Technical Documentation

Engine
Working Instructions B2

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 7L 58/64 CD

Works No. . . . . . . . . . . . . . . . . . . . . . . . . 1 110 467

Plant No. . . . . . . . . . . . . . . . . . . . . . . . . . 4010356

6722-- 1
MAN Diesel SE : D-86224 Augsburg : Telefon (0821) 3 22-0

10356 B2--01 E 10.07 101/ 02

. 2007 MAN Diesel SE

All copyrights reserved for reprinting, photomechanical reproduction (photocoying/microcopying) and translation of
this documents or part of it.

10356 B2--01 E 10.07 102/ 02

Table of contents

N 1 Introduction

: : : N 1.1 Preface
1.2 How the working instructions/work cards are organised, and how to use
: : : N them
: : : N 1.3 Status/availability Required tools/appliances

N 2 Work cards, arranged by subjects/key words

N 3 Work cards, arranged by subassembly groups

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6722 10.07 L 58/64 CD 101 /01

Introduction

1 Introduction

2 Work cards,
arranged by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 1--02 E 08.97 101/ 01

Table of contents

N 1 Introduction

: : : N 1.1 Preface
1.2 How the working instructions/work cards are organised, and how to use
: : : N them
: : : N 1.3 Status/availability Required tools/appliances

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6722 10.07 L 58/64 CD 101 /01

Preface 1.1

Work cards and maintenace The working instructions/work cards are closely related to the maintenance
schedule schedule of the engine contained in Volume B1 of the technical
documentation. The latter briefly specifies the maintenance work to be
done, whereas this volume gives a step-by-step description, with
illustrations, of the operating sequences required to maintain the
operational reliability and efficiency of the engine. The work cards have an
introductory part describing the purpose of the work, and contain
information also stating which tools and appliances are required. For most
of the jobs, several work cards have to be consulted.

Work cards serve the particular prupose of providing essential information

in concise form.

Ordinal system Work cards have in the first part been arranged by subjects/key words; in
the second part, the order follows the subassembly group system of the
engine. Both parts contain indices giving the contents of work cards that
concern your engine.

6682 1.1--01 E 08.07 General 101/ 01

How the working instructions/work cards
are organised, and how to use them 1.2

Structure Work cards contain the following information as a rule:

- Notes on the purpose of the jobs to be done,
- on the relevant work cards, i.e. those work cards containing further
essential or useful information,
- on the necessary tools and appliances,
- any supplementary details/technical data and
- the individual operating sequences, starting in each case with the
original condition and followed by the individual working steps.
Tools are marked with the tool number in illustrations and texts; other parts
are marked with their item number.

Numbering The ordinal number of the work cards - on top at the right - is composed of
the three-digit subassembly group number (or of a neutral numerical
combination) and a counting number, for example:

021. 02

Counting number (card 2)

Subassembly group (crankshaft)

How to find the work cards The work cards are contained in the lists of Section 2 and 3. The list, Part
required 1 is a summary of work cards by subjects/key words, the list, Part 2
contains working instructions arranged in an order following the
subassembly group system of the engine.

Access to the ordinal system of the list, Part 3 is ensured by the

subassembly group list. Illustrated by a cross section and a longitudinal
section of the engine, it lists the subassembly group numbers in tabulated
form, respresenting the order in which the work cards of this section have
been arranged.

Safety notes Text passages in italic type draw the attention to dangers sources of
failure, technical necessities, supplementary information. The following are
used:

▲▲▲ Danger! Imminent danger.

Possible consequences: Death or most severe injuries, total damage
to property.

▲▲ Caution! Potentially dangerous situation.

Possible consequences: Severe injuries.

▲ Attention! Possibly dangerous situation.

Possible consequences: Slight injuries, possible damage to
property.

Important! For calling attention to error sources/handling errors.

Tip! For tips regarding use and supplementary information.

6682 1.2--01 E 08.97 General 101/ 02

Clearances and tolerances Clearances and tolerances, temperatures and pressures are contained in
temperatures and pressures Section 2.5, Volume B1.

Values for the tightening of bolted connections and the appropriate

000.29, 000.30 and 000.31
lubricants are contained in work cards 000.29 000.31.

Ordering tools Information concerning the ordering of tools or parts of these is given in
Section 3.4 of Volume B1, or in the spare parts catalogue B3.

6682 1.2--01 E 08.97 General 102/ 02

Status/availability
Required tools/appliances 1.3

Tools/appliances In the opening paragraphs of the work cards, the tools/appliances required
for the maintenance work described therein are listed under the item
Tools/appliances required. See example in Table 1 .

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 322.056 Optional
2 Bracket 322.056--1 Optional
1 Ledge 322.056--4 Optional
4 Shackle A0.6 002.452 Standard
1 Open--jaw and ring wrenches (Set) -- Inventory
1 Hexagon screw drivers (Set) -- Inventory
1 Lifting tackle with rope -- Inventory
Table 1. Example:: List of required tools/appliances

Status/availability Besides the required quantity, the designation and the tool number, the
table contains information regarding status/availability of the listed tools.
The following terms are used in this connection:
- Inventory . . . means that a tool/appliance is not part of the standard
scope of supply. In principle, we take it for granted that such tools/ap-
pliances are available.
- Optional . . . . means that a tool/appliance is not part of the standard
scope of supply. Such tools are supplied by MAN Diesel SE on re-
quest.
- Standard . . . means that a tool/appliance is included in the scope of
supply for the engine plant as a standard or is considered to be
standard workshop equipment.
Basic tools The basic tool characterised as standard is not part of the standard scope
of supply of MAN Diesel SE. On request, the scope of supply can be ex-
tended by the basic tool. The components of the basic tools are listed in
the following Table 2 .

6682 1.3--02 E 01.07 General 101/ 05

Tool Designation Number

Set of basic tools, complete 009.229

Set of socket wrench inserts (10x12,5 to 34x12,5) 009.230

Socket wrench insert DIN 3124 -- 10x12,5 001.787

Socket wrench insert DIN 3124 -- 11x12,5 001.751
Socket wrench insert DIN 3124 -- 12x12,5 001.788
Socket wrench insert DIN 3124 -- 13x12,5 001.752
Socket wrench insert DIN 3124 -- 14x12,5 001.753
Socket wrench insert DIN 3124 -- 15x12,5 001.789
Socket wrench insert DIN 3124 -- 16x12,5 001.790
Socket wrench insert DIN 3124 -- 17x12,5 001.754
Socket wrench insert DIN 3124 -- 18x12,5 001.798
Socket wrench insert DIN 3124 -- 19x12,5 001.755
Socket wrench insert DIN 3124 -- 21x12,5 001.799
Socket wrench insert DIN 3124 -- 22x12,5 001.756
Socket wrench insert DIN 3124 -- 24x12,5 001.757
Socket wrench insert DIN 3124 -- 27x12,5 001.758
Socket wrench insert DIN 3124 -- 30x12,5 001.759
Socket wrench insert DIN 3124 -- 32x12,5 001.760
Socket wrench insert DIN 3124 -- 34x12,5 001.769
Socket wrench insert DIN 3124 S -- 36x20 001.779
Socket wrench insert DIN 3124 S -- 41x20 001.780

Cross handle DIN 3122 A -- 12,5 001.891

Extension DIN 3123 B -- 12,5x75 001.908

Extension DIN 3123 B -- 12,5x125 001.911
Extension DIN 3123 B -- 12,5x250 001.912

Universal joint DIN 3123 C -- 12,5 001.876

6682 1.3--02 E 01.07 General 102/ 05

Tool Designation Number

Ratchet DIN 3122 C -- 12,5 001.521

Set of combination wrenches (5,5 to 34) 009.231

Combination wrench DIN 3113 AK -- 5,5 002.050

Combination wrench DIN 3113 AK -- 6 002.051
Combination wrench DIN 3113 AK -- 7 002.020
Combination wrench DIN 3113 AK -- 8 002.021
Combination wrench DIN 3113 AK -- 9 002.052
Combination wrench DIN 3113 AK -- 10 002.023
Combination wrench DIN 3113 AK -- 11 002.053
Combination wrench DIN 3113 AK -- 12 002.054
Combination wrench DIN 3113 AK -- 13 002.024
Combination wrench DIN 3113 AK -- 14 002.055
Combination wrench DIN 3113 AK -- 15 002.025
Combination wrench DIN 3113 AK -- 16 002.056
Combination wrench DIN 3113 AK -- 17 002.026
Combination wrench DIN 3113 AK -- 18 002.057
Combination wrench DIN 3113 AK -- 19 002.027
Combination wrench DIN 3113 AK -- 20 002.058
Combination wrench DIN 3113 AK -- 21 002.059
Combination wrench DIN 3113 BL -- 22 002.070
Combination wrench DIN 3113 BL -- 24 002.071
Combination wrench DIN 3113 BL -- 27 002.072
Combination wrench DIN 3113 BL -- 30 002.073
Combination wrench DIN 3113 BL -- 32 002.074
Combination wrench DIN 3113 BL -- 34 002.075

Single ended open-jaw wrench DIN 894 -- 36 000.566

Single ended open-jaw wrench DIN 894 -- 41 000.567
Single ended open-jaw wrench DIN 894 -- 46 000.568
Single ended open-jaw wrench DIN 894 -- 50 000.569

Screw driver with hexagon A 8.06506 -- 0,8x5,5 000.391

Screw driver with hexagon A 8.06506 -- 1,2x9 000.393
Screw driver with hexagon A 8.06506 -- 2x12 000.395

6682 1.3--02 E 01.07 General 103/ 05

Tool Designation Number

Screw driver for recessed-head screws

DIN 5262 B-Gr. -- 1 000.401
Screw driver for recessed-head screws
DIN 5262 B-Gr. -- 2 000.402

Hexagon screw driver DIN 911 -- 3L 000.307

Hexagon screw driver DIN 911 -- 4 000.293
Hexagon screw driver DIN 911 -- 5 000.294
Hexagon screw driver DIN 911 -- 6 000.295
Hexagon screw driver DIN 911 -- 8 000.297
Hexagon screw driver DIN 911 -- 10 000.298
Hexagon screw driver DIN 911 -- 12 000.299
Hexagon screw driver DIN 911 -- 14 000.300
Hexagon screw driver DIN 911 -- 17 000.301
Hexagon screw driver DIN 911 -- 19 000.302

Tommy bar DIN 900 A -- 5 000.507

Tommy bar DIN 900 A -- 8 000.262
Tommy bar DIN 900 A -- 10 000.263
Tommy bar DIN 900 A -- 12 000.264
Tommy bar DIN 900 A -- 16 000.266

Adapter DIN 3123 A -- 20x12,5 001.923

Adapter DIN 3123 A -- 12,5x20 001.927

Pliers for retaining rings DIN 5254 A -- 10-25 002.121

Pliers for retaining rings DIN 5254 A -- 19-60 002.122

6682 1.3--02 E 01.07 General 104/ 05

Tool Designation Number

Pliers for retaining rings DIN 5256 C -- 19-60 002.162

Pliers for retaining rings DIN 5256 C -- 40-100 002.163

Feeler gauge DIN 2275 C -- 0,05-1 000.451

Crow bar S 550 A -- 15 001.391

Gripping pliers with slip joint DIN 5231 D-L -- 240 002.198

Hammer DIN 1041 -- 300L 000.693

Tool box, 5-parts, 530x200x200 009.470

Table 2. Basic tools

6682 1.3--02 E 01.07 General 105/ 05

Work cards,
arranged by subjects/key words

1 Introduction

2 Work cards,
arranged by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 2--02 E 08.97 101/ 01

Table of contents

N 001 Operating media systems/Pipes

000.03 Operating media systems

: : N Flushing and cleaning
000.08 Cooling water system
: : N Cleaning
000.15 Pipes
: : N Replacement
000.16 Pipes
: : N Cleaning, Acid Bath Treatment and Preservation
000.17 Solderless screwed pipe unions
: : N Mounting
000.18 Solderless screwed pipe unions
: : N Additional parts

N 002 Operating media/Auxiliary agents

000.04 Lubricating oil

: : N Assessing and treating
000.05 Lube oil/fuel
: : N Carry out drop test
000.07 Cooling water
: : N Checking
000.14 Engine or components
: : N Preservation treatment
000.19 Loctite Products
: : N Use

N 003 Machine elements

000.11 Galvanized bearings

: : N Assessing
000.11 Deep--groove bearing
: : N Assessing

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6722 10.07 L 58/64 CD 101 /03

 000.11 Bimetal bearings (without a third layer)
: : N Assessing
000.21 Seals made from elastomer
: : N Storage, cleaning, mounting
000.22 Threaded inserts
: : N Use
000.29 Tightening of bolted connections
: : N Tightening torques (illustrated)
000.30 Tightening of bolted connections
: : N Tightening torques (table)
000.31 Tightening of bolted connections
: : N Tightening torques (turning moment)
000.32 Tightening of bolted connections
: : N General remarks
000.34 Surface examination by means of
: : N penetration methods
000.34 Surface examination by means of
: : N Magnetic leakage flux methods

N 004 Hydraulic tensioning tools/ High--pressure pump

000.33 Working and safety regulations

: : N Using high--pressure tools/ hydraulic tensioning tools
009.03 High--pressure pump
: : N Use
009.05 High--pressure hoses
: : N Use
009.06 Dial gauge (measuring device)
: : N Checking the bolt elongation
009.01 Hydraulic tensioning tool (single)
: : N Use
009.02 Hydraulic tensioning tool (single)
: : N Checking, Renewing the seal rings
009.07 Hydraulic tensioning tool
: : N Use
009.08 Hydraulic tensioning tool
: : N Disassembling and assembling
009.09 Hydraulic tensioning tool (tandem)
: : N Use
009.10 Hydraulic tensioning tool (tandem)
: : N Disassembling and assembling
009.11 Hydraulic tensioning tool (single)
: : N Use
009.12 Hydraulic tensioning tool (single)
: : N Venting, checking, replacing of sealing rings
009.13 Hydraulic tensioning tool (tandem)
: : N Use

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6722 10.07 L 58/64 CD 102 / 03

 009.14 Hydraulic tensioning tool (single)
: : N Use
009.16 Hydraulic tensioning tool (single)
: : N Disassembling and assembling
009.17 Hydraulic tensioning tool (single)
: : N Use
009.18 Hydraulic tensioning tool (single)
: : N Disassembling and assembling

N 005 Operating data/Operating results

000.25 Ignition and compression pressures

: : N Determination
000.40 Charge air cooler/crankcase
: : N Measuring the differential pressure

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6722 10.07 L 58/64 CD 103 /03

Operating media systems/Pipes

001 Operating media systems/pipes

002 Operating media/auxiliary agents
003 Machine elements
004 Hydraulic tensioning tools/high-pressure pump
005 Operating values/operating results

6682 001--01 E 08.97 101/ 01

Operating media systems
Flushing and cleaning 000.03

Purpose of jobs to be done

Keep operating media systems free from contamination and residues,

prevent operating problems/damage.

Brief description

Operating media systems are to be flushed prior to putting the engine into
operation, individual parts are to be cleaned. This applies to the systems
for lube oil, fuel, cooling water and compresssed air and includes,
depending on the system:
Flushing of system(s) (step 1),
flushing of system(s) (step 2),
draining of system(s) and
cleaning of components.

1. Lube oil system

The pipe section between the indicator filter and the engine admission
flange requires careful cleaning. To permit full visual inspection of the in-
side of this pipe it should be interrupted at each pipe elbow by a pair of
flanges. Any weld seams on the inside have to be ground smooth as a
matter of principle.
000.16, the individual sections of this pipe have
As described in work card 000.16
to be pickled, neutralized and treated with an anti-corrosion oil that is dis-
solved by the lube oil to be filled in later on (e.g. Esso Rustban No. 335,
Shell Ensis Oil, Valvoline Tectyl, Tecto 6 SAE 30). Unless installed immedi-
ately, openings have to be closed by covers. Our personnel in charge of
commissioning has been instructed to check this pipe for cleanliness prior
to filling the system.

▲ Attention! Dirt particles penetrating into the engine interior may

cause serious damage to bearings!
1.1 Flushing the engine lubricating oil system
Despite careful installation and cleaning, some dirt particles will inevitably
remain in the pipelines. Therefore, the entire lubricating oil system has to
be thoroughly flushed prior to initial operation of the engine. On engines
with an engine-mounted lube oil pump, the electrical standby pump or the
priming pump has to be used for this purpose.
1.2 Flushing oil
For the flushing process, we recommend using a special flushing oil of a
low viscosity of 45-70 cSt / 40 ƒ C (e.g. SAE 20) which, being highly fluid,
need not be preheated.
Where flushing oil is not available, the SAE 40 oil intended to be later used
in operation can be used. In this case, the oil has to be preheated to
40-50 ƒ C (preheating equipment, separator preheater). The engine cooling

6682 000.03--01 E 01.07 General 101/ 06

 water has simultaneously to be heated to not less than 60ƒ C so as to pre-
clude condensed water formation (which means corrosion in the crank-
case).
Continuous cleaning of the oil by means of a filter and separator is re-
quired during and after the flushing process.
1.2.1 First stage of flushing process
In this operation only the piping system outside the engine is being
flushed.
The lube oil admission on the engine has to be bypassed. A provisional
line is to be installed from the indicator filter to the crankcase which serves
as the return pipe.

Automatic filter without continu- The filter rod elements of the automatic filter are to be removed, the filter
ous flushing casing and the filter bypass lines are to be included in the flushing pro-
cess.

Automatic filter with continuous The filter rod elements of the automatic filter are to be removed, the filter
flushing casing and the filter bypass lines are to be included in the flushing pro-
cess.
In case an indicator filter is not connected in series, the filter rod elements
are not to be removed. In this case, precleaning by an indicator filter is
not possible so that the automatic filter is already to be used for cleaning
during the first flushing process. As the automatic filter routes the dirt par-
ticles back to the tank, the separator alone, which is also in operation,
causes the dirt particles to be removed from the oil circuit.
The lube oil cooler is also to be included in the flushing process. Manual
operation of the temperature control valve will alternately flush the cooler
or its bypass line. The lube oil separator is to be taken into operation.
During the entire flushing process, all the oil-carrying lines are to be
sounded by tapping, particularly in the region of weld seams.

Oil circuit with indicator filter When the maximum differential pressure has been reached in the indicator
filter, switch over to the other filter chamber and appropriately clean the
strainer elements. When filter contamination has been reduced to a mini-
mum, this first flushing stage can be terminated.
However, a minimum flushing period of 24 hours must be ensured.
On completion of the flushing process, the strainer elements of the indica-
tor filter have to be cleaned and checked for possible damage.

Oil circuit without indicator filter In this case, the filter rod elements remain in the automatic filter because
cleaning is only effected by the latter. Flushing is to be continued until
filter contamination has been reduced to a minimum, i.e. until the flushing
intervals of automatic filters without continuous flushing have been re-
duced to one flushing cycle per hour at maximum and the indicated differ-
ential pressure of automatic filters with continuous flushing has been re-
duced to the minimum.
However, a minimum flushing period of 24 hours must be ensured.

Important! In case a run-in filter is fitted on the engine, the differen-

tial pressure of this filter has to be monitored continuously and the filter
cleaned, if necessary.
The inserts with filter rod elements are to be installed in the automatic filter
(in case they have been removed), the slide for the bypass line is to be
closed.
1.2.2 Second stage of flushing process
Following installation of the filter element rods in the automatic filter, flush-
ing is to be continued for approx. 2 hours.
Mounting the pipeline (in clean condition) from the indicator filter to the
lube oil inlet on the engine results in the engine with its bearing points and

6682 000.03--01 E 01.07 General 102/ 06

 spray nozzles being included in the flushing process. Moreover, the oil
tank for run-down lubrication (if applicable) is to be included in the flushing
circuit.
To remove the dirt that may have collected in the run-down lube oil tank,
the oil inlet/oil outlet pipelines should be crossed. Provisional, short hoses
are to be installed for this purpose. The oil admission to the turbocharger
is to be blocked. The orifice plate installed in the admission line is to be
removed. The pressure regulating valve is to be unloaded.
During flushing, the engine is to be turned by two revolutions each at
30-minute intervals. The cylinder lube oil pump must not be switched on
except during the turning cycles.
When there are but minor differential pressures building up in the auto-
matic and indicator filters (one flushing cycle per hour), the flushing pro-
cess may be terminated.
However, a minimum flushing period of 12 hours must be ensured.

Important! In case a run-in filter is fitted on the engine, the differen-

tial pressure of this filter has to be monitored continuously and the filter
cleaned, if necessary.
Reconnect the pipelines that were dismantled.
Flushing processes are to be carried out under the supervision of person-
nel of MAN Diesel SE.
1.3 Draining and cleaning of system components
In case a special flushing oil was used, the entire lube oil system has to be
thoroughly drained. The remainders in the cooler, the filter and the separa-
tor preheater are to be drained via the drain pipes. Filter inserts have to be
appropriately cleaned and checked for possible damage.
In case the lubricating oil also used for engine operation was used for
flushing, draining of the system can be dispensed with provided the oil
analysis is satisfactory.
1.4 Run-in filter
If necessary, a run-in filter is mounted directly on the engine. The inserts in
the run-in filter are used for a period commencing when the test run at the
engine manufacturer’s works is carried out and lasting until the commis-
sioning period at the plant is terminated.
The filter insert is to be cleaned according to the manufacturer’s instruc-
tions before it is used.
As the run-in filter does not have a change-over cock, a limited service life
will result in operation (up to approx. 200 operating hours, depending on
the condition of the lube oil). The end of the service life is indicated by a
differential pressure transmitter on the run-in filter. Prolonged operation
with the contamination indication released may result in problems with the
lubricating oil supply. For this reason, increased attention is to be paid to
the lube oil pressure before the engine if the differential pressure alarm is
on, and the filter insert is to be cleaned as soon as possible, according to
the manufacturer’s instructions.
After the system-running-in period (after completion of commissioning as a
rule) -- in any case, before starting continuous operation of the
plant -- the filter insert is to be removed. The filter casing remains on the
engine. After removal of the filter insert, the run-in filter does no longer
have any effect. This is indicated by a corresponding notice on the filter
casing.
In case modifications are carried out in the lube oil system requiring flush-
ing of the same, or if flushing the system becomes necessary for other
reasons, the filter insert has to be re-installed and has to remain in the
filter casing until the flushing process has been completed.

6682 000.03--01 E 01.07 General 103/ 06

2. Fuel delivery system

What has been specified for the lube oil pipe described under item 1 also
applies to the pipe fitted between the duplex filter to be installed immedi-
ately upstream of the engine and the engine entry.
2.1 Flushing the fuel oil system
In order to remove all of the dirt accumulated in the pipelines during erec-
tion, this system also has to be subjected to two-stage flushing, for which
gas oil or Diesel fuel oil has to be used.
2.1.1 First stage of the flushing process
In this stage of the flushing process, the entire piping system, i.e. that
installed by the shipyard and the plant-related system, is being flushed via
the existing simplex or duplex filter.
The automatic filter and the viscosity control system are to be bypassed
via their bypass lines.
The shut-off valves of all the injection pumps are to be closed.
The fuel supply and return pipes are to be connected by a provisional pipe
section at the last cylinder. Switch-over of the three-way cock installed up-
stream of the mixing tank provides for a return via the flushing line to the
HFO service tank. For this reason, the tank should not yet contain any
heavy fuel oil at this stage. In this case, the three-way cock for fuel selec-
tion may be switched to fuel supply from that tank, after the system has
been filled up with Diesel fuel oil or gas oil respectively, and an adequate
amount of this fuel has returned to the HFO service tank. The Diesel fuel
oil or gas oil is in that way circulated through the entire system.
The flushing process is to be carried out as described under item 1.3.1.
Based on experience, a flushing time of 24 hours is prescribed.
2.1.2 Second stage of the flushing process
The entire system including automatic filter and viscosity control system
are involved in this flushing operation.
Flushing has to be continued until but minor differential pressures are
building up in the filters.
On termination of this flushing operation, all the filter inserts are to be
cleaned and checked for possible damage. The shut-off valves of the in-
jection pumps are to be opened, the bypass line of the viscosity control
system is to be closed. All the pipelines that had been dismantled are to
be reconnected (in cleaned condition).
On completion of the second stage of the flushing process which, as pre-
vious experience has shown, takes approx. 6 hours, the shut-off valves of
the fuel oil pumps are to be opened.
The flushing operations are to be performed under the supervision of per-
sonnel of MAN Diesel SE.
2.2 Draining and cleaning of system components
The final preheater, the filter chambers and the mixing tank are to be emp-
tied from sludge via their drain pipes. After a settling time of 24 hours,
sludge is also to be removed from the service tank.

6682 000.03--01 E 01.07 General 104/ 06

3. Cooling water system

Prior to initial operation of the engine and injection valve cooling system it
must be ensured that the surfaces contacted by the cooling water are free
from corrosion and other deposits.
Where spots of corrosion are found, the system has to be cleaned as de-
000.16.
scribed in work cards 000.08 and 000.16
The cooling water system is to be flushed with freshwater prior to initial
operation of the engine. A cleanser should be added to the water to en-
sure that any traces of the preservation agent used are removed. Table 1
lists some suitable cleansers in alphabetical order. Cleansers of other
makes may be used provided that they have properties equivalent to the
agents listed. Following the cleansing operation, the system is to be
flushed with plain freshwater.
For filtering out the coarse dirt particles, the provisional installation of dirt
traps is indispensable. The mesh width has to be 1 mm for the high-
temperature and low-temperature systems.
The smallest gap in the injection valve is 0.5 mm. To avoid that dirt par-
ticles can deposit there, resulting in a reduced heat dissipation, provisional
installation of a dirt trap having a mesh width of $ 0.4 mm is required for
flushing of the cooling water system for the injection valves.
By installing two shut-off slide valves each, any leakage of water during
cleaning or the removal of the dirt traps is prevented.
Following the flushing operation, the freshwater is to be treated in
accordance with the quality requirements for cooling water (Operating
instructions, sheet 3.3.7).

Supplier Product Concentration Duration of cleaning/temperature

Drew HDE - 777 2 - 5% 4 hrs at 50 - 60 ƒ C
Unitor Seaclean 0.5% 4 hrs at 50 - 60 ƒ C *
Vecom Ultrasonic 4% 12 hrs at 50 - 60 ƒ C
Multi Cleaner
* Can also be used for short-term engine operation.
Table 1. Cleansers for the removal of oil-containing residues

4. Compressed air system

4.1 Plant-specific system

The entire system has to be carefully cleaned prior to initial engine opera-
tion. The inside of all the compressed-air and control pipes must be free
from combustible media, slag, scale and corrosion.

