
|
500.35) |
Data for torque moment |
(Page |
||
|
|
|
500.40) |
Declaration of weight |
(Page |
||
|
|
|
500.45) |
Special tools:
Plate no Item no |
Note |
Hand tools:
Allen key, 3 mm.
Hammer.
Drift.
Replacement and wearing parts:
Plate no Item no |
Qty/ |
96.03-ES0S
508-01.05 |
Inspection of Fuel Injection Pump Roller Guide |
Edition 01S |
|
|
|
Working Card
Page 2 (2)
L23/30H
Dismounting of Roller Guide.
1)Remove the support ring (1) and spring (2) and take up the roller guide (3), see fig 1.
Fig 1.
Inspection of Roller Guide.
2)If the event of any marks or scores from seizures, these must be polished away.
3)Inspect he spherical stud for deformations (replace as necessary).
Examine the surface of the roller for marks and other deformations.
Make sure that there is free ply between the roller and the bush and the shaft pin, and replace the bush if necessary.
Replacement of Roller, Bush and Shaft Pin.
4)Remove the lock screw which secures the roller guide shaft pin anti push out the shaft pin.
The roller, shaft pin, and bush can now be replaced as required.
5)Blow through the lubricating ducts in roller guide and roller guide housing, and clean the lubricating grooves.
Mounting of Roller Guide.
6)When assembling the parts which is carried out in the reverse order.
7)For adaption of the thrust piece of the roller guide, see working card 514-01.20.
8)When the roller guide housing(6) to be replaced into a new part, special care should be done at the mounting checking the contact surface between each cam & roller to give a smooth rolling motion, especially for the alignment of center line between cam shaft and roller guide housing.
08028-0D/H5250/94.08.12
96.03-ES0S
1999.11.16-S.H.B(No. 8) note to be added by S S H1
Working Card |
Control and Adjusting of Valve Clearance |
508-01.10 |
Page 1 (3) |
Edition 01H |
|
|
|
|
|
|
|
|
|
L23/30H |
08028-0D/H5250/94.08.12
Safety precautions:
Stopped engine
Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.
Description:
Control and/or adjusting of valve clearance.
Starting position:
Cover for rocker arm are removed.
All indicator valves open.
Related procedure:
Manpower: |
|
|
|
Working time |
: |
1/4 |
hour |
Capacity |
: |
1 |
man |
Data: |
|
|
|
Data for pressure and tolerance |
(Page 500.35) |
Data for torque moment |
(Page 500.40) |
Declaration of weight |
(Page 500.45) |
Special tools: |
|
|
Plate no |
Item no. |
Note |
52008 |
022 |
Exhaust |
52008 |
010 |
Inlet |
52010 |
011 |
|
Hand tols:
Ring and open end spanner, 24 mm. Big screw driver.
Replacement and wearing parts:
Plate no |
Item no |
Qty/ |
See also plate 50502.
96.38 - ES0S
508-01.10 |
Control and Adjusting of Valve Clearance |
Working Card |
Edition 01H |
Page 2 (3) |
|
|
|
|
|
|
|
L23/30H |
|
|
Adjusting of Inlet Valve Clearance.
1)Turn the engine so that the roller, rests on the circular part of the cam, i.e. the inlet valves and the exhaust valves are closed.
2)Loosen the adjustment screws on valve bridge and rocker arm, see fig 1.
Fig. 1.
3)Clearance between valve bridge and valve spindle, see page 500.40.
4)Place the feeler gauge marked with "correct" 0,50 mm above the valve spindle nearest to the rocker arm bracket, see fig 1.
5)Adjust the clearance between valve bridge and valve spindle by means of the adjustment screw on the rocker arm (above the push rod) and tighten the lock nut.
Fig 2.
The feeler gauge is to remain in this position when adjusting the clearance of the other valve.
6)Place another feeler gauge, at the same size 0,50 mm above the other valve spindle, see fig 2.
7)Adjust the clearance between valve bridge and valve spindle by means of the adjusment screw on the valve bridge, and tighten the lock nut, see fig 2.
8)Check that the clearance is correct simultaneously at both valve spindles.
Adjusting af Exhaust Valve Clearance.
08028-0D/H5250/94.08.12
96.38 - ES0S
Working Card |
Control and Adjusting of Valve Clearance |
508-01.10 |
Page 3 (3) |
Edition 01H |
|
|
|
|
|
|
|
|
|
L23/30H |
9)Carry out adjustment in the same way as described for the inlet valves, but using the feeler gauge for exhaust valve clearance 0,90 mm.
10)The feeler gauges for checking the clearance have two gauges which are marked "incorrect" and "correct", the latter to be used when adjusting the valve clearance, see fig 3.
After tightening up the counter nuts on rocker arms and valves bridge, be sure that the feeler gauges marked "correct" can be inserted into the two clearances simultaneously as where it must not be possible to insert the gauges marked "incorrect".
Fig 3.
08028-0D/H5250/94.08.12
96.38 - ES0S