▲▲ Caution! The presence of combustible media, i.e. anti-cor-

rosion oil, constitutes an explosion hazard!
Cleaning the air pipes is effected by purging them three to four times,
using the 30-bar compressed air from the starting air receivers.
The plant-specific pipeline has for this purpose to be disconnected from
the main starting valve and the engine entry which then is exposed has to
be closed off. The control air pipe upstream of the engine is also to be
removed.

▲ Attention! Purging causes high-level noise! Make sure to wear

ear muffs!
On completion of the cleaning procedure, all pipelines that have been dis-
mantled must be reconnected.

6682 000.03--01 E 01.07 General 105/ 06

 4.2 Engine-specific system
In case there are any doubts as to whether or not the pipelines are free
from combustible media (e.g. anti-corrosion oil), the following steps are to
be carried out before the emergency start valve/main starting valve is
actuated “live” for the first time:
1. Dismantle the starting pipe upstream of the first cylinder and check it
in both directions for the presence of combustible media.
2. Remove the starting valves, and purge the air route towards the pipe
opening.
3. After the main starting valve, provide a connection for compressed
air, and purge the pipeline/spaces towards the cylinder, gently at the
beginning, for an extended period of time (using the contents of sev-
eral air bottles).
▲ Attention! Purging causes high-level noise! Make sure to wear
ear muffs!

▲▲ Caution! The presence of combustible media, i.e. anti-cor-

rosion oil, constitutes an explosion hazard!
4. Leave the pipelines open for 24 hours so that the solvent residues
can evaporate.
5. Install the starting valves, and restore the initial state.

6682 000.03--01 E 01.07 General 106/ 06

Cooling water system
Cleaning 000.08

Purpose of jobs to be done

Free operating media systems from contamination/residues,

ensure/restore operational reliability.

Brief description

Cooling water systems that show contamination or deposits impede

effective component cooling and may endanger a stable emulsion of water
and anti--corrosion oil. Contamination and deposits are to be removed at
regular intervals.
This includes:
cleaning of systems and, if necessary,
removing calcareous deposits,
flushing of systems.

Cleaning

The cooling water system has to be checked for contamination at the

specified intervals. If heavily fouled, immediate cleaning is necessary. This
work should preferably be done by a specialist firm which will provide the
cleansers suitable for the particular type of deposits and materials used in
the cooling system. Only in the event that procurement of the services of a
specialist firm is not possible, the cleaning should be performed by the
engine operator.
Oil sludge Oil sludge produced by lube oil entering the cooling system or by an
excessive concentration of anti-corrosion agents can be removed by
flushing with fresh water, with some cleaning agent being added. Table 1
lists appropriate agents in alphabetical order. Products of other
manufacturers may be used provided their properties are comparable. The
manufacturer’s instructions for use are to be strictly observed.

Manufacturer Product Concentration Duration of cleaning procedure /

temperature
Drew HDE - 777 4 - 5% 4 hrs at 50 - 60 •C
Nalfleet Maxi-Clean 2 2 - 5% 4 - 6 hrs at 60 •C
Unitor Aquabreak * 0.05 - 0.5% 4 hrs at ambient temperature
* Can also be used in case of short engine operating periods
Table 1. Cleaning agents for removing oil sludge

Calcareous and rust deposits Calcareous and rust deposits may form if excessively hard water or too
low a concentration of anti-corrosion agent has been used in operation. A
thin layer of scale need not be removed as, according to experience, this
provides protection against corrosion. Calcareous layers of > 0.5 mm in
thickness, however, will impede the heat transfer to an extent which
results in thermal overloading of the components to be cooled.
Rust in the cooling system adversely affects the stability of the emulsion in
case anti-corrosion oil is being used for cooling water trreatment.
Washed-off rust particles can act like an abrasive (e.g. on the sealing

6682 000.08--01 E 03.06 General 101/ 02

 elements of the water pumps). Together with the water hardness
constituents, they form so-called iron sludge which settles predominantly
in areas of low flow rates.
In general, products used for dissolving calcareous scale deposits are also
suitable for removing rust. Table 2 lists appropriate agents in alphabetical
order. Products of other manufacturers may also be used as long as their
properties are comparable. The manufacturer’s instructions for use are
likewise to be strixctly observed. Prior to cleaning, check whether the
agent concerned is suitable for the materials to be cleaned. The agents
listed in Table 2 are also suitable for stainless steel.

Manufacturer Product Concentration Duration of the cleaning procedure /

temperature
Drew SAF-Acid 5 - 10% 4 hrs at 60 - 70 •C
Descale-IT 20% 4 hrs at 60 - 70 •C
Ferroclean 10% 4 - 24 hrs at 60 - 70 •C
Nalfleet “Sea Shield” Safe Acid 5% 4 hrs at 60 - 70 •C
Unitor Descalex 5 - 10% 4 - 6 hrs at approx. 60 •C
Table 2. Cleaning agents for removing calcareous and rust deposits

In case of emergency Only in exceptional cases, if none of the special agents the application of
which does not present problems is available, calcareous deposits may be
removed by using aqueous hydrochloric acid or amido sulphur acid as a
means of emergency. The following is to be observed for application:
- Heat exchangers made of stainless steel must never be treated with
aqueous hydrochloric acid.
- Cooling systems containing non-ferrous metals (aluminium, red brass,
brass, etc.) have to be treated with inhibited amido sulphur acid. This
acid should be added to the water at a concentration of 3 - 5%. The
temperature should be 40 - 50ƒ C.
- Aqueous hydrochloric acid may only be used for cleaning steel pipes.
The use of hydrochloric acid for system cleaning always involves the
risk of acid residues remaining in the system even after thorough
neutralisation and flushing. Such residues promote corrosion pitting.
We therefore recommend having the cleaning operation performed by a
firm specialising in this field.
Carbon dioxide bubbles which form in the dissolution process of the
calcareous deposits may obstruct the access of the cleaning agent to the
water scaling. It is, therefore, absolutely necessary to circulate the water
containing the cleaning agent so that the gas bubbles are carried away
and can escape. The duration of the cleaning process depends on the
thickness and composition of the deposits. For guide values, please see
Table 2.
After cleaning Following the cleaning of cooling spaces using cleaning agents, the
system has to be flushed several times. In doing so, make sure to replace
the water. Where acids have been used for cleaning, subsequently
neutralise the cooling system with appropriate chemicals, and then flush it.
When this has been done, the system can be refilled with appropriately
treated water.
▲ Attention! Do not start the cleaning process before the engine
has dooled down. Hot engine components are not allowed to be
charged with cold water. Prior to proceeding to refilling the cooling
water system, make sure that the venting pipes are open. Clogged
venting pipes obstruct the excape of air and involve the danger of
thermal overloading of the engine.
The relevant regulations have to be observed for the disposal of cleaning
agents or acids.

6682 000.08--01 E 03.06 General 102/ 02

Pipes
Replacement 000.15

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

Pipes are to be replaced/supplemented if necessary. In this connection,

materials are to be selected in accordance with the requirements, and
processed properly.
This includes:
selection of suitable materials,
proper processing and
proper installation.

Preliminary remarks

When pipes of the fuel, lube oil, cooling water or starting air system or
pneumatic controls are to be repaired, modified or replaced, the notes
stated below should be obeserved so as to avoid trouble in later operation.

Instructions

Pipe sizes/materials Seamless mild steel pipes as to DIN 2391 made of St 35 GZF material to
DIN 1629, or seamless copper pipes to DIN 1754 made of C-Cu F25 or
F30 respectively as to DIN 17671 and/or pipes made of high-grade steel
X6 CR Ni Ti 1810 as to DIN 2462 are to be used as replacements for
pipes on the engine or engine control system. Normally, the replacement
pipes to be mounted on the engine should be of the same dimensions as
the ones installed originally.

Manufacture Pipes of small diameter can be bent while they are cold, using
commercially available standard pipe bending equipment. If solderless
pipe joints as to DIN 2353 are used, heat treatment can be dispensed
000.17).
within the majority of cases (please refer to work card 000.17
In the air duct systems of the pneumatic controls or starting system,
non-corroding, i.e. chrome-plated, galvanized or brass pipe joints are to be
used exclusively. Since, depending on the point of installation either metric
or Whitworth threads of cylindrical or conical shape are required, particular
attention should be paid to the type of thread required.
In case, due to the use of other pipe qualities or larger dimensions,
hot-bending is necessary or if soldering or welding work is carried out on
the pipes, the pipes have afterwards, by all means, to be treated in an acid
bath, in caustic solution and water (please refer to work card 000.16).
000.16

6682 000.15--01 E 07.97 101/ 02

Manufacturing lube oil piping Larger-diameter lube oil pipes and the pipe/s behind the lube oil filter/s in
particular have to be manufactured by bending. Connecting flanges and
sockets are to be joined to the pipes by gas welding.
Gas welding does not produce the slag of the filler rod covering, which is
of particular importance, since the weld seam root has to reach the inside
of the pipe, i.e. the gap of the joint must be completely filled. Unfilled gaps
of joints at the inside of pipes are not admissible because particles of
foreign matter could accumulate there, which are difficult to be removed or
would not be cleaned away by the pipe cleaning operation. During
operation these particles might be carried to the bearings of the engine
causing damage to the bearings and thereby endangering operational
reliabilty. Where prefabricated pipe bends have to be welded into
pipelines, adapter flanges have to be provided in adequate number and
appropriately positioned to permit unimpeded inspection, trimming and
checking of the weld seams at the inside of the pipes.
The aforementioned welded connections can also be made by the WIG
welding process.
No matter whether using the gas welding or the WIG welding method, the
tack welding and the finish welding seams of welded conncetions have in
each case to be produced by one and the same welding method.

Installation/mounting Pipeline installations should be fitted and mounted in such a way that
vibrations are reduced to a minimum. Pipes must not be mounted on
vibrating or oscillating parts. Even soft copper pipes will by the vibrational
effect become hard and brittle and ultimately tend to cracking.

6682 000.15--01 E 07.97 102/ 02

Pipes
Cleaning, Acid Bath Treatment and
Preservation 000.16

Purpose of jobs to be done

Keeping operating systems free from contamination and residues,

ensuring/restoring of operational reliability.

Brief description

Pipes, which are replaced or supplemented, must after

manufacture/processing be cleaned mechanically or chemically and, if
necessary, preserved.
Depending on the actual situation, this includes:
mechanical cleaning of components,
chemical cleaning of components,
carrying out of pressure test, and
preservation.

Preliminary remarks

All pipes to be mounted on the engine as replacements require mechanical

or chemical cleaning on completion of manufacture. If there is a longer
period between cleaning and mounting (replacement pipes), the pipes
must be preserved and their ends must be closed. Plastic plugs or caps in
vivid colours are most suitable for this purpose because they will not be
overlooked.
Pipes for cooling water, heating, exhaust gas and combustion air systems
are normally cleaned mechanically. Pipes for lube oil, fuel oil, compressed
air, gas, steam and condensation systems must be cleaned mechanically
and chemically. Shut--off and regulating elements as well as other units are
not to be fitted to the individual systems before the latter have been
cleaned.
Pipes to be bent in the hot state must be filled with fine--grained sand
exclusively, which must be completely dry. If the sand used is damp,
steam can develop involving accident hazards. Either the entire pipe
systems or parts of them are to be subjected to a pressure test. The entire
lube oil, fuel oil and compressed air systems must be thoroughly flushed
before the engine is put into operation.

Mechanical cleaning

Scale and welding pearls must be carefully removed from the welds with
the aid of a chisel, file or grinding wheel. The entire pipe section is to be
tapped with a hammer and, if possible, compressed air is to be passed
through simultaneously so that even minor particles (sand filled in for hot
bending) are removed.
All pipe conncetions must be closed and must stay closed until they are
installed.

6682 000.16--01 E 11.98 General 101/ 03

 An acid bath is required for pipes that have to be cleaned mechanically
and chemically. The acid bath equipment essentially consists of:
- a hydrochloric acid bath for steel pipes
- a water bath for washing off the acid
- a caustic bath for neutralizing and phosphating treatment,
- a sulphuric acid bath for copper pipes.
The acid fumes developing from the hydrochloric acid bath and sulphuric
acid bath have to be exhausted by ventilators and diverted via wet
seperators. The caustic bath fume, too, has to be exhausted into the open
by means of a ventilator. The local safety regulations have to be observed.
The water bath needs a connection for water and compressed air. The
caustic bath requires a heating system for heating up to 80ƒ C.

▲ Attention! According to the safety regulations for the handling of

acids and lyes, all persons working with acids and lyes have to wear
acid - resistant overalls, rubber boots, rubber gloves and saftey
goggles. A water hose connected ready for use must be available in
the immediate vicinity of the acid and caustic baths.

Acid bath treatment of steel pipes

First pickle in the hydrochloric acid bath, subsequently treat in trisodium

phosphate bath for neutralizing the acid and for simultaneously providing
temporary preservation.
The hydrochloric acid (HCl) is commercially available with a concentration
of 31--33 % and an arsenic content of less than 1 %.
Mixing ratio for the HCl:H20 bath= 3:2 (parts by weight).

▲ Attention! Pour the acid into the water and not vice versa!
The temperature of the bath should not be below 20ƒ C. The duration of
treatment has to be determined by visual observation.
If threads have already been cut into the pipes, care is to be taken that the
tips of the threads do not suffer damage from acid attack. This is the
decisive point determining the duration of treatment in such cases.
After completion of the pickling process, acid solution adhering to the
pipes has to be washed off in the water bath.
Any further remainders of acid solution left in the scores and pores of the
surface structure are to be neutralized in a trisodium phosphate bath in the
course of which the pipes are provided with a phosphate layer giving
short--time protection against oxidation.
The mixing ratio for the Na3 PO4:H20 bath= 1:8 (parts per weight).
Treatment temperature: 80ƒ C.

Important! Copper piping should not be treated in the hydrochloric

acid bath if subsequently steel piping is to be treated again. The reaction
of copper (Cu) with aqueous hydrochloric acid (HCl) leads to the formation
of copper chloride (CuCl2 ) which is dissociated in the aqueous solution. If
subsequently a steel pipe is immersed in the bath again the less noble iron
in the steel will oxidize because its positive charge is discharged and the
ferric ions enter the solution whereas the metallic copper is separated out.
The steel pipe material is then covered with a layer of copper which is not
very adhesive. Copper depositing on the inner walls of fuel conducting
pipes is undesirable. Copper particles that come loose by the action of the
flowing fuel oil would produce adverse effects in the injection elements
such as pumps and nozzles.

6682 000.16--01 E 11.98 General 102/ 03

Treating copper pipes

First pickle in sulphuric acid bath, possibly followed by trisodium

phosphate bath to neutralize acid and to achieve phosphatization.
Sulphuric acid (H2SO4) is commercially available at a concentration of
98 % (concentrated acid). It has to be transported in closed containers.
Mixing ratio of the H2SO4:H2O bath = 1:8 (parts by weight).

▲ Attention! Again, pour acid into the water and not vice versa!
Once the acid bath has been prepared, it should be allowed to settle for
24 hours before it is used.
Duration of treatment: At the beginning, copper piping is to be treated for
15 minutes, and correspondingly longer as the bath is getting older.
When the pipes have been taken out of the sulphuric acid bath, they have
to be submitted to thorough flushing with water and drying by a low flame.
Neutralization in the trisodium phosphate bath is not absolutely necessary.
However, it is recommended in case of long--term storage to prevent
formation of verdigris.

Pressure testing of pipes

Water pipes are pressure--tested with water; lube oil, fuel oil and air pipes
are pressure--tested with slushing oil. For the testing pressures required
please refer to section 2.

Preservation of pipes

For short--term storage in shelterd places and/or in dry warehouses,

Phosphatin and oil film are considered to be sufficient as corrosion
protection. For long--term storage for product support service purposes,
Phosphatin offers an appropiate basic preservation prior to the
preservation properly using slushing oil, paint or grease. Pipe ends and
connections have to be sealed with colour plastic caps. Plastic caps in
signal colours offer the advantage to be recognized more easily when the
pipes are fitted to the engine. It is most important that they are removed
before the pipes are installed.

6682 000.16--01 E 11.98 General 103/ 03

Solderless screwed pipe unions
Mounting 000.17

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

Solderless screwed pipe unions are preferably used where pipes of minor
diameters can be bent in cold state. In this case, the pickling and
neutralising process can be dispensed with.
The work/steps include:
proper processing and
proper installation.

Tools/appliances required

Quant Denomination No. Availability

1 Tools, basic scope 000.002 Standard
1 Pipe cutter -- Inventory
1 Spot facer -- Inventory
1 Machinery oil -- Inventory

Advantages of solderless screwed pipe unions

Solderless screwed pipe unions are preferably used where pipes of minor
diameters can be bent in cold state, i.e. which have not to be submitted to
heat treatment for this purpose. In this case, the pickling and neutralizing
process which otherwise is usually necessary can be dispensed with.
Copper pipes have to be provided with reinforcing sleeves on the inside.
Please refer to work card 000.18.
000.18

Sequence of operations

1. Cut off the pipe at right angles and deburr it.

Pipe cutters (as shown in the figure) are most suitable for such work.
The pipe is cut through using a cutting wheel. The inner edge of the
pipe can then be deburred by means of the three blades inside the
handle, or by using a spot facer. The chips must be carefully
removed by passing air through it.
2. The thread as well as the cutting and wedge ring (4) are to be oiled
(not greased). Then push the nut and the ring over the pipe as shown
in the illustration.
If the cutting and wedge ring cannot be pushed over the end of the

6682 000.17--01 E 07.97 101/ 03

 pipe, or if this is only possible with difficulty, do not expand the ring
but rather reduce the pipes diameter by grinding/filing.

Figure 1. Tools required -- Spot facer, pipe cutter (left) and pipe bender (right)
3. Screw on the union nut by hand until it can be felt to contact the
cutting and wedge ring. The pipe is then to be pressed against the
stop in the inner cone and the union nut is to be tightened by
approximately 1/2 to 3/4 turn. In that way, the cutting and wedge ring
will engage the pipe, and there is no need to press the pipe any
further. Finally, tighten the union nut by one further turn
approximately. The ring then cuts into the pipe, building up a visible
collar (6) in front of its cutting edge.
A marking line (7) will facilitate adherence to the correct tightening.

1 Union nut 3 Pipe 5 Inner cone

2 Stop 4 Cutting and wedge ring 6 Visible collar

Figure 2. How screwed pipe unions work and how to check them. Initial condition illustrated on top on the left, after tightening --
at the bottom on the left, checking -- on the right
4. Pipes with smaller outside diameters can be secured in screwed
unions without having to be preassembled if they are firmly screwed
in on the engine.
Pipes with a larger outside diameter, and all the connections in free

6682 000.17--01 E 07.97 102/ 03

 pipes should be preassembled in a vice.The spanner should be about
15 times as long as its opening is wide (if necessary extend by a
pipe). The other operations are as described above. Final tightening
is easier if the union nut has been loosened a few times so that new
oil can enter between the friction faces.
Important! It is to be made sure that every pipe end comes into the
same inner cone in which it had been fitted before.
5. After final tightening unscrew the union nut and check if a visible
collar (6) has been produced and fills the space in front of the cutting
edge; if not, tighten slightly more. It does not matter whether the
cutting and wedge ring can be turned on the pipe end.
On completion of the joint and whenever the joint has been released,
the cap nut of the union is to be tightened with a spanner that has not
been extended; for this purpose no excessive force is to be used.

7 Marking

Figure 3. Assembly of screwed pipe unions. Assembly on site -- left, preassembly in vice -- right.

Supplementary notes

The straight pipe end that extends into the screwed joint should be at least
twice as long as the union nut’s height (H).
Longer pipelines or pipes subjected to higher stresses require pipe
supports.
An appliance equiped with exchangeable rolls (as shown in figure 1) is
recommended for the bending of steel and copper pipes. The bending
radius (R) should not be less than twice the pipes outside diameter
(R = 2D).

H= Height of the union

nut (1)
2H= Minimum distance of a
bend
R= Bending radius
D= Outside diameter

Figure 4. Minimum distances/bending radii

6682 000.17--01 E 07.97 103/ 03

Solderless Screwed Pipe Unions
Additional parts 000.18

Purpose of jobs to be done

Use/replacement of components,
proper processing and installation.

Brief description

Additional parts for solderless screwed pipe unions extend their range of
use. The following parts can be used: reinforcement sleeves, insert
nozzles and screwed hose connections.
The work/steps include:
proper processing and
proper installation.

Preliminary remarks

Reinforcing sleeves , insert nozzles and screwed hose connections are

used together with solderless screwed pipe unions. Their range of use is in
that way extended, among others to copper pipes and hose connections.

Instructions

Reinforcing sleeves When using solderless screwed pipe unions on soft copper piping,
reinforcing sleeves have to be used to prevent the pipes from being
squeezed as the union nut is being tightened.

1 Reinforcing sleeve

Figure 1. Use of reinforcing sleeves. Left at the top-- sleeve inserted, left at the bottom -- sleeve driven in. Finish--assembled
screwed pipe union at the right.

Insert nozzles The use of insert nozzles permits the air admission and venting time of
units to be adapted to the respective requirements. Such nozzles can
subsequently be inserted into the screwed pipe unions, for which purpose
the union nut has to be loosened and the pipe has to be pulled out. Please
note that the pipe end has to be shortened by the length of the nozzle
collar.

6682 000.18--01 E 07.97 101/ 02

 2 Insert nozzle

Figure 2. Using insert nozzles. Insert nozzle at the left, finish--assembled screwed pipe union at the right.

Screwed hose connections All pneumatic air systems will necessarily have transitions from a pipe to a
hose and vice versa, where it is necessary to connect moving parts. If it is
impossible to perfectly shape pipe ends so that they form standard hose
sockets, a screwed hose connection has to be used for such joints. It is
not permitted just to slide the hose onto a pipe that has been cut off flush.
The hose (3) has to be cut off at right angles and slid onto the hose socket
up to the stop. The hose must then be secured by a hose clip or hose
clamp (4) so that it cannot slide off.

3 Hose
4 Hose clamp

Figure 3. Using screwed hose connections

6682 000.18--01 E 07.97 102/ 02

Operating media/Auxiliary agents

001 Operating media systems/pipes

002 Operating media/auxiliary agents
003 Machine elements
004 Hydraulic tensioning tools/high-pressure pump
005 Operating values/operating results

6682 002--01 E 08.97 101/ 01

Lubricating oil
Assessing and treating 000.04

Purpose of jobs to be done

Record and assess characteristics of operating media,

keep their condition within the admissible range.

Brief description

Lube oil is, according to the maintenance schedule, to be assessed

regarding its condition at regular intervals and maintained continuously.
This includes:
having an oil sample analysed,
maintenance of the operating media, and
changing the operating media.

Assessment of oil

Drop test/oil analysis The condition of the lubricating oil in the engine should be continually ob-
served. The intervals at which oil samples are to be drawn for examination
in a suitably equipped laboratory (it is recommended that this be done by
the supplier’s customer service department) are specified in the mainte-
nance schedule. Oil samples should be drawn with the engine operating,
downstream of the filter. Only then will results be obtained that are repre-
sentative of the oil being circulated in the engine.
A reliable conclusion as to whether the used oil is still suitable for further
use can only be drawn from a complete laboratory analysis in which the
values are determined by standardised test procedures.
We recommend using a test kit specifically developed for making routine
on-site tests of fuel and lubricating oils. Together with the firm Drew Mar-
Tec, MAN Diesel SE has developed such a test kit, which contains easy-
to-handle equipment. Using this test kit, the condition of the heavy fuel oil
bunkered and its characteristics that are important for conditioning, as well
as the condition of the used lube oil, can be determined with adequate ac-
curacy. Information material can be obtained from Messrs. Drew Mar-Tec,
Stenzelring 8, 21107 Hamburg, Germany.

6682 000.04--02 E 01.07 General 101/ 03

 The following characteristics are generally sufficient for routine examin-
ation of a used oil:

Characteristic Limit value Measuring method

Viscosity at 40 •C mm2/s > 110 ISO 3104
< 220
Flash point (PM) •C > 185 ISO 2719
Water content % by vol. < 0.2 ISO 3733
(0. 5% admissible only for a short
period)
TBN (relating to fresh oil) % TBN  50 ISO 3771
Contamination % by wt. < 1.5 in general, depending upon DIN 51 592
actual dispersant properties and
increase in viscosity IP 316
Metal content mg/kg Dependent upon the engine type ASTM 5185-91
and the operating conditions
Table 1. Examination of lubricating oils - characteristics/limit values

Colour The colour does not allow conclusions to be drawn about the degree of
contamination of used doped lubricating oil, because the dispersant/
detergent properties keep minute soot particles (<1.0 ³m) in suspension,
which even at low concentrations give the oil a deep black colour. The total
contamination of lubricating oils can be determined, for example, accord-
ing to DIN 51592 or IP 316. The appearance of the droplet sample also
allows conclusions to be drawn.

Fuel contained in the Fuel oil or fuel oil constituents may enter the lubricating oil both by leak-
lubricating oil ages and by unburnt or only partly burnt fuel oil consitutents in the com-
bustion chamber. At present, a standardised procedure for determining the
fuel oil constituents in the lubrication oil does not exist. Meanwhile, there
are various procedures which, however, have not been standardised so
far.
Fuel in the lubricating oil may affect the viscosity and flash point of the lu-
bricating oil. If a laboratory analysis cannot be done, the viscosity can be
roughly determined as follows:
Drip samples of fresh oil with a viscosity one class higher and one class
lower than the oil used in the engine, and a sample of the used oil from the
engine onto an inclined glass or metal plate, making sure that the temper-
ature of all three samples is the same. It then can be seen from the flow
velocity whether the used oil has a higher or lower viscosity than it had
when it was new.

Water contained in the If laboratory testing to determine the water content is not possible, apply
lube oil one droplet of the used oil to a hot plate. If the oil contains water, the latter
will evaporate rapidly and, in overcoming the capillary force of the oil, it will
escape with an audible noise (spatter test). The water content of the oil
should not exceed 0.2%. If the water concentration is found to be >0.5%,
the oil must be changed unless it is possible, e.g. by careful centrifuging
and/or heating the oil charge for a short time, to reduce the water content
to <0.2%. Water contained in the oil promotes corrosion of the bare metal
parts of the running gear, and the formation of oil sludge, i.e. an increase
in viscosity, among other things.
Inadequate ventilation of the tank and crankcase are frequently the cause
of excessive water content in the lubricating oil. Therefore, it is necessary
to drain sludge and water from the lowest point of the service and storage
tanks at regular intervals.

Air contained in the An air emulsion (oil has a whitish appearance) or severe surface foaming
lube oil is mostly caused by leaks at the suction side of the pump, through which

6682 000.04--02 E 01.07 General 102/ 03

 air is entrained by the oil. Among other things, the formation of a hydro-dy-
namic state of lubrication in the bearing is impeded, and the aging of the
oil is accelerated.

Oil treatment

The filters installed in the main flow serve the purpose of holding back dirt
particles up to a specified mesh width. The automatic filter installed in all
engines, irrespective of the type or the system configuration, bears the
main load. Depending on the application, an indicator filter, designed as
double filter and connected in series downstream of the automatic filter,
can also be used. In particular, this is required by the classification so-
cieties for single-engine operation in marine engine plants.
If the right components are used and the system is maintained in the best
possible way, servicing the filter/s at the maintenance intervals specified
for the Diesel engine is sufficient.
The separator serves the purpose of cleaning the lubricating oil from dirt
particles. In this connection, the dirt accumulating during engine operation
such as, e.g., soot, abrasive particles etc. is discharged from the system
by the separator.
Unlike the lube oil filter, the lube oil separator works in the by-pass. Design
criterion is that the lube oil content can be circulated within the period
specified by the Diesel engine manufacturer by a corresponding guiding
figure.
The separators with automatic discharge nowadays available on the
market, which are recommended for use in the described systems, have
been optimised to a large extent, both with regard to the hydraulic dis-
charge process and control technology, so that it is possible to maintain
the necessary balance between dirt entry and dirt removal, if the separator
is selected and used properly. The Diesel engine manufacturers’ minimum
requirement to be met by the operator is that synchronous operation of the
lube oil separator with the Diesel engine is ensured.

Oil change

It is not possible to make firm predictions as to the expected service life of

an oil charge, since the engine manufacturer usually does not know the
fuel and lubricating oil grades being used, nor the conditions under which
the engine is operating, nor whether the oil receives the proper care.
A change of the oil becomes necessary when the chemical and physical
characteristics of the oil charge have changed to such an extent that the
lubricating, cleaning and neutralizing properties are no longer adequate.
This can only be determined by a complete analysis.
The characteristics stated in Table 1 are to be adhered to.
When changing the oil, the entire oil charge is to be drained while it is still
warm from operation. If the main piping systems cannot be fully emptied,
the entire system is to be flushed with flushing oil before filling in the new
oil charge.

6682 000.04--02 E 01.07 General 103/ 03

Lube oil/fuel
Carry out drop test 000.05

Purpose of jobs to be done

Record and assess characteristics of operating media,

keep their condition within the admissible range.

Brief description

Drop tests allow, with little effort, the evaluation of important

characteristics. They are useful in addition to lube oil and fuel analyses.
They can, however, not replace these.
The work includes:
Preparation of drop test and
assessment of drop test.

Sequence of operations (in lube oil sampling)

Dip a cleaned stick (glass rod or wire) which is pointed at its lower end into
the lube oil at service temperature.
Let the oil adhering to this stick drip onto filter paper and let dry for several
hours at room temperature.
Compare the filter paper with the samples shown on the reverse hereof.

Evaluation of the lube oil spot test

The spot test of a droplet on filter paper is indicative of the degree of

contamination, the presence of water or fuel and the detergent/dispersive
property still existing. The state of the oil being used can in that way be
roughly deduced. A spot test is no substitute for an oil analysis. Abnormal
appearance of the sample, compared with test samples from previous oil
charges which had been in the engine for the same length of time, will
indicate irregularities such as poor combustion, fuel or water leakage,
insufficient oil care etc. Figures 1 ... 5 illustrate the appearance of used,
doped (HD) oils. A lube oil corresponding to Figure 1 is but slightly
contaminated, that of Figure 5 is spent to a degree such that immediate oil
change is necessary. An appearance as shown in Figure 4 calls for a
complete analysis providing reliable information on the condition of the oil
charge in use.
Doped lube oils contain additives for finely suspending combustion
residues and/or preventing these from depositing in the engine
(detergent/dispersant effect). The dirt particles are smaller than the
capillaries in the paper are, which accounts for the pronounced flowing
effect in the external zone. As the dispersant effect is decreasing, dirt
particles coagulate thereby clogging the capillaries. The core of the droplet
has a dark colour. A radiant--like appearance of the margin is indicative of
water or fuel contained in the lube oil.
Spot test sampling has to be done at the intervals stated (please also refer
to the maintenance schedule), drawing always at the same point from the

6682 000.05--01 E 07.97 101/ 02

 oil circulating system with the engine running and collecting the spot test
filter samples in a log.
One and the same kind of filter paper should be used for all spot test
comparisons. The spot tests shown were made with the above--mentioned
filter paper.

Figure 1. Spot tests of doped lube oils -- Figure 1 but slightly contaminated/Figure 4 calling for analysis/Figure 5 requiring oil
change

Fuel oil sampling

The spot test on filter paper provides information on the type of fuel, i.e.
whether it is a distillate or a fuel mix. In the case of heavy fuel oils, the
appearance of the spot test permits to draw conclusions on the
compatibility of the mixed components. It is advisable to make spot tests
of every new bunkering charge, and to collect the results in a log.

6682 000.05--01 E 07.97 102/ 02

Cooling water
Checking 000.07

Purpose of jobs to be done

Record and assess characteristic values of operating media,

avoid/reduce harmful effects.

Brief description

The fresh water to be used for filling cooling water circuits must comply
with the specifications. Cooling water in the system must be checked at
regular intervals according to the maintenance schedule.
The work/steps include:
recording characteristic values of operating media,
assessment of operating media and
checking the concentration of anti--corrosion agents.

Tools/appliances required

Means for checking the Either use the MAN Diesel water testkit or a corresponding testkit contain-
fresh water quality ing all the necessary instruments and chemicals for determining the water
hardness, the pH value and the chloride content (can be obtained from
MAN Diesel SE or from Messrs Mar-Tec Marine, Hamburg), or
Durognost tablets used to determine the water hardness (Messrs Gebr.
Hegl KG, Hildesheim), and
pH value indicator paper with colour checking pattern to determine the pH
value (Messrs Merk AG, Darmstadt), or alternatively liquid pH value indi-
cator or electronic measuring unit, and n/10 silver nitrate solution and
5-percent potassium chromate solution to determine the chloride ion con-
tent.

Means for checking the When using chemical additives:

concentration of additives Testing means according to the recommendations of the supplier.
Usually, the testkits delivered by the producers also contain testing means
for determining the fresh water quality.

When using anti-corrosion oils:

Emulsion tester (Messrs Hamburger Laborbedarf Dargatz, Hamburg), and
concentrated hydrochloric acid.

6682 000.07--01 E 01.07 General 101/ 03

Check the characteristic values of the water

Brief specification

Characteristic value/ Water for charging Water in circulation

Feature and topping up
Type of water Fresh water, free of Treated cooling water
foreign matter
Total hardness max. 10•dGH *) max. 10•dGH *)
pH value 6.5 - 8 at 20•C min. 7.5 at 20•C
Chloride ion content max. 50 mg/l max. 50 mg/l
Table 1. Quality specifications for cooling water (brief)

*) dGH = German hardness

Check the water hardness The water hardness should be tested in compliance with the instructions
accompanying the Durognost tablets.
Water of a hardness exceeding the specified limit is to be mixed with distil-
late or softened water, or to be softened by adding the chemicals stated
below.
The water hardness is reduced by 1•dGH if the following quantities of
chemicals are added to 1000 l of water:
approx. 40 g anhydrous trisodium phosphate (Na3PO4), and
approx. 20 g anhydrous sodium carbonate (Na2CO3).

Important! The chemicals are to be dissolved in water, in a sepa-

rate tank outside the engine circuit (in order for the water hardness constit-
uents to be separated outside the engine circulation system) and subse-
quently be gradually added via the compensating tank, with the engine
running.
Chemicals to increase the water hardness are virtually insignificant nowa-
days because emulsifiable anti-corrosion oils are hardly used any longer.
These chemicals only served the purpose of suppressing foaming in such
cases.

Check the pH value Indicator paper, a liquid indicator, or an electronic measuring unit is to be
used for measuring. Make sure to observe the instructions given by the
respective producer.
The pH value indicates the concentration of hydrogen ions and provides a
comparative value for the agressiveness of the water. If the pH value is
lower than the specified limit, it can be corrected by adding sodium nitrite
(NaNO2) or sodium hydroxide (NaOH); sodium nitrite should be given pref-
erence. Which quantity is required depends on the pH value found.

Check the chloride ion content Add exactly 5 cm3 of n/10 silver nitrate solution (AgNO3) to 350 cm3 of the
water sample in the glass and mix thoroughly. Add 5 drops of a 5-percent
potassium chromate solution (K2CrO4). If red colouration occurs, the chlo-
ride ion content is less than 50 mg/l.
If the chloride ion content is too high, add water with a low chloride content
(distilled water or totally desalinated water) until red colouration occurs.
Then check once again for hardness and pH value.

Testkit of the producer of the ad- As far as the testkit of the supplier of the additive contains testing means
ditive to determine the characteristic values of the fresh water, these can be
used.

6682 000.07--01 E 01.07 General 102/ 03

Check the concentration of anti-corrosion agents

Brief specification

Anti-corrosion Concentration
agent
Chemical additives in compliance with quality specification in Volume
B1, Section 3, Sheet 3.3.7
Anti-corrosion oil initially, after filling in, 1.5 - 2 % by volume; when
operating conditions have stabilised 0.5 - 1 %
by volume
Anti-freeze in compliance with quality specification in Volume
B1, Section 3, Sheet 3.3.7
Table 2. Concentration of cooling water additives

Check the concentration of The concentration should be checked weekly and/or in accordance with
chemical additives the maintenance schedule, using the testing instruments and reagents
specified by the respective producer, and in accordance with the instruc-
tions issued.
A protection by chemical anti-corrosion agents is only ensured if the con-
centration is exactly adhered to. In this connection, the concentrations
recommended by MAN Diesel SE (see quality requirements in Volume B1,
Section 3, Sheet 3.3.7) are to be adhered to by all means. These recom-
mended concentrations may differ from the producer’s specifications.
For reasons of environment protection, chemical additives are almost ex-
clusively used nowadays. Emulsifying anti-corrosion oils have lost impor-
tance.

Check the concentration of The concentration of the anti-corrosion oil is determined by means of the
anti-corrosion oils emulsion tester by acid cleavage with concentrated hydrochloric acid.

Check the concentration of The concentration is to be checked in accordance with the instructions of
anti-freeze agents the producer, or a suitable laboratory is to be entrusted with the determina-
tion of the concentration. In case of doubt, MAN Diesel SE, Augsburg,
should be consulted.

6682 000.07--01 E 01.07 General 103/ 03

Engine or components
Preservation treatment 000.14

Purpose of jobs to be done

Counteract corrosion attacks,

carry out/repeat preventive measures.

Brief description

Specific corrosion prevention and preservation measures are to be applied

by choosing a suitable corrosion inhibitor as well as the method of
application and by fixing the intervals between checks of the
represervation.
This includes:
selection of a suitable corrosion inhibitor,
corrosion prevention measures for new engines and spare parts, and
preservation of engines and engine parts in case of shut--down.

Corrosion inhibition

Corrosion of bare metal surfaces is mostly caused by atmospheric influ-

ence, its nature and severity varies depending on the prevailing climate
(continental, industrial, marine, tropical climate). Corrosion occurring, e.g.
in piping, fittings and heat exchangers due to the contact with residual wa-
ter in the systems or air humidity is not readily visible and often remains
undetected until it becomes evident as damage occurs. The most common
method of preservation is by applying a protective coating to the metal sur-
face, which must be appropriately dense and coherent, properly stick to
the surface, repel water and be insensitive to the aggressive media.

Temporary character of Even a most efficient preservation treatment will only provide protection for
protection a limited period of time. Periodic checks are therefore indispensable to
ensure that represervation is carried out in time.
The addition of vapour phase corrosion inhibiting oil (VCI) has proved to
be useful for preservation of closed spaces. A characteristic of these oils is
that they continuously emit a small amount of gaseous inhibitors so that, in
a closed space, a vapour phase develops which serves as supplementary
preservative if necessary. It is of importance, however, that the crankcase
is completely sealed and that the preserved Diesel engine or Diesel engine
components are stored in a dry, thoroughly ventilated room in which a
moderate temperature is maintained.

6682 000.14--01 E 04.05 General 101/ 04

Corrosion inhibitors

There are various types of corrosion inhibitors available to meet the spe-
cific purposes and prevailing conditions. They can be classified as follows:
1. Corrosion inhibitor with solvent additive
This type of inhibitor consists of wax or oil on mineral-oil basis to which,
e.g. solvent naphta is added, and which can be applied to the metal
surfaces to be protected by dipping, spraying or brushing, without having
to be heated. The protective film forming after evaporation of the solvent
can later be wiped off or washed off. If used for the preservation of the
inside of the engine, the corrosion inhibitor needs not to be removed prior
to putting the engine into operation, provided that the protective pre-
servative film can be dissolved by the lubricating oil in operation. Such
protective agents can also be used for individual engine components and
for external preservation of complete engines.

▲ Attention! The solvents contained are inflammable and may de-

velop explosive vapours.
2. Corrosion-inhibiting grease
These protective greases are applied to the metallic surfaces by brushing
or scrubbing. If the grease used is soluble in oil, and provided that only a
thin film of it has been applied, it can be left on the preserved inner com-
ponents when putting the engine into operation provided, however, the
engine had been properly sealed and dust or dirt were unable to enter.
Preservative grease on external engine parts or single components has in
any case to be cleaned away prior to putting the engine into operation,
which can easily be done by washing with an oil-dissolving fluid (e.g. Die-
sel fuel oil). Care must be taken, however, to prevent the cleaning fluid
from entering the engine and mixing with the lube oil.
3. Slushing oils
These slushing oils are mineral oils containing corrosion inhibiting agents
and can appropriately be used for spraying or brushing individual engine
components, or for the preservation of internal parts of completely as-
sembled engines. It is also possible to run the engine, after it has been
thoroughly cleaned, for a short period of time with such a slushing oil,
whereby efficient preservation of the engine’s oil system can also be
achieved.
4. Corrosion-inhibiting dipping compounds, vapour phase corrosion inhibit-
ing oil or paper are further products for the preservation of single compo-
nents.

Preserving new engines and spare parts

Prior to being shipped, engines receive either a standard or a special pre-

servation treatment in the factory. Special preservation is applied where it
is known that bad climatic conditions will be encountered in transit or at the
place of destination, and when it is to be expected that the engine will be
stored for a prolonged period of time prior to being operated. Provided the
engines are stored at a dry place, the supplier of the anticorrosive oil guar-
antees effectiveness of the protection for a period of three months as a
rule. For longer periods of engine storage, a represervation treatment be-
comes necessary. Such treatment is described further below. Represerva-
tion of the complete engine normally is applicable to four-stroke engines
only.
1. Remove covers on crankcase, on gear box of camshaft drive and on
camshaft proper. Should bags containing a hygroscopic substance (silica
gel) have been suspended inside the crankcase, remove these.

6682 000.14--01 E 04.05 General 102/ 04

 2. Remove the valve protection cap and all the pipe sealing plugs (turbo-
charger, fuel oil, lube oil, cooling water and starting air pipes).
3. Fill up the fuel and lube oil pipes and the nozzle cooling system with
slushing oil; if a hand pump is provided, fill the lubricating oil system with
slushing oil.
4. Spray the crankcase, all the running gear components, gears of the
camshaft drive, camshaft, valve gear, all the pipe openings and openings
on the exhaust gas turbocharger with an ample amount of slushing oil. If
possible, turn the running gear by means of the turning gear or turning rod
for several revolutions and refill the fuel pipe with slushing oil.
If the running gear cannot be turned, fill injection pumps, pipes and injec-
tion valves with fresh slushing oil by actuating the shut-down levers. Make
sure that the fuel control lever is in the maximum admission position.
5. If necessary, suspend new bags containing hygroscopic substance (e.g.
silica gel supplied by BASF, D-67063 Ludwigshafen/Rhein) to preclude
condensed water formation.
Before doing this, wait until all the slushing oil has dripped down in the en-
gine. Distribute the bags inside the engine, in tins with their open ends
pointing down. The number of bags placed inside the engine should be
recorded in the logs to ensure that all of them are taken out before the en-
gine is started.
6. Remount all the covers and seal the engine airtight. For this purpose,
seal all the openings with grease-free paper and adhesive tape, and plug
the pipe connections with plastic caps or wood stoppers. All the gaps and
bores on the engine are to be treated with slushing oil and sealed subse-
quently because later cleaning would involve additional expenditure.

Important! After airtight sealing, it is not permitted to turn the en-

gine’s running gear any longer.

Preservation of engines for shut-down

To ensure that the preservation is effective, it is essential that all the inte-
rior and exterior engine components are carefully cleaned prior to being
treated with a preservative. Maintenance and overhaul work should be car-
ried out according to the maintenance schedule and recorded in the en-
gine operating logs.

Steps 1. Drain all the fuel oil of the engine. The fuel oil service tank should be
carefully cleaned.
The service tank is topped up with a low-viscous slushing oil of SAE
CLASS 10 to 20 instead of fuel oil (e.g. Fuchs Anticorit 1); this will
ensure adequate internal preservation of the fuel-carrying piping and
engine components delivering fuel.
2. Operate the engine for approximately 30 minutes with the slushing oil
filled in, to ensure that all the pipes and the injection system are filled
with slushing oil. Prior to engine shut-down, introduce a small amount
of the low-viscous slushing oil into the intake pipe (of the exhaust gas
turbocharger) by spraying.
3. After shutting the engine off, spray a small amount of slushing oil (ap-
prox. 0.5 l) into the main starting air and control air pipes, too.
▲ Attention! Do not start the engine in this condition under any
circumstances. Explosion hazard! Put up a warning sign, and
purge the pipes according to work card 000.03 prior to the next start-
ing procedure.
4. After shut-down of the engine system, all the pressure gauges should
indicate zero. The engine has to be blocked against inadvertent turn-
ing of the running gear. The turning gear should be engaged (if appli-
cable).

6682 000.14--01 E 04.05 General 103/ 04

 5. Preservation of the cooling water spaces is not required if a slushing
oil had been added to the engine cooling water during operation. If a
chemical additive had been used, the cooling water has to be re-
placed and a slushing oil is to be admixed at a concentration of
approximately 3-5%, and engine operation is to be continued for
some more time. If the engine is going to be shut-down for a pro-
longed period of time, or if there is the danger of freezing, it is neces-
sary to drain the cooling water completely from the engine, turbochar-
ger and the coolers of the individual circuits, making sure that the
drain cocks are constantly left open with the engine shut-down. When
draining the cooling water, make sure also to empty the water space
of the cooling water pump. The exhaust valves complete with cage
and the injection valves are to be removed and emptied separately.
6. A corrosion inhibitor has to be applied to all the bare, external engine
components by brushing or spraying. This applies to the control link-
age and the control rods of the injection pumps in particular. The
opening for the crankshaft in the cylinder crankcase is to be closed
by means of lubricating grease.
Important! Engines that have already been operating and for which
a temporary operation for preserving purposes is impossible may be sub-
jected to the preservation treatment described under ”Preservation of new
engines and spare parts”. It should be made sure that prior to preservation
the fuel oil, the lube oil and cooling water are drained. Again, the engine
requires careful cleaning of all its components.
7. Spray the crankcase with a corrosion inhibitor (e.g. Fuchs Anticorit
6120-42 DFV or Valvoline Tectyl 51111).
In addition, preserve the camshaft using a corrosion inhibitor which
forms a soft, waxy layer (e.g. Valvoline Tectyl 542).
Furthermore, 5 - 6 litres of VCI oil are to be poured into the crank-
case.
8. The silencer is to be covered with foil, and the exhaust pipe is to be
blanked off in order to avoid that a draught passes through the en-
gine.
9. The preservation is to be renewed every six months.

6682 000.14--01 E 04.05 General 104/ 04

Loctite Products
Use 000.19

Purpose of jobs to be done

Use of auxiliary agents,

proper processing and mounting.

Brief description

Loctite is a liquid synthethic, which cures between narrow--fitting metallic

surfaces to form a tough, hard layer. Loctite products can be used for
fastening, sealing and gluing. Selection according to Tables 1 to 3.
The work/steps include:
proper assembly,
disassembly and
reassembly.

Preliminary remarks

The filling compound LOCTITE is a liquid synthetic which automatically

cures between narrow--fitting metallic surfaces to form a tough, hard layer
exhibiting excellent adhesion to the ridges left by the machine tools and
noticeably improves the surface contact between two parts. It is available
in several types of different viscosity for various gap widths, for fastening,
for securing, for sealing and for glueing.

▲ Attention! LOCTITE must not be used inside the crankcase as a

substitute for locking fasteners, feather keys etc. provided for in the
design.
In the case of screwed connections requiring tightening to a given torque,
LOCTITE 222 and 243 may be used as the case may be, since the
lubricity of these two products corresponds to that of the lubricating oil.
The curing time which LOCTITE requires can be reduced by adding the
accelerator T or by warming up the joint to elevated temperatures. For
recommended products, please see Tables 1 2 3 .

▲ Attention! The shelf life of LOCTITE is limited to approximately

1 year at room temperature. If stored longer, its properties will
change, rendering it useless. Therefore make sure to note the date
printed on the receptacle.

Operating Sequence 1 -- Assembly

Steps 1. Carefully clean the jointing surfaces using LOCTITE 706 quick
cleaner (evaporation time approximately 3 minutes) or any other
appropriate cleaning agent to remove dirt and grease.

6682 000.19--01 E 01.05 General 101/ 04

 2. If necessary, apply accelator T by means of a spray bottle and allow
it to dry for about 3 minutes. The filling compound will cure more
quickly if the accelerator is used (see the Table).
3. Apply a thin coat of the appropriate LOCTITE product (see Table) to
one of the two surfaces to be jointed.
Important! Both of the jointing surfaces should be sparingly and
evenly coated if the joint is a press fit or if the surface areas are
comparatively large. In the latter case, LOCTITE may be spread using a
clean brush or a spatula.
In the case of blind--end holes, moisten the walls of the bore to prevent the
liquid LOCTITE product from being displaced by the air--pressure building
up during assembly.The content of the bottle must not come into contact
with metal parts prior to application.
4. Join both parts in the correct position.
5. Scrape off and remove filling compound outside the joint using care
not to dislodge the jointed parts.
6. The filling compound must be allowed to cure (refer to instructions for
use), then finish--assemble the parts.
7. If necessary, heat the joint to approximately 120ƒ C, whereby the final
strength of the joint is reached earlier.

Sequence 2 -- Disassembly

1. Try if the joint can be undone with the aid of normal tools and by hand
force.
2. Should this prove to be impossible, heat the joint to approximately
200ƒ C and separate the parts (fire hazard!).

Sequence 3 -- Reassembly

1. Mechanically remove the old LOCTITE layer on both parts

completeley, taking care not to damage the jointing surfaces. The
layer cannot be removed with the use of chemicals.
2. Degrease the parts carefully and reassemble as described under
operating sequence 1.
¡Tip! Cleanness can be checked by means of ultra--violet radiation.
LOCTITE is fluorescent and even the slightest traces of it will show.

6682 000.19--01 E 01.05 General 102/ 04

Loctite-Product 222 243 245 270 272 275 648
Spec. number 04.10170 -9222 -9243 -9245 -9270 -9272 -9275 -9648
Colour of product purple blue blue green red- green green
orange
Temperature range for use •C 150 150 150 150 200 150 175
Viscosity (mPa. x s) 90 - 180 200 - 400 550 - 400 - 600 4000- 550 - 300 - 600
1000 15000 1100
Gap: optimum
max.
for threads up to max. M36 M36 M36 - M20 M48 M20 - M20
M80 M80
Strength properties: *)
Compressive shear strength 1) N/mm2 3-9 6 - 14 6 - 14 11 - 20 14 - 20 10 - 20 16 - 30
Initial break away torque 2) Nm 8 - 20 14 - 34 13 - 33 25 - 54 18 - 28 25 - 55 30 - 55
Max. screwing torque Nm --- --- --- 45 - 70 20 - 31 35 - 65 40 - 60
Curing: Open assembly time
for steel max. hrs. 24 24 24 24 24 24 24
for nonferrous metals max. Min. 5 1 5 5 5 1
Hand--tight min. Min. 15 - 30 15 - 30 30 - 60 15 - 30 10 -20 3-5
Final strength max. hrs. 12 12 12 12 12 12
KTW - BAM -
Special
p approved approved high
g strengthg
properties
i low mean strength difficultl to separate
diffi
strength
* 1) DIN 54452, 2) DIN 54454
Table 1. Loctite products for thread securing

Thread sealing Surface sealing

Loctite-Product 620 577 586 518
Spec. number 04.10170 -9620 -9577 -9586 -9518
Colour of product green yellow red red
Temperature range of use •C 230 150 150 150
Viscosity (mPa. x s) 800 - 1600 4000-8000 4000-6000 25000 -
50000
Gap: optimum
max. --- --- --- 0,5
for threads up to max. M60 M80 M60 ---
Strength properties: *)
Compressive shear strength 1) N/mm2 20 - 35 5 - 13 10 - 25 4 - 14
Initial break away torque 2) Nm 20 - 45 9 - 25 25 - 55 5 - 13
Max. screwing torque Nm --- --- 30 - 55 ---
Curing: Open assembly time
for steel max. hrs. 24 24 24 24
for nonferrous metals max. Min. 5 1 60 1
Hand--tight Min. 60 - 120 15 - 30 120 30
Final strength max. hrs. 24 12 24 12
DVGW - BAM -
Special
p approved approved
properties
i
* 1) DIN 54452, 2) DIN 54454
Table 2. Loctite products for the sealing of threads and surfaces

6682 000.19--01 E 01.05 General 103/ 04

 shaft/hub Plain surface
Loctite-Product 603 620 307 3) 406 496
Spec. number 04.10170 -9603 -9620 -9307 -9406 -9496
Colour of product green green yellow colourless colourless
Temperature range of use •C 150 230 120 80 80
Viscosity (mPa. x s) 100 - 150 800 - 1600 800 - 3200 10 - 30 100 - 120
Gap: optimum 0,05 0,05 --- 0,05 0,05
max. 0,15 0,20 0,1 0,1 0,1
for threads up to max. --- --- --- --- ---
Strength properties: *)
Compressive shear strength 1) N/mm2 16 - 25 20 - 35 15 - 30 1) 12 - 25 1) 12 - 25 1)
Initial break away torque 2) Nm 40 - 60 20 - 45 12 - 32 2) 18 - 26 2) 20 - 30 2)
Max. screwing torque Nm 40 - 60 --- --- --- ---
Curing: Open assembly time
for steel max. hrs. 24 24 24 seconds seconds
for nonferrous metals max. Min. 5 5 max. 5
Hand--tight Min. 20 60 - 120 10 - 20
Final strength max. hrs. 12 24 24 12 12
for
Special materials
Properties difficult to
glue e.g.
Viton
1) Tensile strength N/mm2

2) Tensile shear strength N/mm2

3) with accelerator 7471
Table 3. Loctite products for gluing

6682 000.19--01 E 01.05 General 104/ 04

Machine elements

001 Operating media systems/pipes

002 Operating media/auxiliary agents
003 Machine elements
004 Hydraulic tensioning tools/high-pressure pump
005 Operating values/operating results

6682 003--01 E 08.97 101/ 01

Galvanized bearings
Assessing 000.11

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

Bearing shells are to be checked at regular intervals. Usually, only the

loaded bearing shell is checked. From wear condition and appearance of
the bearing shell running surface, conclusions can be drawn on the load
conditions, the lube oil care etc.
The work/steps include:
Measuring components and
assessing contact pattern/wear.

Related work cards

Work card Work card Work card

000.10

General

1 Anti-corrosion layer
2 Galvanized layer
3 Nickel barrier
4 Bearing metal
5 Steel support shell

Figure 1. Galvanized bearings - structure

Galvanized bearings (multi-layer bearings) are used for the main bearings
and big end bearings of four-stroke engines. These multi-layer bearings
are composed of a steel support shell, a bearing-metal layer of leaded
bronze or aluminium tin alloy and a running layer, which has been applied
galvanically.
The soft running layer possesses better running-in and dry-running
properties than the leaded bronze or aluminium tin alloy layer. This layer,
therefore, must remain serviceable as long as possible and all reworking

5600 000.11--01 E 06.99 General 101/ 09

 of the running layer must be prohibited. Due to the fact that every bearing
must adapt itself again every time after it is refitted, bearings which are
running well are to be opened as rarely as possible.
If the lube oil is painstakingly filtered and separated, galvanized bearings
achieve a very long service life. For this reason, it is of utmost importance
that the filters and separators are cleaned in good of time and that the oil
is checked regularly.
Damaged bearing shells (upper and/or lower shell) can be replaced
individually or in pairs.
After reinstallation of bearing shells which have already run, or after
replacement, the bearing caps are to be carefully examined for
impermissible heating by touching them with the hand after approx.
30 minutes idling operation and after approx. 5 hours running with slowly
increasing loading of the engine (comparison with neighbouring bearings)
Undersize bearings (with smaller diameter) are available for crankshaft
journals that have been reworked. The undersize bearings are delivered
ready for fitting.

Wear limits

Bearing shells are to be replaced if their galvanized layer is worn over

more than 30% of the developed running surface. Bearing shells with
about 20 % running-surface wear should also be replaced when
large-scale overhaul work is being carried out on the engine at the same
time.

Figure 2. Degree of running surface wear

Bearing shells that have reached 30,000 operating hours are generally to
be replaced when the engine is overhauled.
If the bearing-metal layer of bearing shells already becomes visible after
approx. 5000 operating hours, or if the running layer is worn on about 20%
of the developed running surface, this is an indication for dirt accumulation
and insufficient cleaning of the lube oil.

5600 000.11--01 E 06.99 General 102/ 09

Appearance of the bearing surface

Using this series of illustrations, an evaluation of the removed bearing

shells can be made. It provides hints on the reusability or necessity for
replacement by new bearings.
1. Normal wear pattern with the running layer still present

Figure 3. Normal wear pattern

The predominantly matt grey running surface is smoothed and reflects
slightly in the zones of maximum loading. The bearing can be used again.
2. Normal wear pattern with partly worn through running layer

Figure 4. Partly worn through running layer

When the running layer has been worn through, a reddish-brown wear
pattern becomes visible in the case of leaded bronze bearings. On
aluminium-tin alloy bearings, a difference is visible between light and dark
zones. The light zone represents a fresh or new wear pattern, the dark
zone results from surface oxidation and has no derogatory effect on the
running behaviour. The bearing can be used again and is only to be
replaced when the characteristics listed under “Wear Limits” become
noticeable.
3. Shiny reflections on both edges of the bearing

Figure 5. Shiny reflections

During running-in the bearing becomes slightly “crowned”. Any weakly
shining reflections at the edges of the bearing usually disappear after the
bearing has run for a considerable length of time. The bearing can be used
again, unless Figure 6 (edge-carrying wear) is also applicable.

5600 000.11--01 E 06.99 General 103/ 09

 4. Edge-carrying wear (on one or both edges)

Figure 6. Edge-carrying wear

A bearing that only “carries” on the edges is impermissible. Possible
causes of this fault are deviations in journal geometry or that the bore for
the bearing is out of true. These are factors which must be remedied
under all circumstances. If heavy wear is evident at the edges, the bearing
is to be replaced.
5. Carrying wear on one edge

Figure 7. Carrying wear on one edge

Single-edge wear is encountered on outside bearings and it is permissible
as long as the crankweb deflection is in order (cause of defect: weight of
the flywheel or of the vibration damper).
Carrying wear on one edge is not permissible in the case of intermediate
bearings. Here, the cause of the defect, for instance journal wobble,
deformation of the bearing seat, uneven initial tension on the tie-rods, dirt
on the bearing rear, must be eliminated. In cases of heavy single-edge
carrying wear, the bearing is to be replaced.
6. Traces of carrying wear at the point of contact between the
bearing shells (on one or on both sides)

Figure 8. Traces of carrying wear at the point of contact between the bearing shells
If heavy traces of wear are evident in the vicinity of the joint faces of the
bearing, there exists the danger of the shaft journal cutting through the
lubricating film at the parting line. Therefore, bearings should not show
contact patterns within the first approx. 10 degree, measured from the joint
faces. If traces of carrying wear nevertheless appear near to the point of
contact between the shells, the cause of the defect must be eliminated. If
such wear is only found on one side, the back of the bearing must be
checked for dirt or for carbon deposits. In addition, it is possible that there

5600 000.11--01 E 06.99 General 104/ 09

 is a misalignment of the bearing seat. In case traces of carrying wear are
found on both sides, the Figures 18 (cold shots on the back of the bearing)
and 19 (bearing spread) are to be taken into account. Bearings with heavy
traces of carrying wear in the vicinity of the joint faces are to be replaced.
7. Striation and embedding of foreign particles in the running
surface

Figure 9. Striation and foreign particles in the running surface

Hard dirt particles suspended in the lube oil are held back by the bearing
shells and cause striation in the running surface. These particles often
remain embedded in the running surface. Depending on the hardness of
the foreign particles, the bearing journals may also become scored. Light
traces of striation which do not penetrate the running layer are harmless,
and such bearings can be used again. Striation scratches which are wider
than 1 mm prevent the build-up of the wedge-shaped oil film. Bearings
with a number of wide striation scratches in the lower shell of the main
bearings, or the upper shell of the big end bearings, which penetrate into
the leaded-bronze or aluminium-tin alloy layer are to be replaced. This
applies, above all, when the striation scratches are very close to the edge
of the bearings. If wide striation scratches appear in the bearing shells, the
surface of the bearing journal is to be checked under all circumstances. If
necessary, the journal is to be smoothed or reworked using emery cloth
and/or an oil stone, or portable regrinding equipment is to be used from a
specialist firm. The causes which led to the formation of striation must be
eliminated. To do this, the complete lube-oil circuit including separator,
lube-oil filter and lube-oil pipes between filter and engine is to be checked
(scale, welding beads etc.). If other bearings in the equipment are supplied
with lube-oil via this bearing, it is imperative that these are checked as
well.
8. Cracks in the running layer

Figure 10. Cracks

A few isolated cracks in the running layer are harmless. It is only
necessary to replace the bearing if a large number of cracks is evident in
the loaded zone.

5600 000.11--01 E 06.99 General 105/ 09

 9. “Bark Beetle” effect

Figure 11. Barks beetles

If a large number of small cracks have formed in the loaded zone of the
galvanic layer (often crazed cracks) and then, as a result of material
fatigue, crumbling or erosion of the crack area occurs (similar to the
appearance of the bark-beetle infection in trees), then the bearing is to be
replaced.
10. Separation or detachment of the running layer

Figure 12. Separation or detachment of the running layer

If areas of the running layer have become detached, the bearing is to be
replaced. Only if the bearing shows merely a single, small area of layer
detachment (smaller than 2 cm2), and the remaining running layer in the
immediate vicinity of the damaged area is in order and shows no signs of
detachment (check carefully with a pointed tool, e.g. a pocket knife), can
the bearing be used again
11. Running layer heavily smudged or smeared

Figure 13. Smearing of the running layer

If the galvanic layer is smeared over a wide area (creep formation), and
possibly worn through in the middle, this points to a lack of lube oil which
might have been caused by insufficient pre-lubrication prior to starting the
engine. The cause of the lack of lube oil is to be eliminated, and the
bearing is to be replaced.

5600 000.11--01 E 06.99 General 106/ 09

 12. Roughening of bearing-metal layer

Figure 14. Roughening of the running layer

If the bearing shows signs of considerable roughness of the bearing metal,
it is to be replaced, particularly in order to prevent excessive journal wear.
Besides, the journal is to be smoothed.
13. Crumbling of the bearing-metal layer

Figure 15. Crumbling

Bearings which exhibit crumbling of the bearing-metal layer must be
replaced. The bearing journal is to be checked and smoothed or reworked
as necessary.
14. Overheating of the bearing-metal layer

Figure 16. Overheating of the running layer

If the bearing metal shows overheating features (blue-violet colouring), or
already shows reticular heating cracks, the bearing is to be replaced. The
bearing journal must, under all circumstances, be subjected to a magnetic
crack test. If there are signs of cracking, the bearing journal is to be
ground down until it is “free” of cracks. When grinding, attention must be
paid to surface quality, ovality and conicity. If no cracks or hardening were
found, it suffices that the bearing journal is smoothed.

5600 000.11--01 E 06.99 General 107/ 09

 15. Electro-erosion

Figure 17. Electro-erosion

If generator units are inadequately grounded, stray electric currents and
possibly electro-erosion in the bearing may occur. In such cases, the
running layer is roughened in the form of scars. The scars are sometimes
oblique to the direction of running. In extreme cases of erosion, the
surface of the journal becomes visibly rough. It is imperative that the
cause of the damage is ascertained and remedied. The bearing is to be
replaced and the journal smoothed or reworked.
16. Corrosion

Figure 18. Corrosion

Features of running-surface corrosion are surface discolorations due to
chemical changes in the bearing material, and corrosive, mostly locally
restricted material wear off. The lube oil must be examined for
contamination due to water, acids etc. If the corrosion is in an advanced
stage, the bearing is to be replaced. It often occurs in such cases that the
bearing journal has also been attacked by corrosion, if so, it is to be
smoothed or reworked.
17. Cold shots on the bearing shell at the point where the two shells
join

Figure 19. Cold shots on the bearing shell at the point where the two shells join
Cold shots or pitting on the joint faces of the bearing shell indicate that
relative movement is occurring due to loss of pretension or insufficient
protrusion. The causes of the fault are to eliminated. In not too severe
cases, care must be taken before reinstallation of the bearing shells that
only the “cold shot” material is removed. This is to be carried out with great
care. In addition, the rear of the bearing is to be checked for the presence
of cold shots (see Figure 18). If severe damage has occurred

5600 000.11--01 E 06.99 General 108/ 09

 (considerable wear off and creep of material), the bearing shells are to be
replaced.
18. Cold shots on the rear of the bearing

Figure 20. Cold shots on the rear of the bearing

Cold shots on the rear of the bearing which occur in large numbers and
which cover more than 5% of the total area are not permissible. In such
cases, the bearing is to be replaced. The pretension of the bolts, the
bearing protrusion, the bearing spread (see Figure 19) and the condition of
the bearing locating bore are to be checked. The bearing protrusion can
only be approximately determined at the place of installation by one-sided
unscrewing of the bearing bolts. Cold shots in the bearing locating bore
are to be checked for cracks. If cracks are found, consultation with the
engine manufacturer is necessary. In case no cracks were found, the
material accumulations in the bearing locating bore and, if the bearing is to
be reused, also on the rear of the bearing is to be removed carefully.

Bearing spread

D Bearing diameter
S Spread

Figure 21. Bearing spread

Bearing shells must have sufficient positive spread to ensure proper
contact in the bearing locating bore when installed. The amount of spread
depends on the bearing diameter and may be several millimetres when
new. Even used bearings must still show sufficient residual spread so that
by all means a considerable pressure must be exerted onto both abutting
ends when inserting the bearing into the locating bore. Bearing shells
which fall into the bore very easily (spread zero or negative) must not be
used any more. “Expanding” the shell is not permissible.

5600 000.11--01 E 06.99 General 109/ 09

Deep-- groove bearing
Assessing 000.11

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

Bearing shells are to be checked at regular intervals. Usually, only the

loaded bearing shell is checked. From wear condition and appearance of
the bearing shell running surface, conclusions can be drawn on the load
conditions, the lube oil care etc.
The work /steps include:
Measure components and
assess wear pattern/condition.

Related work cards

Work card Work card Work card

000.10

General

The deep groove bearings used in main bearings and big-end bearings are
based on aluminium or leaded bronze and have the structure as shown in
Figure 1.
The soft running layer exhibits running-in and emergency running
properties superior to those of the bearing metal shell. Therefore, this
running layer should remain in a serviceable condition as long as possible,
and no corrective treatment is allowed. Since every bearing must newly
match upon reinstallation, properly running bearings should be opened as
rarely as possible.
Deep-groove bearings reach a high service life provided the lube oil is
carefully filtered and separated. Timely cleaning of the filters and
separators and checks of the oil are therefore of significance.
If the bearing metal layer of bearing shells becomes visible over the whole
surface after approx. 5000 operating hours or in case that approx. 20% of
the unrolled running surface of the running layer is worn-out, this is an
indication for considerable stress due to dirt particles and insufficient
cleaning of the lube oil.
Bearing shells with advanced wear can either be replaced individually
(upper or lower shell) or together.
When used bearing shells have been reinstalled or after a replacement,
the bearing caps should be carefully felt by hand to check for inadmissible
heating (comparison with the neighbouring bearings) after approx. 30
minutes idling and after approx. 5 hours operation under increasing load.

6682 000.11--02 E 05.98 101/ 05

 Undersize bearings are available in ready-to-install condition to fit
remachined crankshafts. These are subjected to the same evaluation
criterias as normal bearings.

1 Running layer
(approx. 75%)
2 Bearing metal lands
(approx. 25%)
3 Nickel dam
(approx.5%)
4 Supporting steel shell

Figure 1. Structure of a deep--groove bearing

Wear criterias

The running layer as new consists of approx. 75% galvanic running layer
and approx. 25% bearing metal lands. The decisive criterion for the wear
condition on a deep-groove bearing is the relation of the bearing metal
land width to the groove width, and the extent of worn surface. A pocket
lense of not less than five-fold magnification is necessary for checking the
wear condition of the running surface. Whenever the condition of grooves
is checked, the running surface in the zone of less loading should be
inspected for comparison because the condition of grooves mostly is
virtually as new in this zone.
Consulting the series of pictures permits the removed bearing shells to be
judged for their reusability or substitution by new bearings.

1. No wear or slight wear. Bearing shell can be reused.

A B

Figure 2. Wear not critical

1. The groove geometry corresponds to the as-new condition. The
running layer is fully intact inside the grooves. Dark spots in the
running layer primarily consist of embedded oil coke particles.
(See Figure 2A.)
Diagnosis: The bearing metal land/running layer ratio is approx. 25% :
75%. Can be reused!
2. The running layer has evenly worn out of the grooves approx.
0.005 mm. The bearing metal lands do not show signs of wear. Dark

6682 000.11--02 E 05.98 102/ 05

 spots in the running layer primarily consist of embedded oil coke
particles. (See Figure 2B.)
Diagnosis: The worn-down running layer makes the bearing metal lands
appear slightly wider. Can be reused!

C D

Figure 3. Wear not critical

3. Small-sized foreign particles embedded in the entire running surface.
Bearing metal lands have not undergone noteworthy changes.
(See Figure 3C.)
Diagnosis: Can be reused!
4. Running layer dislocated and spread over the bearing metal lands.
Bearing metal lands to some extent no longer visible.
(see Figure 3D)
Diagnosis: Can be reused!

2. Wear of the bearing metal lands. Substitution necessary depending on extent.

E F

Figure 4. Wear of the bearing metal lands

1. The bearing has worn down locally to such an extent that the running
layer groove/bearing metal land relation is approx. 50% : 50%. The
width of the bearing metal lands has increased from 25% (as--new
condition) to 50%. The running layer still exists in the grooves. (See
Figure 4E.)
Diagnosis: The bearing is still apt for use as long as the extent of the worn
zone does not reach the limits shown in Figure 6.
If a wear degree as defined under point 2 is to be expected within the next
maintenance interval, the bearing should be replaced for reasons of safety.
2. The bearing metal lands have worn locally. There are no grooves
and/or the running layer has disappeared. (See Figure 4F.)
Diagnosis: If this state of wear extends to the limits shown in Figure 6, the
bearing requires replacement.

6682 000.11--02 E 05.98 103/ 05

3. Wear of the running layer. Substitution necessary depending on extent.

G H

Figure 5. Wear of the running layer

1. Particles broken off the running layer in the grooves due to local
overloading. (See Figure 5G.)
Diagnosis: The bearing is apt for use as long as the extent of the wear
zone has not reached the limits shown in Fiugre 7.
If a wear condition as described under point 2 is to be expected within the
next maintenance interval, the bearing should be replaced for safety
reasons.
2. Empty grooves. Empty grooves appear in certain zones after the
broken running layer has been washed out. There may already be
local wear and tear of the bearing metal lands. (See Figure 5H.)
Diagnosis: If this wear condition has reached the limits shown in Figure 7,
the bearing requires replacement.

Wear ratio 50% / 50%

Bearing metal lands worn

down

A max. 30% of the

shell circumference
B max. 50% of the
shell circumference
C max. 5% of the
shell circumference
D max. 35% of the
shell circumference
E max. 70% of the
shell width
F max. 35% of the
shell width
G max. 20% of the
shell width
H max. 10% of the
shell width

Figure 6. Extent of wear zones

6682 000.11--02 E 05.98 104/ 05

 Bearing metal lands worn
down
Running layer broken out

Empty grooves

I max.. 25% of the

shell circumference
B max. 50% of the
shell circumference
E max. 70% of the
shell width
F max. 35% of the
shell width
K max. 10% of the
shell circumference
L max. 40% of the
shell circumference
M max. 40% of the
shell width
N max. 30% of the
shell width
O max. 15% of the
shell width

Figure 7. Extent of wear zones

6682 000.11--02 E 05.98 105/ 05

Bimetal bearings (without a third layer)
Assessing 000.11

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule, check
the state/wear condition of the components.

Brief description

Bearing shells (bimetal bearings) are used in crankshaft and connecting

rod bearings as well as in camshaft bearings. They are to be checked or
replaced at regular intervals according to the maintenance schedule.
The work /steps include:
Measure components and
assess wear pattern/condition.

Related work cards

Work card Work card Work card

000.10

General

1 Bearing metal
2 Aluminium bonding
layer
3 Steel shell

Figure 1. Composition of bearing

Roll-bonded bimetal bearings with a material combination of
steel/aluminium alloy (AlSn20) are used as main bearings, big-end
bearings and camshaft bearings. Visual examination of the degree of wear
on a bimetal multi-layer bearing shell (composition as shown in the figure
below) under normal wearing conditions is not possible. Contrary to the
three-metal multi-layer bearings with a galvanised running layer, bimetal
bearings do not have visual indicators permitting judgements of the degree
of wear from the contact surface coloration. The only way of determining
the degree of wear of a bimetal multi-layer bearing shell under normal
running conditions therefore is to measure the wall thickness of the

6682 000.11--03 E 07.97 101/ 03

 bearing shell and compare the result with that measured in the as-new
condition. As the admissible wear rates are in the range of hundredths of
millimeters, measurements of the bearing clearance do not provide for a
reliable indication of bearing wear.

Appraisal of the running behaviour and criteria for replacement

Figure 2. Measuring the wall thickness

The bearing shell has to be replaced if the wear limits stated in ”Technical
details: dimensions, clearances, tolerances” are reached.

Important! The wall thickness (A) will in each case have to be

measured in the zone of maximum loading, or at 90ƒ relative to the joint.

1. Bearing wear pattern uniform over the entire bearing width

A B

Figure 3. Normal bearing wear pattern

1. Individual, superficial scores produced by solid particles do not affect
safe operational reliability.(see Figure 3-A)
Criterion: If the wall thickness still is within the admissible wear rate
tolerance, the bearing is suitable for further use.
2. Running surface slightly scored. If the scores can be seen but not
measured or felt, the bearing is suitable for further use. If the wall
thickness has reached the lower tolerance limit, replacement is
necessary. (see Figure 3-B)
Criterion: If the scores can be distinctly felt and/or measured, the bearing
shell has to be replaced.

6682 000.11--03 E 07.97 102/ 03

2. Bearing wear pattern showing traces of seizure

C D

Figure 4. Bearing wear pattern showing seizure

1. The bearing wear pattern shows distinct edge loading with traces of
seizure in the running layer. The cause of edge loading has to be
established and, if possible, remedied before a new bearing shell is
installed. (see Figure 4-C)
Criterion: The bearing is unsuitable for further use.
2. The bearing wear pattern shows large zones of damage with seizure
of varying intensity. The cause of such damage has to be eliminated
before a new bearing shell is installed. (see Figure 4-D)
Criterion: The bearing is unsuitable for further use.

3. Bearing wear pattern showing patches of broken-off bearing metal

Figure 5. Bearing wear pattern showing patches of broken-off material

The loaded zone of the bearing shell shows spots of broken-off bearing
metal caused by material fatigue of the running layer. (see Figure 5-E)
Criterion: The bearing is unsuitable for further use.

6682 000.11--03 E 07.97 103/ 03

Seals made from elastomer
Storage, cleaning, mounting 000.21

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

Seals made from elastomer (rubber products) are to be stored properly

and replaced during overhaul work.
The work/steps include:
storage of components/appliances,
cleaning of components and
proper mounting.

Explanatory remarks

When doing maintenance and overhaul work, seals made of natural or

synthetic rubber are to be renewed. Only in case of emergency may
completely intact seals be reused. It is recommended to order new seals
inmediately when used up to ensure that they are available when required.
The following sections are passages taken from DIN 7716 and ISO
2230-1973.

Storing elastomer seals

The useful life of rubber products is adversely affected by oxygen, ozone,

heat, light, humidity, solvents and mechanical loading. For this reason, the
serviceability of the rubber seals installed depends, among other things,
on correct storage. Therefore, the following should be given particular
attention.
1. The store should be kept cool, dry, dustfree with slight air circulation
2. The storing temperature should not drop below -10 EC and not
exceed +25 EC. For neoprene products (chloroprene rubber), the
storing temperature should not drop below +12 EC.
3. In storage rooms that are heated, rubber products are to be shielded
from the heat. The distance between the heat source and the
material stored should be not less than 1 m. A larger distance is
required in rooms using blast-heated air for heating (danger of drying
out).
4. Rubber products should not be stored in damp rooms. The relative air
humidity should be below 65 %.
5. Rubber products should be protected from direct sun light and strong
artificial light having a high ultra-violet content. The effects of ozone
are also extremely unfavourable. It is therefore necessary to ensure
that the storing location is not in the vicinity of fluorescent lamps or
other light sources emitting ultra-violet radiation. Due to the effect of

6682 000.21--01 E 07.97 101/ 03

 ozone, rubber products are not to be stored in the vicinity of electrical
installations, motors or generators.
6. Rubber products are not allowed to be stored in the same rooms as
solvents, fuels, lubricants, anti-corrosion oils, chemicals, acids,
disinfectants and similar.
7. It must be ensured that stored rubber products are not subjected to
any form of tension such as pull, pressure or other causes of
deformation (e.g. O-rings are not to be suspended from hooks
because of the danger of permanent deformation and fissure
forming).
8. Rubber products manufactured of different compositions, e.g.
perbunan and silicone rubber, must not physically touch in storage.
This applies in particular to parts of different colours. Contact with
copper and other materials containing manganese is also to be
avoided.
9. Rubber products are to be packed (sealed) in polyethylene foil bags
or similar (the foils must not contain any softening agent). The bags
are to be provided with a label for identification of the particular type
of elastomer (e.g. perbunan, silicone rubber) and the production date.
The labels prevent mix-ups. In addition, the bags are to be packed in
cartous to protect them from effects of light. Points 6 - 7 should be
duly observed.
10.
▲ Attention! In case of fire or if fluorocaoutchouc FKM (trade
names: Viton, Fluorel, Techoflon, Dai-el) is heated to a temperature
above 315 EC, toxic fumes will develop.
In the presence of water, hydrogen fluoride fumes will convert into
hydrofluoric acid which may cause poorly healing cauterisation.
For fighting fires, always use suitable breathing apparatus, safety
masks and safety clothing.
Dispose of in compliance of the appropriate local regulations.

Cleaning

Rubber products are to be cleaned in warm soapy water and dried at room
temperature. If necessary, seals which have been stored for a longer
period of time can be cleaned in a 1.5 % sodium carbonate solution.
Sodium carbonate solution residues are to be rinsed off with normal tap
water (do not use sea water!).
Solvents such as trichloride ethylene, carbon tetrachloride and
hydrocarbons must not be used for cleaning purposes. Sharp-edged
objects, wire brushes, emery paper etc. are inappropriate for cleaning, too,
because the seals would suffer damage

Assembly

General fundamentals The installation of rubber products requires particular care and attention. In
particular, the following should be observed during assembly and
installation.
O-rings - When being installed, sealing rings must not be stretched by more than
30 % of their inner diameter, and for a short period of time only.
- Sealing rings must not be twisted as being installed (be careful with
rings of larger diameter and small cross-sectional area). Some of the
sealing rings are provided with a line running round the circumference
which must be fully visible and uninterrupted over the entire
circumference after the ring has been fitted.
- Sealing rings must not be slipped over sharp edges, threads, slots etc.
If necessary, the sharp edges are to be covered up.

6682 000.21--01 E 07.97 102/ 03

 - When slipping sealing rings over, they are not to come into contact with
anti-corrosion oil. Bushings must be free of anti-corrosion oil in the area
required for fitting the seals. The solvent used for cleaning must have
dried away completely.
- The fitting spaces required by the sealing rings are to be coated with a
suitable lubricant (see below).
Radial sealing rings The sealing lips of rotary shaft seal rings should always face the medium
that is to be sealed off.

Lubricants Components and sealing rings are to be treated with an appropriate

lubricant prior to assembly. Only the lubricating greases listed in the Table
are permissible for the various rubber products. Other lubricants and/or
agents for aiding assembly are only to be used after the manufacturer of
the seals has been consulted.
In the case of rotary shaft seals, only the lubricants listed below, or those
specified by the manufacturer are to be used.
Inappropriate lubricants may cause premature failure of the seals.
Lithium-saponified lubricating greases generally are multi-purpose greases
used for the lubrication of rolling and plain bearings (e.g. multi-purpose
grease MAN 257-NLGI 2). Greases containing silicone are specially
labeled and identified as such.

g ring
Sealing g Lubricating grease
Q lit
Quality lithium containing
saponified silicone
Perbunan NBR X X
Silicone VMQ X -
Viton FKM X X
Butyl rubber IIR X X
Neoprene CR X X
Table 1. Lubricants for elastomer seals

6682 000.21--01 E 07.97 103/ 03

Threaded inserts
Use 000.22

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

Threaded inserts serve for making firmly locking threads in components

produced from grey cast iron or light metal. Damaged threads can be
repaired.
The work/steps include:
proper mounting
and, if necessary,
dismounting.

Tools/appliances required

Commercially available twist drills, with diameters as required for the

respective type and make of threaded insert.
From the supplier of threaded inserts:
Special taps,
Turning-in tool, and turning-out tool if applicable
Drift punch
Standard tools

Explanatory remarks

Threaded inserts ar used, e.g. to produce wear-resistant threads in

components made of cast iron, light metal etc. Similarly, a damage to a
threaded bore can be repaired using a threaded insert to permit the same
bolt size being further used. For this purpose, the old thread has to be
bored open, a new thread has to be cut and the appropiate threaded insert
is to be turned in. Two different types of threaded inserts are avaible: Type
A - standard (non-secured) and tape B - autosecuring (one turn
hexagonally deformed). Please refer to Figure 1.

6682 000.22--01 E 07.97 101/ 03

Operating sequence 1- installation

Thrilling Commercially available twist drills are to be used. For diameters and
drilling depths, please refer to the suppliers sales assortment. Never
counterbore the core hole. Slight deburring, however, is permitted.

Tapping Only special taps are permitted for cutting the thread receiving the insert
(see Figure 3). The depths of thread should be equal to the length of the
threaded insert plus 0,3 ... 0,8 x P (P = pitch) (F in Figure 2 is too short).

A Diameter
B Length of the treaded
C Tang
K Threaded insert Type A
consistently round shape on
the inside
J Threaded insert Type B
(1 turn of thread of hexagonal
shape on the inside)

Figure 1. Threaded insert Type A - nonsecured (left). Type B - auto-securing (right).

E Core hole diameter

F Core hole depth
(length of threaded
insert plus transition)

Figure 2. Twist drill/bore hole

G Diameter of the special

tap, suitable for A

Figure 3. Special tap

C Tang
H Fitting tool

Figure 4. Fitting tool

6682 000.22--01 E 07.97 102/ 03

 L Tang breaker/punch
M Unfitting tool

Figure 5. Left. Tang breaker/punch, right. unfitting tool

Fitting The fitting tool (H) is to be used for installation. Place the threaded insert
in the bias shell of the tool with the tang facing the direction of insertion.
Turning the spindle will cause the tang to be engaged by the spindle and
introduce the insert far enough into the bias shell to bring the first turn into
engagement with the last turn of the shell. Place the tool in straight
position onto the bore of the work piece and continue turning the spindle
whereby the threaded insert is fitted in the mating thread (see Figure 4) .
The threaded insert should be fitted 0,3 ... 0,8 x P below the surface. It
must be seated in the fully tapered thread only.

Break the tang The tang (C) only serves for fitting. After fitting , it should be removed
using a special tang breaker (Figure 5) or a drift punch. The tool should be
placed in the thread on the tang of the threaded insert fitted. Give a short
and strong stroke onto the drift of the tool. The tang will break away at the
point programmed for (notch D).
In case of blind holes, breaking the tang away is not imperative. In case
the tang has not been removed, attention should be paid to the maximum
screw-in depth of the bolt.

Operating sequence 2 - removal

If in exceptional cases the threaded insert has to be removed again, an

unfitting tool is available that can be used as shown in Figure 6. With its
wedge-shaped section, this tool is to be vigorously pressed into the thread
and turned anti-clockwise until the insert comes loose/can be turned out.

6682 000.22--01 E 07.97 103/ 03

Tightening of bolted connections
Tightening torques (illustrated) 000.29

Purpose of jobs to be done

Indicating tightening torques for essential bolted connections.

Guaranteeing operational reliability.

Brief description

Bolted connections which are tightened by torque or by torsion angle using

hydraulic tensioning tools have to be tightened or released to the
specified values.
Work cards 000.29 and 000.30 contain the necessary information.

Explanations

The illustrations in work card 000.29 serve the purpose of identification in

terms of vicinity and location of the components to be connected. The
illustrations provide the identification numbers, e.g. 020--1, which are
000.30. The identification numbers in turn
numerically listed in work card 000.30
guide the user to the tightening torques and the relevant work cards.

6722 000.29--01 E 09.07 L 58/64 CD 101/ 04

Figure 1. Cross-section/side view of engine

6722 000.29--01 E 09.07 L 58/64 CD 102/ 04

Figure 2. Details and sectional views

6722 000.29--01 E 09.07 L 58/64 CD 103/ 04

Figure 3. Details and sectional views

6722 000.29--01 E 09.07 L 58/64 CD 104/ 04

Tightening of bolted connections
Tightening torques (table) 000.30

Purpose of jobs to be done

Indicating tightening torques for essential bolted connections.

Guaranteeing operational reliability.

Brief description

Bolted connections which are tightened by means of hydraulic tensioning

tools must be checked for correct tension, according to the maintenance
schedule.
Work cards 000.29 and 000.30 contain the necessary information.

6722 000.30--01 E 09.07 L 58/64 CD 101/ 10

6722 000.30--01 E 09.07 L 58/64 CD 102/ 10
6722 000.30--01 E 09.07 L 58/64 CD 103/ 10
6722 000.30--01 E 09.07 L 58/64 CD 104/ 10
6722 000.30--01 E 09.07 L 58/64 CD 105/ 10
6722 000.30--01 E 09.07 L 58/64 CD 106/ 10
6722 000.30--01 E 09.07 L 58/64 CD 107/ 10
6722 000.30--01 E 09.07 L 58/64 CD 108/ 10
6722 000.30--01 E 09.07 L 58/64 CD 109/ 10
6722 000.30--01 E 09.07 L 58/64 CD 110 / 10
Tightening of bolted connections
Tightening torques (turning moment) 000.31

Purpose of jobs to be done

Indicating tightening torques for essential bolted connections.

Guaranteeing operating safety.

Brief description

Screwed connections should be tightened by means of torque spanners as

far as possible. For especially important connections, the values are
000.30. Approximate values for other screws are
specified in work card 000.30
given in this work card.
Work cards 000.29 and 000.30 contain the necessary information.

Tightening of screwed If bolted connections other than those listed in work card 000.30 are to be
connections acc. to the torque tightened using a torque wrench, Table 2 should be looked up for approxi-
mate tightening torques. The following should be observed:
- The load acting on a bolted connection depends on the tightening
torque applied, on the lubricant used, the finished condition of the
surfaces and threads, and on the materials paired. It is, therefore, of
great importance that all these conditions are met.
- Table 2 lists the tightening torques for various threads as a function of
the coefficient of friction, i.e. of the lubricant used. The torques are
based on bolt material of the strength class 8.8 with the bolts stressed
up to approximately 70 % of the elastic limit. For other strength
classes, the tightening torques listed in the table have to be multiplied
by the corresponding conversion factors. The strength class is stamped
on the bolt head.

Strength class 5.6 6.8 10.9 12.9

Conversion factor x 0.47 0.75 1.4 1.7
Table 1. Conversion factors for tightening torques as a function of the bolt strength
class.
Approximate coefficient of friction:
m = 0.08 for lubricants containing molibdenum disulphid
(MoS2) - (MOLYKOTE paste type G-n or HSC and
Optimoly-paste White T),
m = 0.14 for surfaces that are not finish-treated, with a thin film
of oil or grease using Loctite (see work card 000.19).
000.19

6682 000.31--01 E 08.97 101/ 02

 Tightening torque Tightening torque
Thread in Nm Thread in Nm
Nominal Coefficient of Nominal Coefficient of
size friction m size friction m
0.08 0.14 0.08 0.14
M5 4 6 M 24 475 690
M6 7 10 M 24x2 500 750
M8 17 25 M 27 700 1020
M 10 34 50 M 27x2 730 1100
M 12 60 85 M 30 950 1380
M 14 95 135 M 30x2 1015 1540
M 14x1.5 100 145 M 33 1270 1870
M 16 140 205 M 33x2 1350 2060
M 16x1.5 150 220 M 36 1640 2400
M 18 200 280 M 36x3 1710 2550
M 18x1.5 215 320 M 39 2115 3120
M 18x2 205 300 M 39x3 2190 3300
M 20 275 400 M 42 2630 3860
M 20x1.5 295 450 M 42x3 2760 4170
M 20x2 285 425 M 45 3260 4820
M 22 370 540 M 45x3 3415 5180
M 22x1.5 395 595 M 48 3950 5820
M 22x2 380 565 M 48x3 4185 6370
Table 2. Tightening torques for bolts of the strength class 8.8

6682 000.31--01 E 08.97 102/ 02

Tightening of bolted connections
General remarks 000.32

Purpose of jobs to be done

Impart the necessary knowledge,

ensure the operational reliability of bolted connections.

Brief description

Bolted connections are, depending on their type and significance, to be

tightened by various methods: tightening without specification, at torque,
according to torsion angle, according to change in length, by means of
hydraulic tensioning tools.
Work cards 000.29 and 000.30 contain the necessary information.

Related work cards

Work card Work card Work card

000.29 000.30 000.31

Tightening using standard tools Different methods of tightening bolted connections are being used,
depending on the purpose the connection serves and the significance it
has. Bolted connections of a standard type for which no special
specifications have to be followed can be secured using normal ring,
socket or open-end wrenches without an extension.

▲ Attention! Self-locking hexagon nuts are to be used once only!

After they have been used for assembly, they must be replaced by
new self-locking hexagon nuts!

Tightening at torque Bolted connections for which a certain tightening torque is specified in
work cards 000.29 and 000.30 require a torque wrench. The lubricant
specifiactions are of significance because, depending on the lubricant
applied, the loads acting on the bolted connections will differ although the
torque is the same. The supplier’s specifications are to be observed for
pretreating the bolted connection and for applying the lubricant.
If a torque wrench is also used for the loosening of bolted connections,
care should be taken that the maximum torque of the wrench is not
exceeded (danger of suffering damage). In no case whatsoever is the use
of extension pipes permitted. Torque wrenches do also have to be
checked for correct indications/setting at regular intervals.
In case torque wrenches are used for tightening bolted connections other
than those listed in work card 000.30,
000.30 approximated tightening torques can
000.31.
be looked up in work card 000.31

Tightening acc. to torsion angle or Bolted connections for the tightening of which a specific torsion angle is
acc. to torque plus torsion angle prescribed should in a first step be tightened to the point of snug contact of
the nut or bolt using an open-end ring or socket wrench or to the specified
torque using a torque wrench. In a second step, the nut or bolt is to be
further tightened by the specified torsion angle.

6682 000.32--01 E 06.05 General 101/ 02

Tightening acc. to bolt elongation The method of tightening bolted connections primarly or exclusively by
elongation of the bolt/compression of the parts to be connected has lost in
significance compared with others. The elongation/compression is
nowadays only used as a control measure supplementing the hydraulic
tensioning procedure.

Disadvantages of the methods Disadvantages with the tightening of bolted connections using ring,
described above open-end or socket wrenches and torque wrenches respectively are the
following:
- Side forces of considerable magnitudes are being introduced into the
connection,
- the effective preload depends on the lubricant used and/or on the
frictional conditions and
- these methods cannot be used for bolted connections involving a
relatively large nominal diameter.
Tightening using hydraulic When hydraulic tensioning tools are used for the tightening of bolted
tensioning tools connections, the above-mentioned disadvantages do not occur. This
method can reliably be used even for the largest size of bolts. The screw,
the bolt or the axle are hydraulically elongated and released after the nut
has been tightened or loosened. Please refer to the work cards ”Hyraulic
Tensioning Tool - Use” and the safety regulations.

6682 000.32--01 E 06.05 General 102/ 02

Surface examination by means of
penetration methods 000.34

Purpose of jobs to be done

Examination of components for cracks/surface defects.

Evaluation regarding usability/remachining possibilities/tightness.

Brief description

Surface examinations are carried out on high--grade components which

are subjected to high stresses, in order to ensure that they are in perfect
condition and/or to be able to correctly classify defects found.
The work/steps include:
cleaning and preparing the components for examination,
checking the components.

Tools/appliances required

Qty Designation No. Availability

1 Wire brush -- Inventory
1 Special cleaner -- Inventory
1 Penetrant -- Inventory
1 Developer -- Inventory
1 Protective clothing -- Inventory

Application ranges

Surface examinations by the penetration method are based on the

application of liquid media having a low surface tension and a high
capillary action. They can be proved in pores and cracks up to a gap
width of approx. 0.25 mm provided that there is a connection to the testing
surface. The penetration method can be applied on almost all materials
and within a temperature range of between approx. -5ƒ C and 50ƒ C. Using
special testing means, an application of the method is possible in case of
surface temperatures of up to 175ƒ C. An indication of surface defects (in
the following desginated as defect) is possible independent of their type
and direction and independent of the geometry of the object to be
examined. Other non-destructive examination methods can only be
applied with restrictions under the requirements stated above.
In the case of a similar method, fluorescent penetration oils are used.
These require an additional emulsion process. The evaluation of surface
defects is made under ultraviolet light.
In all cases, the manufacturer’s instructions for use are to be observed.
The following statements illustrate the process and the general application
possibilities.

6682 000.34--01 E 05.01 General 101/ 06

Operating sequence 1 -- Precleaning of the components to be examined

Depending on the type and condition of the component to be examined,

differing cleaning methods are to be applied. The surface to be examined
always has to be metallically bright, clean and free from grease. All kinds
of coatings and layers such as electroplated coatings, corrosion and layers
of scale are to be removed. This is necessary to ensure that the penetrant
can completely wet the surface and penetrate into the surface defects.

Precleaning

1 mechanically
(wire brush)
2 mechanically
(e.g. shot-plasting)
3 chemically
(degreasing by hot
steam)
4 chemically
(cleaning agent)

Figure 1. Possibilities for precleaning the components to be examined (source of illustration: Messrs Helling)

Operating sequence 2 -- Application of the penetrant

The penetrant can be applied to the component to be examined in every

way desired. It is to be ensured that the surface to be examined remains
completely wet during the whole penetration period. The appropriate
penetration period depends on the properties of the penetrant, the
examination temperature and the material of the components to be
examined. Generally, it is within the range of between 3 and 5 minutes
for castings, and between 10 and 20 minutes for homogeneous metals.

Penetration process

1 Splashing
2 Application by brush
3 Spraying
(spray can)
4 Spraying
(compressed air
spraying gun)

Figure 2. Possibilities for applying the penetrant

6682 000.34--01 E 05.01 General 102/ 06

Operating sequence 3 -- Intermediate cleaning of the component surface

The excessive penetrant which adheres to the component surface has to

be removed completely. In this connection, it is to be noted that the
penetrant remains in possible defects. The cleaning method depends on
the penetrant used.

Intermediate cleaning

1 Nonfuzzing cloth or
sponge which had
been soaked in water
2 Washing by means of
a brush
3 Rinsing with water
4 Special cleaner
(suitable for the
penetrant used)

Figure 3. Possibilities for intermediate cleaning

Operating sequence 4 -- Drying of the cleaned component surface

After removal of the excessive penetrant, the component surface to be

examined has to be dried as quickly as possible. In this connection, it is to
be noted that the the penetrant does not become dry in possible defects.
The complete drying process can be dispensed with in case a wet
developer together with water as carrier fluid is used for the developing
process.

Drying process

1 Air drying
2 Dry, nonfuzzing cloth
3 Compressed air
(free from water and
oil)
4 Hot air

Figure 4. Possibilities for component drying

Operating sequence 5 -- Developing process

Apply the developer to the component surface to be examined as

uniformly as possible, in a thin coat. Besides wet developers on water
basis and/or solvent basis, dry developers are also used. As a rule, the
development period corresponds to the penetration period of the
penetrant.

6682 000.34--01 E 05.01 General 103/ 06

 Developing process

1 Water-based wet
developer
(submerging)
2 Solvent-based wet
developer (spray can)
3 Solvent-based wet
developer (compr. air
spraying gun)
4 Solvent-based wet
developer (electro-
statical/airless)

Figure 5. Possibilities for applying the developer

Operating sequence 6 -- Evaluation of the results

The developer (white) withdraws the penetrant (red) from possible defects
and represents them in the form of coloured bleedings. Size, type and
shape of the bleedings allow conclusions as to the formation of the defect.
In Figure 7, such defect indications are represented diagramatically.

Evaluation of results

1 Visual inspection
2 Documentation on
transparent adhesive
foil
3 Photographs
4 Documentation by
taking photos and/or
video recording

Figure 6. Possibilities for recording the examination results

1 Cold cracks 6 Accumulation of pores

2 Hot cracks 7 Spongy structure
3 Grinding cracks 8 Pores
4 Cracks (severe bleeding)
(severe bleeding) 9 Stress corrosion cracking
5 Pores

Figure 7. Fault indications

6682 000.34--01 E 05.01 General 104/ 06

 Figure 8. Valve cone with stress cracks at the fillet

Figure 9. Valve cone with cracks on the valve seat armouring

6682 000.34--01 E 05.01 General 105/ 06

Recommended manufacturers for test chemicals (special cleaner/penetrant/developer)

Manufacturing firm Special cleaner Penetrant Developer

Tiede
Bahnhofstraße 94-98 Tiede-PEN RL-40 Tiede-PEN PWL-1 Tiede-PEN DL-20
D-73457 Esslingen
MR Chemie GmbH
Nordstraße 61-63 MR 79 MR 68 NF MR 70
D-59427 Unna
Brent GmbH
Rostocker Straße 40 ARDROX ARDROX ARDROX
D-41199 Mönchengladbach 9PR88 9VF2 9D1B
Helling KG GmbH & CO.
Sylvesterallee 2 NPU VP 30 D 70
D-22525 Hamburg
Table 1. Manufacturers/test chemicals

Figure 10. Test chemicals of various manufacturers

(special cleaner/penetrant/developer respectively)

6682 000.34--01 E 05.01 General 106/ 06

Surface examination by means of
Magnetic flux leakage methods 000.34

Purpose of jobs to be done

Examination of components for cracks/surface defects.

Evaluation regarding usability/remachining possibilities/tightness.

Brief description

Surface examinations are carried out on high--grade components which

are subjected to high stresses, in order to ensure that they are in perfect
condition and/or to be able to correctly classify defects found.
The work/steps include:
cleaning and preparing the components for examination,
checking the components.

Tools/appliances required

Qty Denomination No. Availability

1 Yoke magnetising device -- Inventory
1 Permanent magnetising device -- Inventory
1 UV light source -- Inventory
1 Magnetic particles (dry) -- Inventory
1 Magnetic particles (in suspension) -- Inventory
1 Special cleaner -- Inventory
1 Special varnish -- Inventory

Application ranges

Surface examinations by Magnaflux test cause magnetic discontinuities

and thus magnetic flux leakages in the defective areas of ferromagnetic
materials through which a magnetic field flows. These exceed the
component surface. The presence of a magnetic discontinuity and/or a
magnetic flux leakage is proven by applying fine ferromagnetic particles on
the component surface. These particles are partly retained by the
magnetic flux leakage. The accumulation of magnetic particles makes the
contour of the defect visible and generally shows the location, size, shape
and the extent of the magnetic flux leakage.
The magnetic particles are applied to the surface to be examined in the
form of dry powder or in liquid suspension (water, oil, petroleum). The
materials concerned are ferromagnetic materials such as iron, nickel and
cobalt alloys. The ferromagnetic properties of these materials are lost if a
certain temperature, the so-called Curie point, is exceeded. This Curie
point is at approx. 760ƒ C for most ferromagnetic materials.
The magnetic field circulating in the component to be tested can be
produced in different ways. Besides the coil, self and induction flux, yoke

6682 000.34--02 E 03.99 General 101/ 05

 magnetising is the most widely used magnetising method. In all cases,
the manufacturers’ instructions for use are to be observed. The following
statements illustrate the process of yoke magnetising and the general
application possibilities.

Figure 1. Alternating current yoke magnetising device (source Messrs Helling)

Figure 2. Permanent magnet with special varnish and magnetic particles

in spray cans (source Messrs Helling)

6682 000.34--02 E 03.99 General 102/ 05

Yoke magnetising

Figure 3. Course of flux lines during yoke magnetising

As regards yoke magnetising, two methods of magnetising can in principle
be differentiated. The magnetic field can be produced by a permanent
magnet or by an electromagnet.
Mostly, such defects are indicated whose longitudinal direction is vertically
to the connecting line between the magnet poles (horizontally to the field
direction). For this reason, it is necessary to carry out the examination
once again in cross direction (refer to Figures 4/B and 4/C).

A Component without
defect
(homogeneous
magnetic field - no
fault indication)

B Component with defect

in field direction
(homogeneous
magnetic field - no
fault indication)

C Component with defect

horizontally to the field
direction
(inhomogeneous
magnetic field -
magnetic flux leakage -
clear fault indication)
Figure 4. Flux lines in the magnetised component
The component to be examined is to be cleaned and freed from all kinds
of coatings and layers which might preclude the alignment of the magnetic
particles and/or lead to incorrect fault indications.
Generally, narrow partings such as cracks and gaps result in clearer
indications than wider defects such as slag, pores or shrink holes. Defects
which are located underneath the surface result in poorly defined
indications, which become more and more blurred with increasing depth.
Magnaflux testing is therefore mainly applied for detecting defects on the
surface and close to the surface.

6682 000.34--02 E 03.99 General 103/ 05

Applying the magnetic particles

The magnetic particles can be applied employing the dry and/or wet
method. Both methods vary in their application possibilities and, to some
extent, with regard to the indication sensitivity.

Figure 5. Formation of beads by the magnetic particles due to magnetic flux lea-
kages

Dry method In case of the dry method, the magnetic particles are dusted onto the
component surface to be tested by means of a slight air flow. This can be
done by means of a spraying gun or a spray can. The use of dry powder
requires that the surface of the component to be examined is absolutely
dry and grease-free. In connection with this method, the surface
roughness may be slightly higher then in case of the wet method. The dry
method results in the formation of comparatively thick powder beads which
lead to a clear fault indication.
The dry method is of advantage for the examination of components which
may not be wetted by water or test oil and/or on hot component surfaces.

Wet method In case of the wet method, the magnetic particles are flushed onto the
component surface to be examined by means of a carrier fluid. Depending
on the application, water or test oil is used as carrier fluid. By using such
magnetic particle suspensions, the mobility of the individul magnetic
particles is distinctly increased. The particles “float” to the defective areas.
This, however, requires a permanent movement of the carrier fluid in order
to prevent the magnetic particles from depositing.
Decisive for the examination result is also the concentration of the
magnetic particles in the carrier fluid. In general, higher concentrated
magnetic particle suspensions have a greater depth effect resulting in a
quicker fault indication. Suspensions with a lower concentration, on the
other hand, have a higher indication sensitivity, the formation of the
powder beads, however, requires more time. The concentration of
non-fluorescent magnetic particle suspensions is in the range of between
6 and 24 g/l, of fluorescent magnetic particle suspension in the range of
between 0.25 and 2.5 g/l.
The application of the magnetic particle suspension onto the component
surface to be evaluated is effected by means of spray bottles or spray
cans. The suspension is poured close to the area to be examined so that
it can slowly flow over the component surface to be examined.

Execution of the Magnaflux testing

First of all, the cleaned component surface is subjected to a visual

inspection and, if required, covered by a quickly drying special varnish to
reach an improved contrast to the magnetic particles. The application of
the magnetic particles and magnetising are effected at the same time.
The time required for flushing and/or spraying depends on the amount of
powder applied per time unit, the concentration of the suspension, the
grain size, the shape of the component surface to be examined and on the
size of the defect to be proven. Generally, flushing and/or spraying has to
be completed prior to cutting off the magnetic field in order not to destroy
the powder beats above the defects again.

6682 000.34--02 E 03.99 General 104/ 05

 Very fine partings such as grinding cracks and cracks formed during
hardening can only be discovered for certain using magnetic particle
suspensions of a lower concentration and a small grain size.
Finally, the area to be examined is inspected for particle accumulations,
and possible fault indications are judged, marked and, if necessary, fixed.
Depending on the kind of further use of the component, remnants of the
test media are removed, and the component is demagnetised.

Magnetic particle indications

The beads formed in the defective areas during Magnaflux testing provide
a clear idea concerning the progress of the defect, however, not
concerning the depth of the defect. As already explained, clear magnetic
particle images are produced from defects which originate from the
component surface, whereas defective spots which are located
underneath the component surface only provide blurred indications.

Figure 6. Valve cone with stress cracks at the fillet

A special problem in connection with the Magnaflux testing are the false
indications. These are particle accumulations which occur on spots that
are free from defects. False indications do occur, e.g. on sharp cross
section transition points or in cold-formed areas. It does require a certain
amount of experience to distinguish a false indication from a real fault
indication.

Demagnetising

After magnetising, a residual magnetism remains in the test object which,

depending on the further use of the component, may lead to disturbances.
For demagnetising, the component is subjected to an alternating magnetic
field of decreasing intensity. According to our experience, the field
intensity may in this connection be decreased by not more than 10% at
each alternation. At the beginning of the demagnetising process, the field
intensity selected has to be higher or equal to the field intensity used
during testing.

6682 000.34--02 E 03.99 General 105/ 05

Hydraulic tensioning tools/
High-- pressure pump

001 Operating media systems/pipes

002 Operating media/auxiliary agents
003 Machine elements
004 Hydraulic tensioning tools/high-pressure pump
005 Operating values/operating results

6682 004--01 E 08.97 101/ 01

Working and safety regulations
Using high-- pressure tools/
hydraulic tensioning tools 000.33

Purpose of jobs to be done

Impart the necessary knowledge,

ensure safe use (of high--pressure tools).

Brief description

Hydraulic tensioning tool, high--pressure hose and high--pressure pump

are tools, which can, in spite of the high pressures, be used safely if the
instructions for use are followed.
The following are to be observed:
danger of accidents,
safety regulations, and
maintenance instructions.

Preliminary remarks

Despite the high service pressures they require, hydraulic tensioning tools,
high-pressure hoses and the high-pressure pump are devices that can be
operated safely and reliably, provided
- the instructions for use,
- the maintenance instructions and
- the safety regulations
are observed.

Safety regulations

J Study work cards carefully and observe safety regulations.

J Clean dirt away from contact surfaces of engine components or tools,
check the threads and clean them if necessary.
J Only use absolutely serviceable tools. Overhaul or replace defective/
dubious parts.
J Apply the specified tensioning pressures and lubricants.
J Use a low-viscous slushing oil as the hydraulic fluid (no lubricating oil,
no fuel oil).
J The securing ring (knurled, threaded ring) must be screwed up to the
stop after the hose coupling has engaged.
J Hose couplings to which no hose is connected have to be locked with
dummy plugs.
J Wear safety goggles.
J Keep persons away from the extended line of the bolt or hydraulic tool
axes.
J Maintain a safe distance from hydraulic tools and high-pressure hoses,
as far as possible.
J Increase the pressure on the pressure regulating valve slowly, do not
exceed the specified pressure.

6682 000.33--01 E 01.07 General 101/ 06

 J No heavy blows on loaded bolts, nuts and presses.
J Do not excessively bend high-pressure hoses; the minimum bending
diameter is 400 mm.
J After every tensioning process, check if the hydraulic piston has been
properly reset. The procedure is described in the work cards for the
hydraulic tensioning tools.
J When loosening hydraulically tightened bolts, do not exceed the speci-
fied tensioning pressure by more than 5%.
J When checking hydraulically tightened bolts, the loosening pressure
must not be more than 7% below or 5% above the specified tensioning
000.30).
pressure (see work card 000.30

If the loosening pressure is too low (max. 7% below the specified

value), the cause is to be traced (negligent tightening, wear, pro-
nounced settling of the screwed connection).
If the loosening pressure is 10% or more below the specified value,
MAN Diesel SE, Augsburg, is to be consulted for appropriate checking
measures.
If the loosening pressure is too high (tightening pressure plus 5% are
not sufficient for loosening), the cause is to be eliminated as far as
possible (screwed connection damaged/corroded / blocked by paint,
tensioning tool damaged/incorrectly mounted).
If it is not possible to undo the connection in spite of such improving
measures, the tensioning pressure may only be increased far enough
to allow the connection to be released if MAN Diesel SE, Augsburg,
verifiably has given its approval (danger of bolt overstretching/compo-
nent deformation). As an alternative solution, the nut is to be cut open,
and replaced together with the bolt.

Storage and care of the tools

J Store tools at temperatures between 15 and 25•C, if possible, in order

to avoid premature aging of plastic materials, and to keep the hydraulic
fluid at an appropriately low viscosity. Plastic seals are to be protected
against the action of light.
J Keep tools away from dust, dirt, chemicals and liquids so as to avoid
sealing faces to be damaged.
J Depressurise presses and high-pressure hoses before they are stored.
J Do not bend high-pressure hoses. Fit couplings into one another.
J When doing overhaul work, make sure to use original spare parts be-
cause proper performance depends, e.g., on the correct hardness of
O-ring seals.
J Check the pump’s pressure gauge for correct indication at regular inter-
vals.

Basic safety instructions

Obligations and liabilities Obligations and liabilities

- The basic requirement for the safe handling and trouble-free operation
of hydraulic tensioning tools is the knowledge of the basic safety in-
structions and the safety regulations.
- These operating instructions, and the safety instructions in particular,
are to be observed by all persons performing work on the hydraulic ten-
sioning tool.
- Moreover, all the rules and accident-prevention regulations applicable
at the usage site are to be observed.

6682 000.33--01 E 01.07 General 102/ 06

Hazards in connection with the Hazards in connection with the use of hydraulic tensioning tools
use of hydraulic tensioning tools
The hydraulic tensioning tool has been manufactured according to the
state of the art and in compliance with the accepted safety rules. Never-
theless, threats to life or physical condition of the user or third parties
and/or impairments on the tensioning tools or on other material assets
may occur during their use. The hydraulic tensioning tool is only to be
used:
J for the intended purpose,
J in unobjectionable, safe working condition.
Malfunctions which may affect the safety are to be remedied immediately.

Checking and keeping records of Checking and keeping records of the load cycles
the load cycles
After every load cycle (load reversal due to pressurisation and depressu-
risation), the hydraulic tensioning tool has to be subjected to a general vis-
ual inspection, and the thread has to be checked for damage and wear.

Important! At regular intervals (after approx. 100 load cycles), the

hydraulic tensioning tool has to be checked (general visual inspection,
checking the thread for damage and wear, and magnetic crack testing of
all components of the device) and the results have to be recorded in the
service records.

▲ Attention! After 2500 load cycles, the hydraulic tensioning tool

has to be taken out of operation and replaced by a new one! The
load cycles are to be recorded in the service records!

Warranty and liability Warranty and liability

As a matter or principle, our “General Conditions for Sales and Delivery”

apply. These were made available to the operator at the time the contract
was concluded at the latest. In case of damage to persons and property,
warranty and liability claims are excluded if the damage is due to one or
several of the following causes:
- Improper use of the hydraulic tensioning tool
- Improper mounting, taking into operation, operation and maintenance
of the hydraulic tensioning tool
- Operation of the hydraulic tensioning tool with defective safety equip-
ment or with components, safety and protection devices fitted im-
properly or in inoperable condition
- Non-observance of the information provided in the operating instruc-
tions regarding transport, storage, mounting, taking into operation,
operation, maintenance and setting up of the hydraulic tensioning tools
- Unauthorised structural changes carried out on the hydraulic tensioning
tool
- Unauthorised operating pressure changes
- Insufficient monitoring of the hydraulic tensioning tool and parts subject
to wear
- Improper repairs
- Non-observance of the maximum permissible load cycles of the hy-
draulic tensioning tool
- Cases of disaster caused by the detrimental effect of foreign matter
and force majeure.
Intended use Intended use

The hydraulic tensioning tool serves for tightening and loosening the
tightening-screw connections on the Diesel engine specified by MAN Die-
sel SE, Augsburg. This is effected by applying a high operating pressure

6682 000.33--01 E 01.07 General 103/ 06

 and tensioning pressure and their limits respectively, which have been
specified for the screwed connections.

Inappropriate use Inappropriate use

Use of the hydraulic tensioning tool for any other than the purpose stated
above is prohibited. In the case of inappropriate use, dangers may occur.
Such inappropriate use includes, e.g.:
J Use for any other type of screwed connection than the ones specified
J High-strength screwed connections in steel construction
J Tightening-screw connections in other areas.
Organisational measures Organisational measures

Supplementary to the operating instructions, the general legal and other

binding regulations for prevention of accidents and environment protection
are to be observed and according instructions are to be given!
Such obligations of the operator include, e.g.:
J Making available / wearing the personal protective outfit
J Checking all the available hydraulic equipment at regular intervals.
J The personal which is to perform work on/with the hydraulic tensioning
tool is, prior to commencement of the work, to be instructed in refer-
ence to the operating instructions and the safety instructions included
therein.
Safety equipment Safety equipment

Prior to taking the hydraulic tensioning tool into operation, it must always
be ensured that all the safety equipment has been fitted properly and is
fully operational.

Informal safety measures Informal safety measures

The operating instructions are always to be stored together with the hy-
draulic tensioning tool.

Supplementary to the operating instructions, the general as well as the

locally valid regulations for the prevention of accidents and the protection
of the environment are to be made available and observed.

Instructing the personnel Instructing the personnel

Only trained and instructed personnel is allowed to carry out work on and
with the hydraulic tensioning tool. The competences of the personnel with
regard to operation, alteration and maintenance are to be clearly fixed.
Personnel to be trained may only perform work on the hydraulic tensioning
tool under the supervision of an experienced person.

Safety measures in normal Safety measures in normal operation

operation
Prior to taking the hydraulic tensioning tool into operation, it must be en-
sured that no one can be endangered by the tool. At least once during
every load cycle, the hydraulic tensioning tool is to be checked for visible
damage on the outside and for the operability of all the safety equipment.

▲ Attention! During pressurisation, attention must be paid to the

permissible operating/tensioning pressure of the respective hy-
draulic tensioning tool and the screwed connection to be tightened!
For hydraulic tensioning tools/cylinders with a low operating pres-
sure, there is no additional pressure limitation for the max. operating
pressure of the pump. When such a tool is used, particular attention
is to be paid to the pressure gauge!

6682 000.33--01 E 01.07 General 104/ 06

 ▲▲▲ Danger! Take the residual mechanical, hydraulic and pneu-
matic energies occurring on the hydraulic tensioning tool into con-
sideration and take corresponding actions when instructing the op-
erating personnel.

Points of particular danger Points of particular danger

Period of use of hydraulic hose pipes and seals

J Pay attention to the period of use stated by the manufacturer of the
hoses!
Connection of the hose pipe
J Hose connections have to be checked prior to starting operation.
J The connections must be engaged and interlocked.
J Hose pipes may only be disconnected when the hydraulic system is in
unpressurised condition.
Defective hose pipes
J High-pressure hose pipes are subject to an operating pressure of
1500 bar (bursting pressure >3300 bar) and are jacketed by a protec-
tive hose. They are to be checked for damage prior to taking them into
operation.
J Do not bend hose pipes excessively. The minimum bending diameter
of the high-pressure hose pipe is 400 mm.
J Only use hose pipes approved by MAN Diesel SE, Augsburg!
Bruising of limbs between tensioning cylinder and thrust pad
J When screwing the hydraulic tensioning tool onto the bolt, make sure to
keep your hands out of the area where the tensioning cylinder and
thrust pad will be seated!
J While pressurising the tool, make sure to keep your hands out of the
area where the tensioning cylinder and the thrust pad will be seated!
Hot surfaces and components
J Touch hot surfaces of components only when wearing protective gloves
and protective clothing!
J Let components cool off before touching surfaces when not wearing
protective gloves and protective clothing respectively!
Rupture of the bolt
J During pressure build-up, keep out of the direction of force, i.e. the ex-
tended axis of the respective bolt.
Defective components
J After every tensioning process, the threads are to be cleaned and
checked for damage
J Damaged and worn parts (tension screw, nut etc.) must not be used
under any circumstances and are to be replaced immediately.

6682 000.33--01 E 01.07 General 105/ 06

 Due to the high pressures and forces, particular attention is to be paid to
the following:
J Risk of fracture of highly loaded parts during pressure build-up in the
tool (preloading, releasing and routine testing). Broken parts will be
flung in the direction of the force applied, i.e. the extended axis of the
bolts or presses. Such a hazard exists during pressure build-up or
when the hydraulic tool is under full tension and additional stress is in-
duced by heavy blows.
J Risk of ejection of needle-like or razor-sharp hydraulic fluid jets due to
leaky sealing elements, bursting hoses or fracture of fittings. Hazard of
injury of the skin or the eyes at distances of up to one metre.
J Rupture of running gear bolts causing serious engine damage may
occur if the tightening processes have not been carried out according
to the instructions. Possible causes of failure: incorrect pressure built
up during preloading, connection of a hose has been omitted, the hose
coupling has not engaged properly, the tensioning process has not
been properly controlled (length not measured, the number of holes for
nut tightening was neglected).
Hydraulic tensioning tool, sy- Hydraulic tensioning tool, system
stem
J Work on hydraulic equipment may only be done by persons having
special knowledge and experience in dealing with hydraulics!
J Check all pipes, hoses and screwed connections at regular intervals for
leakages and damage that is visible from the outside! Remedy dam-
age immediately! Spurting out oil may cause injuries and fire.
J Hose pipes which are to be opened are to be depressurised according
to the subassembly group description prior to starting repair or assem-
bly and fitting work!
J Use only the hydraulic fluids specified by MAN Diesel SE, Augsburg.
J Install and fit high-pressure hose pipes properly! Do not mix up the con-
nections! Fittings, length and quality of the hose pipes must meet the
requirements.
J When carrying out work on/with the hydraulic tensioning cylinder, wear
safety goggles and protective gloves. Keep out of the immediate vicin-
ity of the device while pressure is being built-up.
Servicing and maintenance, Servicing and maintenance, trouble shooting
trouble shooting
J Carry out the specified adjustments, maintenance and inspection work
in time.
J Secure hydraulic tensioning tools against inadvertent taking into oper-
ation.
Structural changes on the hy- Structural changes on the hydraulic tensioning tool
draulic tensioning tool
J Do not carry out any modifications, attachments or alterations on the
hydraulic tensioning tool without prior written consent of the manufac-
turer.
J All alteration measures have to be approved in writing by Messrs MAN
Diesel SE, Augsburg.
J Hydraulic tensioning tools which are not in an unobjectionable condition
are to be replaced immediately! Use only original spare and wear parts!
In case parts supplied by third parties are used, it is not guaranteed
that they have been designed and manufactured appropriately to the
type of duty and with regard to security.

6682 000.33--01 E 01.07 General 106/ 06

High-- pressure pump
Use 009.03

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

The high--pressure pump produces the pressure required for tightening

and untightening the large bolted connections by means of the hydraulic
tensioning tool. It is driven by compressed air and produces pressures up
to 1,500 bar at low delivery rates.
Information is imparted concerning:
technical data,
putting into operation,
putting out of operation,
maintenance, and
behaviour in case of disturbances.

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.342 Standard
1 Tools, basic scope 009.229 Optional
1 Anti--corrosion oil (Viscosity 6--16 mm2/s) -- Inventory

Technical details

Term Information
Quality Anti--corrosion oil
Pressure range 0 -- 1500 bar
Test pressure 1500 bar
Oil filling 5 litres
Compressed air connection 7 -- 15 bar
Dimensions 431x317x405 mm
Weight 30.5 kg

Structure/operating principle

The following is required for tightening and untightening large-sized bolted

connections:
- the high-pressure pump,

6682 009.03--05 E 02.07 L 40/54, 48/60 B, 48/60 B CR 101/ 05

 - special, pressure-resistant hose lines, and
- hydraulic tensioning tools, with resetting devices if necessary.
The high-pressure pump delivers a relatively low volume of fluid (under
pressures of up to 1,500 bar if required) through push-and-lock hose lines
to one or several hydraulic tensioning tools.
After the piston of the hydraulic tensioning tool has been screwed onto the
bolt thread, the fluid will lift the piston in the casing, whereby the bolt is
elongated; the hydraulic tensioning tool as such is supported on the envi-
ronment of the bolt.
The high-pressure pump is driven by compressed air. The air is passed
through control elements and directed onto one piston. Air admission to
this piston is possible from both sides. This piston carries pistons of a
smaller diameter on either side which draw anti-corrosion oil from their en-
vironment, or deliver oil to the distributor on the opposite side. As soon as
the piston reaches an end position, a pilot valve directs the air flow to the
other side of the piston, and the delivery and intake process is repeated.
The pressure on the air side is normally limited so that a pressure of
1500 bar can be produced on the hydraulic side. A basic pressure of
1500 bar must not be exceeded.

Putting into operation

▲ Attention! Observe the safety instructions given in Work Card

000.33!
000.33

Steps 1. Check the oil level on the oil-level gauge (5); if necessary, open the
oil admission socket (1) and top up anti-corrosion oil.
Important! When topping up anti-corrosion oil make sure that this
is exclusively done through the filling strainer because foreign particles
may cause failures.
2. Connect the high-pressure pump to the hydraulic tensioning tool by
means of the high-pressure hose.
3. Set the shut-off valve (A) to Position II / OUT OF OPERATION.
4. Connect the compressed-air line to the hose connection (6).
5. Adjust the pressure regulating valve (C) so that the pressure gauge
(7) for the supply of compressed air indicates approximately 1 bar.
6. Open the relief valve (B) (counter-clockwise) to relief the oil side of
the high-pressure pump.
7. Check whether the high-pressure hose has been connected correctly
and the hose connections (4) not needed have been plugged using
dummy plugs (block the sliding sleeve of the coupling by means of
the arresting ring).
8. Set the shut-off valve (A) to Position I / OPERATION - the high-
pressure pump will start operating.
9. Close the relief valve (B) (clockwise).
Important! When connecting the high-pressure hose and the hy-
draulic tensioning tool, these must be vented and completely filled with
anti-corrosion oil, too.
10. Stepwise turn the pressure regulating valve (C) for compressed air
clockwise until the desired pressure is indicated on the oil pressure
gauge (3) (depending on the size of the hydraulic tensioning tool, this
is done with a time lag).
Tip! The high-pressure pump operates until the adjusted oil pressure
has been reached, leakage losses are automatically compensated by top-
ping up.

6682 009.03--05 E 02.07 L 40/54, 48/60 B, 48/60 B CR 102/ 05

Taking out of operation

Steps 1. Set the shut-off valve (A) to Position II / OUT OF OPERATION, thus
venting the air side of the high-pressure pump.
2. Open the relief valve (B) to depressurise the oil side of the high-pres-
sure pump (the oil pressure gauge (3) will indicate zero). Pressure
decay in the high-pressure hose takes longer. Therefore, leave the
high-pressure hose connected to the high-pressure pump with the
relief valve open for approx. three minutes after pressure relief.
Otherwise, an internal pressure may remain, which would block the
009.05).
hose coupling (for corrective action, see Work Card 009.05
3. Disconnect the quick-lock coupling of the high-pressure hose.
▲ Attention! Never open quick-lock couplings under pressure. Ac-
cident hazard! The oil pressure gauge (3) must indicate zero.
Tip! If several screwed connections are to be tensioned successively at
the same pressure, the setting of the pressure regulating valve (C) re-
mains the same, it need not be newly adjusted.
4. Leave the high-pressure hose on the hose connection (4) and re-
move the anti-corrosion oil from the hydraulic tensioning tool (for the
description of this procedure, see work card for the respective ten-
sioning tool).
5. Disconnect the high-pressure hose.

Maintenance

The components and connections of the high-pressure pump are to be

checked for tightness from time to time, and overhauled if necessary. The
set of wear parts (2) for the high-pressure pump and pressure regulating
valve (C) has been attached behind the side plate.
Prior to use, the oil level is always to be checked on the oil level gauge (5)
and topped up if necessary. The high-pressure pump must never run
completely dry because air would then be aspirated. Approx. once a year,
the oil charge is to be drained, and fresh anti-corrosion oil is to be be filled
in. On every oil change, the oil space is also to be cleaned.
To remove water from the compressed-air filter on the compressed-air reg-
ulator, the side plate is to be removed, and the screw plug at the bottom of
the compressed-air regulator is to be screwed in by a few turns so that the
water can pressure controller is to be screwed further in by a few turns in
order that the water can flow out. Afterwards, retighten the screw plug
again. See operating instructions of the manufacturer.

In the case of operating troubles

Compressed-air part 1. The high-pressure pump only operates at pressures > 1.5 ... 2 bar.
Reason: The friction of the pilot valve gasket is too high.
Remedy: Lubricate or renew the O-ring seals on the pilot valve.
2. The high--pressure pump does not run, or runs but slowly.
Reason 1: Compressed air side is not tight.
Remedy: Replace the O-ring seals.

Reason 2: Venting holes are clogged with ice.

Remedy: Heat the pump to approx. 20 EC.
3. The high-pressure pump does not generate pressure, or stops at
dead centre.
Reason: Ice clogging on the air side, or functional deficiency.
Remedy: Replace the O-ring seals on the pilot valve or air piston.

6682 009.03--05 E 02.07 L 40/54, 48/60 B, 48/60 B CR 103/ 05

 4. Condensed water emerges at the silencer of the ventilation.
Reason: The compressed air filter is filled with water.
Remedy: Drain the compressed air filter.

Hydraulic part 1. The high-pressure pump is operating, however, not delivering

Reason 1: There is air in the suction pipe.
Remedy: Bleed air from the hydraulic system.

Reason 2: The suction filter is clogged.

Remedy: Clean the suction filter.

2. Hydraulic oil emerges at the silencer.

Reason: Piston seal is worn or not tight.
Remedy: Replace the seal.

1 Oil admission socket

with filling strainer
2 Set of wear parts
3 Oil pressure gauge
4 Hose connection
(tensioning tool)
5 Oil level gauge
6 Hose connection
(compressed air)
7 Compressed-air pres-
sure gauge

A Shut-off valve
B Relief valve
C Pressure regulating
valve

Figure 1. High-pressure pump, GERUS make, type HP25

6682 009.03--05 E 02.07 L 40/54, 48/60 B, 48/60 B CR 104/ 05

 A Shut-off valve
B Relief valve
C Pressure regulating
valve

Figure 2. High-pressure pump - functional diagram

6682 009.03--05 E 02.07 L 40/54, 48/60 B, 48/60 B CR 105/ 05

High-- pressure hoses
Use 009.05

Purpose of jobs to be done

Impart the necessary knowledge,

ensure safe use (of high--pressure tools).

Brief description

High--pressure hoses are required for connecting the hydraulic tensioning

tools with the high--pressure pump. They transmit high pressure.
Information is imparted concerning:
proper use/application and
forcing open of non--return valve.

Tools/appliances required

Qty Designation No. Availability

1 High--pressure hose 009.330 Standard
1 High--pressure hose 009.306 Standard
1 High--pressure hose 009.305 Standard
1 High--pressure hose 009.304 Standard
1 Opener 009.026 Standard

Related work cards

Work card Work card Work card

000.33

Design

Special, pressure-resistent hoselines are used to connect the high-pres-

sure pump with hydraulic tensioning tools. These hoses consist of a steel-
wire-clad synthetic hose on the inside and a protective external hose
which collects the fluid issuing in case of leakage.
Admissible service pressure
J under constant load 1500 bar,
J under pulsating load 900 bar.
Minimum burst pressure 3300 bar.

6682 009.05--01 E 03.07 32/40, 40/54, 48/60, 58/64, 32/44 CR 101/ 02

Using

High-pressure hoses are equipped with quick-lock safety couplings at both

ends, which have to be secured against inadvertent disconnection by an
additional threaded ring. The knurled threaded ring is to be screwed down
to the stop after the coupling has engaged.

▲ Attention! Observe the safety instructions in work card 000.33

000.33!
Take the maximum usability specified by the manufacturer into ac-
count!

Force the non-return valve open After having been used, i.e. after the high-pressure pump has been
switched off and the relief valve has been opened, the hoses should be left
connected for approx. 3 more minutes. Otherwise, residual internal pres-
sure may block the hose coupling when attempting to pull it off. As a re-
sult, it may happen that the high-pressure hose can no longer be inserted
in the coupling. In this case, the non-return valve has to be opened using
the opener (009.026) - see Figure 2 . Other tools must not be used to
avoid damage.
The high-pressure hoses are equipped with non-return valves on both
ends, which provide protection against leakage during storage.

Figure 1. High--pressure hose with opener mounted (left at the bottom)

1 Hydraulic nipple on the

high-pressure hose
2 Threaded piece for
fixing in place
3 Threaded piece for
forcing the valve open

Figure 2. Using the opener

6682 009.05--01 E 03.07 32/40, 40/54, 48/60, 58/64, 32/44 CR 102/ 02

Dial gauge (measuring device)
Checking the bolt elongation 009.06

Purpose of jobs to be done

Tighten and untighten important bolted connections at the correct values,

ensure correct execution of work.

Brief description

The measuring device serves the purpose of determining the bolt

elongation for comparison with a reference value. This is to ensure that
bolts of particular significance are tightened correctly by means of the
hydraulic tensioning tool.
The work/steps include:
proper utilisation/application and
measuring the elongation.

Tools/appliances required

Quant Denomination No. Availability

1 Measuring device 009.051 Standard
1 Magnetic prism with support 009.051--1 Standard
1 Clamping piece 009.051--5 Standard
1 Sleeve 009.051--6 Standard
1 Dial gauge (measuring device) 009.051--14 Standard
1 Extension 009.051--15 Standard
1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard

Related work cards

Work card Work card Work card

000.29 000.30 009.09
009.11

Preliminary remarks

Screwed connections of particular significance require that the bolt

elongation is measured and compared with a reference value. This is to
ensure that the necessary preload resulting from the bolt elongation and
from forcing the corresponding components together is really achieved.
This is not the case if the tensioning tool is blocked or if some of the
tensioning pressure is absorbed by friction.

6641 009.06--01 E 05.98 L 58/64 101/ 02

 1 Stud
2 Knurled nut
3 Thrust pad
4 Casing
5 Piston

Figure 1. Measuring instrument, attached to hydraulic tensioning tool

Operating sequence 1 -- Measure the bolt elongation al

Starting condition Screwed connection released, tensioning tool put in place and ready to be
operated.

Steps 1. Switch on the high--pressure pump and tighten the bolt to the
pretensioning pressure (for the value, please refer to work card
000.30)
000.30 using the tensioning tool.
2. Attach the measuring device (009.051) to the casing of the tensioning
tool. Appropriately match the dial gauge and feeler positions by
omission of the sleeve (6), turning the clamping piece (5), using the
extensions (15, 16). Set the dial gauge to ”0”.
3. Increase the tensioning pressure to the prescribed ultimate level (see
000.30). Tighten the nut by hand, using the tommy bar.
work card 000.30
4. Reduce the pressure to ”0” and load to pretensioning pressure again.
5. The dial gauge reading corresponds to bolt elongation/contact
pressure of components al. Convert the reading into millimeters and
compare with the set point value (refer to work card 000.30).
000.30
▲ Attention! Bolts are to be tightened applying the specified oil
pressure, and not to elongation al. al measurement is a control
measure only.
6. In case of larger deviations from the set point value, repeat the
procedure; otherwise, check the tensioning tool, the screwed
connection and the pressure gauge.
7. Reduce the pressure to ”0”. Dismount the tensioning tool.

6641 009.06--01 E 05.98 L 58/64 102/ 02

Hydraulic tensioning tool (single)
Use 009.01

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

the components to be connected. In this condition, the nuts can be
tightened or loosened without application of force.
The work includes:
untightening and tightening.

Tools/appliances required

Quant Denomination No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.330 Standard
1 High--pressure hose 009.306 Standard
1 High--pressure hose 009.305 Standard
1 High--pressure hose 009.304 Standard
1 Hydraulic tensioning tool 009.301 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.02
009.03 009.05

Technical details

Term Information
Nominal pressure 1,000 bar
Effective piston area 122.5 cm/2
Delivery stroke 10.5 mm

6619 009.01--01 E 04.98 L 58/64 101/ 03

Preliminary remarks

Prerequisite for correct tightening of screwed fitting is a pressure gauge

that gives accurate readings. In case of doubt, check the reading by
comparing with another pressure gauge.

Operating sequence 1 -- Untightening

Steps 1. Place sleeve (4) and tensioning tool (7) with piston (8) over nut (5)
centrically.
2. Connect high-pressure pump (3) with high-pressure hose (2) to
hydraulic tensioning tool and open relief valve on pump.
3. Screw tensioning nut (1) onto bolt (6), using tommy bar (9), tighten
nut snugly and thereby force piston (8) all the way into tensioning
tool (7).
4. Back-off tensioning nut (1) by 450ƒ (1 1/4 turns).
5. Switch on high-pressure pump and tighten carefully until nut can be
009.03).
released (refer to work card 009.03
▲ Attention! In the process, the pressure must not exceed the
000.30).
tensioning pressure by more than 5% (refer to work card 000.30
6. Using tommy bar, turn nut (5) back through the recess in the sleeve,
000.30.
for back-off angle refer to work card 000.30
7. Release pressure, screw off tensioning nut and deposit it.
8. Detach high-pressure hose with plug-in connector from tensioning
tool.
9. Remove hydraulic tensioning tool and sleeve.
10. Screw off nut (5).

1 Tensioning nut
2 High-pressure hose
3 High-pressure pump
4 Sleeve
5 Nut
6 Bolt
7 Hydraulic tensioning
tool
8 Piston
9 Tommy bar

Figure 1. Mounting of the single tensioning tool (009.301)

Operating sequence 2 -- Tightening

Steps 1. Screw nut (5) onto bolt (6) and tighten by hand.
2. Fit sleeve (4) and tensioning tool with piston (7 and 8) centrically.
3. Connect high-pressure pump (3) with high-pressure hose (2) to
hydraulic tensioning tool and open relief valve on pump (refer to work
009.03).
card 009.03
4. Screw tensioning nut (1) onto bolt (6), tighten snugly and thereby
force piston (8) all the way into tensioning tool (7).
5. Switch on high-pressure pump and raise pressure to specified rating
(refer to work card 000.30).
000.30
6. Using tommy bar, tighten nut through recess in the sleeve until it
abuts firmly.

6619 009.01--01 E 04.98 L 58/64 102/ 03

 7. Release pressure, screw off tensioning nut and deposit it.
8. Disconnect high-pressure hose from tensioning tool at the plug-in
connector.
9. Remove hydraulic tensioning tool and sleeve.
▲▲ Caution! When tightening, ensure that nobody is standing in
the area of the extended axis of the screw bolt being tensioned (if
tensioning tool is damaged, there exists the danger of accident).

6619 009.01--01 E 04.98 L 58/64 103/ 03

Hydraulic tensioning tool (single)
Checking,
Renewing the seal rings 009.02

Purpose of jobs to be done

Check state/wear condition of components.

Brief description

Hydraulic tensioning tools have to be checked for tightness at regular

intervals. In case of untightness of tensioning tool, the seal rings have to
be renewed.
The work includes:
checking for tightness.

Tools/appliances required

Qty Designation No. Availability

1 Hydraulic tensioning tool 009.301 Standard
1 Casing 009.301--1 Standard
1 Piston 009.301--2 Standard
1 O--ring seal 009.301--3 Standard
1 Backing ring 009.301--4 Standard
1 O--ring seal 009.301--5 Standard
1 Backing ring 009.301--6 Standard
1 Threaded piece 009.301--7 Standard
1 Seal 009.301--8 Standard
1 Hydraulic nipple 009.301--9 Standard
1 Securing compound Loctite 586 -- Inventory

Related work cards

Work card Work card Work card

009.01 009.03

6619 009.02--01 E 03.03 L 58/64 101/ 02

Technical data

Tool No. 009.301

Effective piston area (cm2) 122.52
Delivery stroke (mm) 10.5
Nominal pressure (bar) 1200
Test pressure (bar) 1300

Operating sequence 1 -- Checking for tightness

Steps 1. Pressurise the hydraulic tensioning tool (009.301) at the

corresponding test pressure for five minutes. Piston (2) should be
lifted to 2/3 of maximum delivery stroke.
2. If hydraulic oil escapes during pressure testing, the O-ring seals (3
and 5) have to be renewed.
Important! Check for correct position of backing rings (4 and 6) -
refer to Figure 1 .
3. Glue the threaded piece (7) into the hydraulic nipple (9) using
LOCTITE Type 586. Use a new sealing ring (8) when fitting the
hydraulic nipple to the casing (1). Screw the hydraulic nipple in
applying the specified tightening torque (60Nm).

1 Casing 6 Backing ring

2 Piston 7 Threaded piece
3 O-ring seal 8 Sealing ring
4 Backing ring 9 Hydraulic nippel
5 O-ring seal

Figure 1. Hydraulic single tensioning tool (009.301)

6619 009.02--01 E 03.03 L 58/64 102/ 02

Hydraulic tensioning tool
Use 009.07

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

components to be connected. In this condition, nuts can be tightened or
loosened without applying force. The piston is pressed back into its initial
position by disk springs.
The work/steps include:
untensioning and tensioning.

Tools/appliances required

Qty Designation No. Availability

1 Hydraulic tensioning tool 009.347 Standard
1 Hydraulic tensioning tool 009.346 Standard
1 High--pressure pump 009.342/(009.341) Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.208 Standard
1 Open--jaw wrench 55 000.570 Standard
1 Tommy bar, 6 mm 000.261 Standard

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.08

Technical details

Term Information
Nominal pressure 1000 bar
Test pressure 1 050 bar
Tool number 009.208 /
009.346 / 009.347
Effective piston area 2 x 20.23 = 40.46 cm2
Delivery stroke 3.5 mm

6682 009.07--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 101/ 04

Preliminary remarks

By means of the piston and the casing of the hydraulic tensioning tool,
supplemented by the thrust pad and the nut, the bolt is elongated relative
to the components to be connected. This is done by anti-corrosion oil be-
ing pressed against the piston underside by means of the high-pressure
pump. If a sufficiently high pressure is applied, the nut of the bolt comes
clear and can either be loosened or fastened to specification.
Hydraulic tensioning tools as well as high-pressure hoses must be com-
pletely filled with anti-corrosion oil prior to use. They have to be vented if
required. The unit should be checked for tightness from time to time (see
work card 009.08).
009.08

Operating sequence 1 - Untensioning a bolt

Starting condition The thread of the bolt has been cleaned.

Steps 1. Place the thrust pad (4) over the nut (6).
2. Using the open-jaw wrench (000.570), check whether the nut (3) has
been firmly screwed onto the hydraulic tensioning tool (1).
3. Screw the hydraulic tensioning tool (1) onto the bolt (7), making sure
that the thrust pad (4) is placed concentrically. Refer to Figure 1 .
Tip! For screwing in place, insert the tommy bar in bore (B).
4. Following attachment, turn the hydraulic tensioning tool (1) including
the nut (3) back by the back-off angle applicable for the correspond-
ing screwed connection (see work card 000.30).
000.30 Refer to Figure 1 .
5. Connect the high-pressure hose to the hydraulic tensioning tool (1)
and high-pressure pump.
009.03), and close
6. Switch the high-pressure pump on (see work card 009.03
the gap (A) produced by turning back.
▲▲▲ Danger! During untensioning, make sure that there is no one
along the extended axis of the bolt to be untensioned!
7. Pump the hydraulic tensioning tool (1) up until the nut (6) can be
loosened.
▲ Attention! The pressure applied should not be more than 7% be-
low and 5% above the tensioning pressure (refer to work card
000.30)!
000.30
8. Insert the tommy bar (5) through the opening in the thrust pad (4),
and slacken the nut (6) - for back-off angle, see work card 000.30.
000.30
9. Release the pressure, disconnect the high-pressure hose from the
hydraulic tensioning tool (1) and the high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by a set of disk springs (2) - this takes approx. 2 to 3 min-
utes. For this purpose, however, the high-pressure pump has to be con-
009.03).
nected and its relief valve has to be open (see work card 009.03
10. Remove the tensioning tool.

Operating sequence 2 - Tensioning a bolt

Starting condition The nut has been screwed on and tightened by hand. The thread of the
bolt has been cleaned.

6682 009.07--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 102/ 04

 ▲ Attention! Correct tensioning of a bolted connection requires the
pressure gauge indication to be correct! In case of doubt, check the
pressure gauge against a reference pressure gauge!

Steps 1. Place the thrust pad (4) over the nut (6).
2. Using the open-jaw wrench (000.570), check whether the nut (3) has
been firmly screwed onto the hydraulic tensioning tool (1).
3. Screw the hydraulic tensioning tool (1) onto the bolt (7), making sure
that the thrust pad (4) is placed concentrically. Refer to Figure 2 .
Tip! For screwing in place, insert the tommy bar in bore (B).
4. Connect the high-pressure hose to the hydraulic tensioning tool (1)
and high-pressure pump.
5. Switch the high-pressure pump on (see work card 009.03
009.03), and ten-
sion the bolt (7) applying the specified tensioning pressure (see work
000.30).
card 000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the bolt to be tensioned!
6. Insert the tommy bar (5) through the opening in the thrust pad (4),
and screw down the nut (6), hand-tight.
7. Release the pressure, disconnect the high-pressure hose from the
hydraulic tensioning tool (1) and high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by a set of disk springs (2) - this takes approx. 2 to 3 min-
utes. For this purpose, however, the high-pressure pump has to be con-
009.03).
nected and its relief valve has to be open (see work card 009.03
8. Remove the tensioning tool.

1 Hydraulic tensioning
tool
2 Disk spring
3 Nut
4 Thrust pad
5 Tommy bar
6 Nut
7 Bolt

A Gap
B Bore for inserting the
tommy bar

Figure 1. Bolt with tensioning tool attached - Untensioning

(Figure shows hydraulic tensioning tool with tool number 009.346)

6682 009.07--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 103/ 04

 1 Hydraulic tensioning
tool
2 Disk spring
3 Nut
4 Thrust pad
5 Tommy bar
6 Nut
7 Bolt

B Bore for inserting the

tommy bar

Figure 2. Bolt with tensioning tool attached - Tensioning

(Figure shows hydraulic tensioning tool with tool number 009.346)

6682 009.07--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 104/ 04

Hydraulic tensioning tool
Disassembling and assembling 009.08

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

whenever they are used. They must be vented, if necessary, and checked
for leaks occasionally. In case they leak, the sealing rings must be
replaced.
The work/steps include:
venting,
checking for leaks,
disassembly and assembly,
replacement of sealing rings/sealing elements.

Tools/appliances required

Qty Designation No. Availability

1 Hydraulic tensioning tool 009.347 Standard
1 Hydraulic tensioning tool 009.346 Standard
1 High--pressure pump 009.342/(009.341) Standard
1 High--pressure hose 009.306 Standard
1 Tools, basic scope 009.229 Optional
1 Opener 009.026 Standard
1 Eye bolt 001.404 Standard
1 Open--jaw wrench 55 000.570 Standard
1 Open--jaw wrench 46 000.568 Optional
1 Hexagon screw driver 12 000.299 Optional
1 Anti--corrosion oil -- Inventory
1 Molecular Gold grease (lubricant) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.07

6682 009.08--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 101/ 05

Tool No./Spare part No.

Item Designation Tool No. Tool No.

- Hydr. tensioning tool, complete 009.346 009.347
1 Hydraulic nipple 009.346-1 009.347-1
2 Sealing ring 009.346-2 009.347-2
3 Threaded piece 009.346-3 009.347-3
4 Nut 009.346-16 009.347-25
5 Piston 009.346-18 009.347-18
6 Casing 009.346-21 009.347-21
7 Casing 009.346-24 009.347-24
8 Disk spring 009.346-10 009.347-10
9 Piston 009.346-17 009.347-17
10 Closing cap 009.346-13 009.347-13
11 Backing ring 009.346-23 009.347-23
12 O-ring seal 009.346-22 009.347-22
13 Backing ring 009.346-19 009.347-19
14 O-ring seal 009.346-20 009.347-20
15 Sealing ring 009.346-4 009.347-4

Preliminary remarks

Hydraulic tensioning tools as well as high-pressure hoses must be com-

pletely filled with anti-corrosion oil prior to use. They have to be vented if
required, and checked for tightness from time to time.
The hydraulic tensioning tool has to be disassembled if backing rings/O-
ring seals are to be replaced, and if it has suffered damage. If disas-
sembled, all the backing rings/O-rings seals are to be replaced for practi-
cal reasons. Major interventions/repairs are advised against, because of
the high working pressures and critical clearances and surfaces. We rec-
ommend that you have the tool overhauled by MAN Diesel SE or one of
the authorised service bases in case of need.

Operating sequence 1 -- Disassembly of the hydraulic tensioning tool

Starting condition The hexagon screw driver has been clamped into the vice.

Steps 1. Place the piston (9) on the clamped-in hexagon screw driver
(000.299).
2. Loosen the nut (16) by means of the open-jaw wrench (000.570), and
unscrew it.
3. Remove the disk springs (8).
4. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool.
5. Using the opener (009.026), open the nun-return valve on the high-
009.05).
pressure hose (see work card 009.05
Important! Unless the non-return valve is open, the casing (7) can-
not be pulled off.
6. Pull the casing (7) off.
7. Disconnect the hydraulic hose from the hydraulic nipple (1).
8. Place the piston (9) on the clamped-in hexagon screw driver.

6682 009.08--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 102/ 05

 9. Loosen the nut (4) by means of the open-jaw wrench (000.568), and
unscrew it.
▲ Attention! The screwed connection of nut and piston has a left-
hand thread!
10. Remove the sealing ring (15).
11. Pull the piston (5) and the casing (6) off.
12. Screw the eye bolt (001.404) into the piston (5), and remove the
latter from the casing (6).
13. Remove the backing rings (11 and 13) as well as the O-ring seals (12
and 14).
14. Clean all the individual components and check them for damage, re-
place them if necessary.
15. Purge the oil bores in the piston (9) with compressed air.

Operating sequence 2 -- Assembly of the hydraulic tensioning tool

Starting condition All individual components have been cleaned, checked for damage, and
replaced if necessary. The hexagon screw driver has been clamped into
the vice.

Steps 1. Check new backing rings (11 and 13) as well as O-ring seals (12 and
14) to see if they are intact.
2. Coat the backing rings (13) and O-ring seals (14) with anti-corrosion
oil and place them in the respective grooves, making sure that they
are evenly tensioned over the entire circumference, and not twisted.
Refer to Figure 1 .
▲ Attention! Make sure that the backing ring and the O-ring seal
are positioned correctly! Always insert the O-ring seals on the pres-
sure side, the backing ring on the opposite side, with the depression
in the backing ring pointing towards the O-ring seal! Refer to Fig-
ure 1 /detail “Y” and “Z”.
3. Coat the backing rings (11) with anti-corrosion oil, and insert them
into the respective grooves.
4. Coat the O-ring seals (12) with anti-corrosion oil, bend them so that
they become kidney-shaped, and insert them into the respective
grooves, making sure that they are not twisted. See Figures 1 and
3 .

▲ Attention! Make sure that the backing ring and the O-ring seal
are positioned correctly! Always insert the O-ring seals on the pres-
sure side, the backing ring on the opposite side, with the depression
in the backing ring pointing towards the O-ring seal! Refer to Fig-
ure 1 /detail “X” and “Z”.
5. Apply a thin film of Molecular Gold grease (lubricant) to the running
surface of pistons (5 and 9) as well as casings (6 and 7).
▲ Attention! Backing rings, O-ring seals, and grooves must remain
free from grease!
6. Press the piston (5) into the casing (6).
7. Put the casing (6) together with the piston (5) onto the piston (9) and
slide them on.
8. Place piston (9) on the clamped-in hexagon screw driver (000.299).
9. Put a new sealing ring (15) onto the piston (9). Refer to Figure 1 .
10. Screw the nut (4) on so that it contacts the piston (9), and tighten it
by means of the open-jaw wrench (000.568).
▲ Attention! The screwed connection of nut and piston has a left-
hand thread!
11. Connect the high-pressure hose (009.306) to the hydraulic nipple (1).

6682 009.08--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 103/ 05

 12. Open the non-return valve on the high-pressure hose by means of
009.05.
the opener (009.026). See work card 009.05
Important! Unless the non-return valve is open, the casing (7) can-
not be put on.
13. Slip the casing (7) onto the piston (9) so that it contacts the cas-
ing (6). Refer to Figure 1 .
14. Disconnect the high-pressure hose from the hydraulic tensioning tool.
15. Install the disk springs (8), observing the correct order. Refer to Fig-
ure 1 .
16. Screw the nut (16) onto the piston (9) and tighten it, hand-tight.
17. Place piston (9) on the clamped-in hexagon screw driver. Screw the
nut (16) on all the way, until it is seated, using the open-jaw wrench
(000.570). Refer to Figure 2 .
Important! The disk springs have to be compressed slightly.
18. Attach the hydraulic tensioning tool to a suitable bolt (see
corresponding work card) so that the hydraulic nipple (1) points
upward.
19. Connect the high-pressure hose to the hydraulic tensioning tool and
high-pressure pump (009.341 or 009.342).
009.03), and pump
20. Switch the high-pressure pump on (see work card 009.03
the hydraulic tensioning tool up.
▲ Attention! Make sure that the tensioning pressure specified for
the selected bolt is not exceeded (see work card 000.30)!
000.30
21. Release the pressure.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated set of disk springs (this takes approx. 2 to
3 minutes. For this purpose, however, the high-pressure pump has to be
009.03).
connected and its relief valve has to be open (see work card 009.03

When the piston is reset by the disk springs, the remaining air escapes
into the high-pressure hose.
22. Disconnect the high-pressure hose.
23. Vent the high-pressure hose by means of the opener (see work card
009.05).
009.05
24. Reconnect the high-pressure hose.
25. Pump the hydraulic tensioning tool up until the tensioning pressure
000.30).
specified for this bolt has been reached (see work card 000.30
Maintain the pressure for five minutes.
Important! After the hydraulic tensioning tool has been pumped up,
there must not be any visible leakage within the period the pressure is
maintained.
26. Release the pressure, disconnect the high-pressure hose from the
hydraulic tensioning tool and high-pressure pump.
27. Remove the tensioning tool.

6682 009.08--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 104/ 05

 1 Hydraulic nipple
2 Sealing ring
3 Threaded piece
4 Nut
5 Piston
6 Casing
7 Casing
8 Disk spring
9 Piston
10 Closing cap
11 Backing ring
12 O-ring seal
13 Backing ring
14 O-ring seal
15 Sealing ring

Figure 1. Hydraulic tensioning tool

7 Casing
8 Disk spring
9 Piston
16 Nut

Figure 2. Hydraulic tensioning tool with nut screwed on

Figure 3. Bending the O-ring seal so that it becomes kidney-shaped

6682 009.08--01 E 02.07 32/40, 40/54, 48/60, 58/64, 48/60 B 105/ 05

Hydraulic tensioning tool (tandem)
Use 009.09

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

components to be connected. In this condition, nuts can be tightened or
loosened without applying force. The piston is pressed back into its initial
position by disk springs.
The work includes:
untightening and tightening.

Tools/appliances required

Quant Denomination No. Availability

1 Hydraulic tensioning tool 009.030 Standard
1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.330 Standard
1 High--pressure hose 009.306 Standard
1 High--pressure hose 009.305 Standard
1 High--pressure hose 009.304 Standard
1 Tommy bar 14 000.265 Standard
1 Tommy bar 12 000.264 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.06 009.10

Technical details

Term Information
Nominal pressure 1,000 bar
Test pressure 1,100 bar
Effective piston area 380.1 cm/2
Delivery stroke 10 mm

6619 009.09--01 E 05.98 L 58/64 101/ 03

Preliminary remarks

The hydraulic tensioning tool is returned automatically to zero position

due to the set of disk springs (4). For correct tightening, the high-pressure
pump must be connected and the vent valve fully opened. If it is necessary
to replace the O-ring seals (2 and 3), pay attention to the correct
009.10).
installation position (refer to work card 009.10

Operating sequence 1 -- Untightening

Steps 1. Check that nut (5) is firmly screwed onto the tensioning
tool (009.030) (depending on the type of screwed connection,
the nuts are different).
2. Screw the tensioning tool onto the bolt which is to be loosened.
When doing so, it is imperative that the gap dimension A = 7 mm
is complied with (refer to Figure 1 ), and that the sleeve is applied
centrally. Fit the tommy bar (000.265) in the bore (D) in order to
screw on.
3. Connect tensioning tool to the pump (009.338) by means of the
high-pressure hose.
4. Start the pump and bring gap dimension (A) to zero and increase
pressure until the release pressure is reached (refer to work
card 000.30).
000.30
5. Using the tommy bar (000.264), turn back the nut to be loosened
(refer to work card 000.30 for the release angle for the various
cases of application).
6. Release the pressure system, uncouple the high-pressure hose and
remove the tensioning tool.
7. Completely unscrew the nut.

1 High-pressure
plug-in coupling
2 O-ring seal, large
3 O-ring seal, small
4 Disk spring
5 Nut
A Gap dimension for
loosening
D Bore

Figure 1. Hydraulic tandem tensioning tool (self-resetting))

6619 009.09--01 E 05.98 L 58/64 102/ 03

Operating sequence 2 -- Tightening

Steps 1. Screw the nut onto the bolt and tighten by hand.
2. Screw the tensioning tool (009.030) onto the puller thread so that
the gap dimension (A) is zero.
3. Connect the tensioning tool to the pump (009.338) by means of
the high-pressure hose and operate the pump until the pressure
reaches the nominal value (refer to specific work cards).
4. Using the tommy bar (000.264), again tighten the nut hand-tight.
5. Release the pressure system, uncouple the high-pressure hose and
take off the tensioning tool.

6619 009.09--01 E 05.98 L 58/64 103/ 03

Hydraulic tensioning tool (tandem)
Disassembling and assembling 009.10

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

whenever they are used. They must be vented, if necessary, and are to be
checked for tightness occasionally. In case they are untight, the sealing
rings are to be replaced.
The work/steps include:
disassembling and assembling,
replacing of sealing rings/sealing elements,
checking for tightness.

Tools/appliances required

Quant Denomination No. Availability

1 Hydraulic tensioning tool (tandem) 009.030 Standard
1 Ball race 009.030--2 Standard
1 Ball 009.030--3 Standard
1 Hydraulic nipple 009.030--4 Standard
1 Seal 009.030--5 Standard
1 Threaded piece 009.030--6 Standard
1 Nut 009.030--8 Standard
1 Piston 009.030--9 Standard
1 Piston 009.030--10 Standard
1 Casing 009.030--11 Standard
2 TURCON seal ring 009.030--12 Standard
2 O--ring seal 009.030--13 Standard
2 TURCON seal ring 009.030--14 Standard
2 O--ring seal 009.030--15 Standard
1 Casing 009.030--16 Standard
1 TURCON seal ring 009.030--17 Standard
1 O--ring seal 009.030--18 Standard
5 Disk spring 009.030--19 Standard
3 Cylindrical notched pin 009.030--20 Standard
1 Opener 009.026 Standard
1 Hexagon screw driver 32 000.306 Standard
1 Tommy bar 16 000.266 Standard

6619 009.10--01 E 05.98 L 58/64 101/ 04

 Quant Denomination No. Availability
2 Eye bolt M12 000.142 Standard
1 Belzona Antiseize (lubricant) -- Inventory
1 Flat strip (nylon) -- Inventory
1 Hammer (wood/plastic) -- Inventory

Related work cards

Work card Work card Work card

000.30 009.03 009.09

Technical details

Term Information
Nominal pressure 1,000 bar
Test pressure 1,100 bar
Effective piston area 380.1 cm/2
Delivery stroke 10 mm

1 Eye bolt (000.142)

2 Ball race
3 Ball
4 CEYN hydraulic nipple
5 Seal
6 Threaded piece
8 Nut
9 Piston
10 Piston
11 Casing
12 TURCON seal ring
13 O-ring seal
14 TURCON seal ring
15 O-ring seal
16 Casing
17 TURCON seal ring
18 O-ring seal
19 Disk spring
20 Cylindrical notched pin

Figure 1. Hydraulic tandem tensioning tool

6619 009.10--01 E 05.98 L 58/64 102/ 04

Operating sequence 1 -- Disassembling tensioning tool

Steps 1. Remove cylindrical notched pin (20), withdraw disk springs (19)
refer to Figure 1 ).
2. Apply opener (009.026) to CEYN nipple (4) and open non-return
valve in nipple. If non-return valve is not open, pistons cannot be
moved in cylinders.
3. Pull off casing (16).
4. Place piston (10) onto clamped hexagon screw driver (000.306)
and loosen nut (8) using tommy bar, dia.16.
Important! Screw connection of piston (10) and nut (8) has
left-handed thread.
5. Pull pistons (9 and 10) out of casing (11).

Operating sequence 2 -- Renewing sealing rings and reassembling tensioning tool

Starting condition All parts are carefully cleaned.

Steps 1. Bend O-ring seals (13, 15,18) so that they become kidney-shaped
and insert them into the respective grooves, paying attention that
they are not distorted (refer to Figure 2 ).

Figure 2. Bending a ring so that it becomes kidney-shaped

2. Chuck the piston (10) into vice, using protective jaws (refer to
Figure 3 ).
3. Before assembling, insert new TURCON seal rings (12,14,17) into
boiling water for five minutes, take them out and dry.
▲▲ Caution! Do not insert the TURCON seal ring into boiling water
or take it out with the bare hand. Danger of scalding!
4. Fit TURCON seal ring (12) on one side of piston (10) into the
respective groove as far as possible. Place two flat strips, spaced
at an angle of approx. 120ƒ , around the sealing ring. With the aid of
the strips, draw the sealing ring carefully over the piston edge to fit
the ring completely in its groove. Remove the strips carefully.
5. Bring the TURCON seal ring back into its original shape.
Important! During the installation, the TURCON seal ring was
expanded. To bring it back into its original shape, it is to be pressed into
the groove by means of a piece of round wood or using the handle of a
hammer (refer to Figure 4 ).
6. Insert TURCON seal rings (14 and 17) in the same way adding them
to the O-ring seals in their respective grooves.
7. Apply a thin coat of Belzona-Antiseize to all metallic fitting surfaces
of the piston and to the thread. Sealing elements and grooves must
remain free.

6619 009.10--01 E 05.98 L 58/64 103/ 04

 8. The further reassembly is carried out in reverse order of disassembly.
When inserting pistons into casing take special care not to damage
sealing rings. For reassembly, too, use opener (009.026). Insert
nut (8) tightly.
Insert disk springs (19) in correct sequence (refer to Figure 1 ).

10 Piston
12 TURCON seal ring
30 Nylon strips

Figure 3. Mounting the TURCON seal ring (12) on the piston (10)

10 Piston
12 TURCON seal ring
13 O-ring seal
21 Piece of round wood or
handle of hammer

Figure 4. Pressing the TURCON seal ring into its final postition (left-hand side prior
to pressing it in; right-hand side after pressing it in)

Operating sequence 3 -- Leakage testing

Steps 1. Make hydraulic load test of tensioning tool on crankshaft bearing

screw, applying the pressure specified for this screw (refer to work
012.02). Check that no vissible leakage occurs
cards 000.30 and 012.02
within five minutes.

6619 009.10--01 E 05.98 L 58/64 104/ 04

Hydraulic tensioning tool (single)
Use 009.11

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

the components to be connected. In this condition, the nuts can be
tightened or loosened without application of force.
The work/steps include:
untightening,
tightening and
resetting of the piston.

Tools/appliances required

Quant Denomination No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.330 Standard
1 High--pressure hose 009.306 Standard
1 High--pressure hose 009.305 Standard
1 High--pressure hose 009.304 Standard
1 Resetting device 009.019 Standard
1 Bridge 009.019--1 Standard
1 Threaded piece 009.019--3 Standard
1 Hydraulic tensioning tool 009.016 Standard
1 Tommy bar 10 000.263 Standard
1 Ring spanner 24x27 000.225 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.06 009.12

6619 009.11--01 E 04.98 L 58/64 101/ 03

Technical details

Term Information
Nominal pressure 1,200 bar
Weight 8.3 kg
Effective piston area 72.72 cm2
Delivery stroke 7 mm
Test pressure 1,300 bar

Operating sequence 1 -- Untightening

Starting condition Hydraulic tensioning tool (009.016) in starting condition (lift = zero)

1 Nut
2 Bolt
3 Thrust ring
4 Hydraulic nipple

Figure 1. Mounted tensioning tool for loosening of bolt

Steps 1. Screw hydraulic tensioning tool onto the bolt to be released.

Be sure to leave a re-setting angle (refer to work card 000.30
and Figure 1 ).
2. Connect tensioning tool by means of high-pressure hose to
high-pressure pump (009.338).
3. Operate high pressure pump and reduce gap width (A) to zero,
then raise pressure further to the required loosening pressure
(max. 5%, of work card 000.30 and 000.33).
000.33
4. Back off nut (1) to be loosened the whole way by use of the
tommy bar (000.263).
5. Release pressure in system, remove high-pressure hose and
tensioning tool.
6. Unscrew nut completely.

Operating sequence 2 -- Tightening

Starting condition Hydraulic tensioning tool (009.016) in starting condition (lift = zero)

6619 009.11--01 E 04.98 L 58/64 102/ 03

Steps 1. Screw nut onto bolt and tighten it by hand.
2. Screw tensioning tool onto tensioning threads so that the gap
width (A) becomes zero.
3. Connect tensioning tool with high-pressure hose to high-pressure
pump.
4. Operate high-pressure pump and raise pressure to nominal value
000.30).
(refer to work card 000.30
5. Again tighten nut hand-tight by means of tommy bar.
6. Release pressure in system, disconnect high-pressure hose and
remove tensioning tool.

Operating sequence 3 -- Resetting the piston of the tensioning tool

Steps 1. The hydraulic tensioning tool must be reset to the starting condition
(lift = zero) before each tensioning or loosening operation by use of
the threaded piece (009.019-3) which is to be screwed into the tap
hole of the piston (refer to Figure 2 ).

4 Hydraulic nippel
5 Hexagon bolt M16x80

Figure 2. Resetting the piston of the tensioning tool

2. Oil seating survace of tensioning tool and threads (5) and attach
resetting device (009.019).
3. Connect tensioning tool with high-pressure hose to high-pressure
pump.
4. Open relief valve on high-pressure pump and reset piston by use of
ring spanner (000.225) and bolt (5).
5. Remove resetting device.

6619 009.11--01 E 04.98 L 58/64 103/ 03

Hydraulic tensioning tool (single)
Venting, checking, replacing of
sealing rings 009.12

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

whenever they are used. They must be vented, if necessary, and are to be
checked for tightness occasionally. In case they are untight, the sealing
rings are to be replaced.
The work/steps include:
venting,
checking for tightness,
disassembly and assembly,
replacement of sealing rings/sealing elements.

Tools/appliances required

Quant Denomination No. Availability

1 Hydraulic tensioning tool 009.016 Standard
1 Piston 009.016--1 Standard
1 Casing 009.016--9 Standard
1 Hydraulic nipple 009.016--12 Standard
1 Threaded piece 009.016--13 Standard
1 Sealing ring 009.016--14 Standard
1 O--ring seal 009.016--16 Standard
1 Backing ring 009.016--17 Standard
1 O--ring seal 009.016--18 Standard
1 Backing ring 009.016--19 Standard
1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Opener 009.026 Standard
1 Resetting device 009.019 Standard
1 Bridge 009.019--1 Standard
1 Threaded piece 009.019--3 Standard
1 Ring spanner 24x27 000.225 Standard
1 Grease (acid--free) -- Inventory
1 Belzona Antiseize (lubricant) -- Inventory

6619 009.12--01 E 04.98 L 58/64 101/ 04

Related work cards

Work card Work card Work card

009.03 009.11

Technical details

Term Information
Weight 8.3 kg

Figure 1. Single hydraulic tensioning tool (009.016)

Operating sequence 1 -- Disassembling and assembling of tensioning tool, replacing sealing elements

A Relief edge

Figure 2. Removing the piston

6619 009.12--01 E 04.98 L 58/64 102/ 04

Steps 1. Place hydraulic tensioning tool (009.016) on clean work bench or
clamp it in a vice, holding it by the flats on the piston (009.016-1),
and connect it to high-pressure pump (009.338) by high-pressure
hose (009.306) (refer to Figure 2 ).
2. Switch on high-pressure pump until oil escapes from the relief
edge (A).
3. Lay hydraulic tensioning tool on its cylindrical surface, open relief
valve on high-pressure pump und drive piston (009.016-1) out of the
casing (009.016-9) without canting it, by use of the copper bolt and
a hammer.
4. Cautioulsy remove O-ring seals (009.016-16 and 009.016-18) and
backing rings (009.016-17 and 009.016-19).
5. Clean all parts and blow them dry with compressed air.
6. Insert new backing- and O-rings, paying attention to the correct
installation position of the rings. O-ring seal always facing the
pressure side, backing ring on the opposite side, with the concave
side of the backing ring facing the O-ring seal.
7. Lubricate fitting surfaces on piston and casing with lubricant Belzona
Antiseize. Do not lubricacte sealing elements and grooves.
8. Stack casing on piston and reassemble parts by use of the resetting
device (009.019) and the ring spanner (000.225) (refer to Figure 3 ).

1 Hexagon bolt M16x80

Figure 3. Installing the piston

Important! In reassembling, turn resetting device several times by

90ƒ for good alignment of the parts.

Operating sequence 2 -- Venting of tensioning tool

Starting condition Hydraulic tensioning tool clamped in a vice, holding it by the flats
on the piston. Hydraulic nipple (009.016-12) pointing up (refer to
Figure 4 ).

Steps 1. Move tenisoning tool hydraulically outwards to approx. 8 mm,

by means of high-pressure pump.
2. Attach resetting device (009.019).
3. Open non-return valve in hydraulic nipple by means of
opener (009.026).
4. Move piston inwards by using resetting device until oil escapes
without air bubbles.

6619 009.12--01 E 04.98 L 58/64 103/ 04

 1 Hexagon bolt M16x80

Figure 4. Venting of the tensioning tool

6619 009.12--01 E 04.98 L 58/64 104/ 04

Hydraulic tensioning tool (tandem)
Use 009.13

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

the components to be connected. In this condition, the nuts can be
tightened or loosened without application of force.
The work/steps include:
attaching components,
untightening and tightening.

Tools/appliances required

Quant Denomination No. Availability

2 Hydraulic tensioning tool 009.301 Standard
1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.304 Standard
2 High--pressure hose 009.305 Standard
2 High--pressure hose 009.306 Standard
2 High--pressure hose 009.330 Standard
1 Tommy bar 12 000.264 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.02
009.03 009.05

Preliminary remarks

The high-pressure pump (009.338) must be connected and the relief

valve opened, before the two hydraulic pistons are forced into their
zero position by means of the tensioning nuts (2 and 10). The release
pressure is usually less than the the tightening pressure.

▲ Attention! Before the tightening process, each hydraulic

piston must be in its zero position (damage to equipment, danger
of accident). When replacing the seal rings (11 and 12), attention
must be paid to the correct installation position.

6619 009.13--01 E 05.98 L 58/64 101/ 03

Operating sequence 1 -- Atttaching the hydraulic tensioning tool

Steps 1. Screw the tension screw (1) onto the bolt (13) which is to be released
until it abuts.
2. Carefully place the sleeve (8) over the tension screw (1) and the
nut (14).
3. Locate the tensioning tool (4) with piston (7) centrally over tension
screw (1) and lower it onto the sleeve (8).
4. Connect the high-pressure hose and join it to the high-pressure
pump (009.338). Open the relief valve on the pump (refer to work
card 009.03).
009.03
5. Screw the tensioning nut (10) onto the tension screw (1) and, using
the tommy bar (3), force the piston (7) all the way into the tensioning
tool (4).
6. Fit the intermediate ring (6) to the tensioning tool.
7. Locate the second tensioning tool (4) with piston (7) centrally over
the tension screw (1) and lower it onto the intermediate ring (6).
8. Connect the second high-pressure hose (relief valve at high-pressure
pump is opened).
9. Screw the tensioning nut (2) onto the tension screw (1) and, using
tommy bar (3), force the piston (7) all the way into the tensioning
tool (4) .

1 Tension screw
2 Tensioning nut
3 Tommy bar, dia. 12
4 Tensioning tool
5 High-pressure nipple
6 Intermediate ring
7 Hydraulic piston
8 Sleeve
10 Tensioning nut
11 O-ring seal ring, large
12 O-ring seal ring, small
13 Bolt
14 Nut

Figure 1. Mounting of the tandem tensioning tool

Operating sequence 2 -- Untightening

Starting condition The complete tensioning tool is screwed firmly onto the bolt which is to be
released, the high-pressure pump (009.338) is connected. Both hydraulic
pistons are in their zero position.

Steps 1. Using the tommy bar (3), turn the tensioning nuts (2 and 10) back
through 270ƒ (3/4 of a turn).

6619 009.13--01 E 05.98 L 58/64 102/ 03

 2. Start the high-pressure pump and with it close the gap that has
formed between the nut and the piston. Continue to pump until
000.30).
release pressure is reached (refer to work card 000.30
3. Turn the nut (14) back by the specified amount (refer to work
card 000.30).
000.30
4. Relieve the pressure system, decouple the high-pressure hoses
and take off the complete tensioning tool.
5. Screw off the nut (14) completely.

Operating sequence 3 -- Tightening

Starting condition Nut (14) is firmly screwed onto bolt (13). The complete tensioning tool is
also screwed on firmly. The high-pressure pump (009.338) is connected.
Both hydraulic pistons are in their zero position.

Steps 1. Switch on the high-pressure pump and tighten to the specified

009.03).
pressure (refer to work cards 000.30 and 009.03
2. Using the tommy bar (3), turn the nut (14) through the recess in
the sleeve (8) until it abuts firmly.
3. Release the pressure from the system, uncouple the high-pressure
hoses and take off the complete tensioning tool.
▲ Attention! Prerequisite for correct tightening of the screwed
fitting is the correct indication on the pressure gauge. In case
of doubt, check the reading by comparing with another (good)
pressure gauge. When tightening, ensure that nobody is standing
in the imagined extension of the axis of the bolt being tightened
(if tensioning tool is damaged, there otherwise exists the
danger of accident!).

6619 009.13--01 E 05.98 L 58/64 103/ 03

Hydraulic tensioning tool (single)
Use 009.14

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

the components to be connected. In this condition, the nuts can be
tightened or loosened without application of force.
The work/steps include:
untensioning and tensioning.

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.330 Standard
1 Hydraulic tensioning tool 009.159 Optional
1 Tommy bars (set) -- Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.16

Technical details

Term Information
Nominal pressure 1.400 bar
Effective piston area 132.11 cm/2
Delivery stroke 8 mm
Thread diameter M72x4
Test pressure 1.850 bar

6641 009.14--01 E 02.00 L 58/64 101/ 04

Operating sequence 1 -- Untensioning

▲▲▲ Danger! During untensioning, make sure that there is no one

in the area of the axis of the bolt to be untensioned!

Starting condition The thread of the bolt to be loosened has been cleaned.

Steps 1. Place the thrust pad (3) over the nut (4).
2. Screw the hydraulic tensioning tool (1) onto the bolt (5), paying
attention that the thrust pad is centered by means of the hydraulic
tensioning tool.
3. Turn the hydraulic tensioning tool back by the angular amount of
000.30).
turning back (see work card 000.30
4. Connect the high-pressure hose (009.330) to hydraulic tensioning
tool and high-pressure pump (009.338)
5. Switch on the high-pressure pump (see work card 009.03009.03) and close
gap (A).
6. Inflate the hydraulic tensioning tool until the nut can be loosened.
▲ Attention! The pressure applied must not be more than 7% below
and 5% above the tensioning pressure (refer to work card 000.30)!
000.30

▲▲ Caution! During pumping, watch the stroke control (7). The

hydraulic tensioning tool may be inflated only to such an extent that
marking (M) on the stroke control reaches the upper edge of the
threaded stop ring (6). Otherwise the hydraulic tensioning tool will
be damaged. Refer to Figure 3 .
7. Insert the tommy bar (2) through the recess in the thrust pad and turn
the nut back (for the angular amount of turning back, see work card
000.30).
000.30
8. Release the pressure, disconnect the high-pressure hose from
hydraulic tensioning tool and high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated compression springs. For this purpose,
however, the high-pressure pump has to be connected.
9. Remove the hydraulic tensioning tool.

6641 009.14--01 E 02.00 L 58/64 102/ 04

 1 Hydraulic tensioning
tool
2 Tommy bar
3 Thrust pad
4 Nut
5 Bolt
6 Threaded stop ring
7 Stroke control

A Gap
M Marking on the stop
control (max. stroke)

Figure 1. Attached hydraulic tensioning tool for loosening a bolt

3 Thrust pad A Gap

8 Engine part

Figure 2. Position of gap (A) in case the hydraulic tensioning tool is attached horizontally or in a hanging manner

6 Threaded stop ring

7 Stroke control

M Marking on the stroke

control (max. stroke)

Figure 3. Position of the marking on the stroke control at max. stroke of the
hydraulic tensioning tool

6641 009.14--01 E 02.00 L 58/64 103/ 04

Operating sequence 2 -- Tensioning

▲▲▲ Danger! During tensioning, make sure that there is no one in

the area of the axis of the bolt to be tensioned!

▲ Attention! Prerequisite for the correct tensioning of a bolted

connection is that the pressure gauge indication is faultless. In case
of doubt, check the pressure gauge using a reference pressure
gauge.

Starting condition The thread of the bolt to be tensioned has been cleaned, the nut has been
screwed down to contact, hand-tight.

Steps 1. Put the thrust pad (3) over the nut (4).
2. Screw the hydraulic tensioning tool (1) onto bolt (5), paying attention
that the thrust pad is centered by means of the hydraulic tensioning
tool.
3. Connect the high-pressure hose (009.330) to hydraulic tensioning
tool and high-pressure pump (009.338).
009.03) and
4. Switch on the high-pressure pump (see work card 009.03
tension the bolt to the specified tensioning pressure (see work card
000.30).
000.30
▲▲ Caution! During pumping, watch the stroke control (7). The
hydraulic tensioning tool may be inflated only to such an extent that
marking (M) on the stroke control reaches the upper edge of the
threaded stop ring (6). Otherwise the hydraulic tensioning tool will
be damaged. Refer to Figure 3 .
5. Insert the tommy bar (2) into the recess in the thrust pad and tighten
the nut.
6. Release the pressure, disconnect the high-pressure hose from
hydraulic tensioning tool and high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated compression springs. For this purpose,
however, the high-pressure pump has to be connected.
7. Remove the hydraulic tensioning tool.

1 Hydraulic tensioning
tool
2 Tommy bar
3 Thrust pad
4 Nut
5 Bolt
6 Threaded stop ring
7 Stroke control

M Marking on the stroke

control (max. stroke)

Figure 4. Attached hydraulic tensioning tool for tensioning a bolt

6641 009.14--01 E 02.00 L 58/64 104/ 04

Hydraulic tensioning tool (single)
Disassembling and assembling 009.16

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

whenever they are used. They must be vented, if necessary, and checked
for leaks occasionally. In case they leak, the sealing rings must be
replaced.
The work/steps include:
venting,
checking for leaks,
disassembly and assembly,
replacement of sealing rings/sealing elements.

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.330 Standard
1 Set of tools 009.134 Optional
1 Insert 22x12.5 009.134--3 Optional
1 Insert 19x12.5 009.134--4 Optional
1 Side nippers 009.134--10 Optional
1 Screw driver 1x6.5 009.134--12 Optional
1 Screw driver 1.2x8 009.134--13 Optional
1 Marking pin 009.134--16 Optional
1 Hammer (wood/plastic) 009.134--18 Optional
1 Mandril 009.134--25 Optional
1 Extractor 009.134--26 Optional
1 Flat strip (nylon) 009.134--27 Optional
1 Opener 009.026 Standard
1 Extension piece 12.5x125 001.911 Standard
1 Cross handle 001.891 Standard
1 Screw drivers (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Belzona Antiseize (lubricant) -- Inventory
1 Felt--tip pen/Marking pen -- Inventory
1 Anti--corrosion oil -- Inventory

6641 009.16--01 E 02.00 L 58/64 101/ 07

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.14

Technical details

Term Information
Nominal pressure 1.400 bar
Effective piston area 132.11 cm/2
Delivery stroke 8 mm
Thread diameter M72x4
Test pressure 1.850 bar

Tool No./Spare part No.

Item Designation Tool No.

- Hydr. tensioning tool, complete 009.159
1* Quick--action coupling, half of 009.159-3
2* Double-ended threaded nipple 009.159-12
3 Piston 009.159-2
4 Stroke gauge 009.159-16
5 Threaded stop ring 009.159-13
6* O-ring seal 009.159-7
7* TurconZ ring 009.159-6
8* O-ring seal 009.159-5
9* Valve ring 009.159-4
10 Casing 009.159-1
11 Screw plug 009.159-15
12* Compression spring 009.159-14
13 Set screw 009.159-18
14 Screw plug, 009.159-17
for dial gauge connection
- Protective cap 009.159-19
- Spare parts package 009.160
* All contained in the spare parts package

6641 009.16--01 E 02.00 L 58/64 102/ 07

 1 Quick-action coupling, half
2 Double-ended nipple
3 Piston
4 Stroke gauge
5 Threaded stop ring
6 O-ring seal
7 Turcon ring
8 O-ring seal
9 Valve ring
10 Casing
11 Screw plug
12 Compression spring
13 Set screw
14 Screw plug

A Thread size
B Outer diameter
C Height
M Marking on the stroke
gauge (maximum stroke)

Figure 1. Hydraulic tensioning tool

Operating sequence 1 -- Disassembling the hydraulic tensioning tool

Steps 1. Mark the positions of the casing, threaded stop ring, and piston (10, 5
and 3) relative to one another.
2. Unscrew the screw plugs (11) and remove the compression springs
(12).
3. Remove the stroke gauges (4) with the extractor (009.134-26) – see
Figure 2 .
4. Remove the protective cap from the one half of the quick--action
coupling (1).
5. Clamp the hydraulic tensioning tool in the vice (23), using the
protective jaws (22) and the mandrel (009.134-25) – see Figure 3 .
6. Unscrew the quick--action coupling half, and unscrew the
double-ended threaded nipple (2).
7. Remove the hydraulic tensioning tool from the vice.
8. Unscrew the set screw (13).
9. Unscrew the threaded stop ring (5) by hand, backing off slightly from
time to time, in order to prevent it tilting.
▲ Attention! Should there be any resistance, do not turn the
threaded stop ring any further; instead, loosen it by means of light
taps with a plastic hammer (009.134-18).
10. Drive the piston (3) out of the casing, using the plastic hammer.
11. Using the side-cutting nippers (009.134-10), cut up the valve rings (9)
and the TurconZ ring (7) and remove them.
12. Remove the O-ring seals (6 and 8), using the scriber (009.134-16).

6641 009.16--01 E 02.00 L 58/64 103/ 07

 13. Clean all individual parts and check them for damage; replace them if
necessary.

Figure 2. Removing the stroke gauge

21 Hydraulic tensioning tool

22 Protective jaw
23 Vice

Figure 3. Clamping the hydraulic tensioning tool in the vice

6641 009.16--01 E 02.00 L 58/64 104/ 07

Operating sequence 2 -- Assembling the hydraulic tensioning tool

Starting condition All individual parts cleaned and checked for damage, and replaced if
necessary.

Steps 1. Check that the new O-ring seals (6 and 8) are undamaged.
2. Apply anti-corrosion oil to the running surface on the piston (3) and to
the O-ring seal (6).
3. Insert the O-ring seal (6) in the respective groove, making sure that it
is evenly tensioned over the whole circumference, and not twisted.
4. Squeeze the O-ring seals (8) into a kidney shape, and insert them
into the respective groove, making sure that they are not twisted
– see Figure 4 .
5. Lay the new valve rings (9) in boiling water for five minutes, take
them out and dry them, squeeze them into a kidney shape, and insert
them into the respective groove.
▲▲ Caution! Do not lay the valve rings in boiling water or take
them out again with your bare hands. Danger of scalding!

Important! When installing the valve rings, be careful to install

them in the correct position, with the groove on the pressure side – see
Figure 1 (Detail X).
6. Clamp the piston into the vice (23), using the protective jaws (22).
7. Lay a new Turcon ring (7) in boiling water for five minutes, take it out
again, and dry it. Insert the ring on one side of the piston into the
respective groove as far as possible, placing two flat strips
(009.134-27) around the ring, about 120ƒ apart. By means of the flat
strips, carefully pull the ring over the piston rim completely into the
groove. Remove the flat strips. See Figure 5 .
▲▲ Caution! Do not lay the Turcon ring in boiling water or take it
out again with your bare hands. Danger of scalding!
8. Press the Turcon ring back into its original shape.
Important! The Turcon ring has been stretched during installation.
To restore it to its original shape, press it into the groove with a wooden
rod or the handle of the hammer – see Figure 6 .
9. Apply Belzona Antiseize to the running surface of the piston and the
casing (10).
10. Position the piston on the casing, check that the markings on piston
and casing coincide (Operating Sequence 1, point 1) and press the
piston into the casing, or hammer it in with the plastic hammer
(009.134-18).
11. Screw the threaded stop ring (5) into the casing until the top of the
threaded stop ring is flush with the top of the casing, backing it off
from time to time to prevent it jamming.
▲ Attention! Should there be any resistance, do not turn the
threaded stop ring any further; instead, loosen it by means of light
taps with a plastic hammer (009.134-18).
12. Screw in the set screw (13).
13. Check that the holes for the stroke gauges (4) in the casing and the
threaded stop ring are in alignment.
14. Hammer in the stroke gauges until the top of the stroke gauge is
flush with the top of the stop ring – see Figure 1 (Detail Y).
15. Insert the compression springs (12) into the holes, and screw in the
screw plugs (11) until the top of the screw plug is flush with the top of
the stop ring – see Figure 1 (Section K-K).

6641 009.16--01 E 02.00 L 58/64 105/ 07

 16. Clamp the hydraulic tensioning tool into the vice, using the protective
jaws and mandrel (009.134-25) – see Figure 3 .
17. Screw a new double-ended threaded nipple (2) into the piston and
tighten it.
18. Screw the half of the quick--action coupling (1) onto the double-ended
nipple, and tighten it.
19. Remove the hydraulic tensioning tool from the vice.
20. Attach the hydraulic tensioning tool at an appropriate place (refer to
work card) in such a way that the half of the quick--action coupling
faces upwards.
21. Connect the high-pressure hose (009.330) to the hydraulic tensioning
tool and the high-pressure pump (009.338).
009.03) and
22. Switch on the high-pressure pump (refer to Work Card 009.03
pump up the hydraulic tensioning tool.
▲ Attention! Be careful not to exceed the tensioning pressure
000.30).
specified for the screw selected (see Work Card 000.30
23. Release pressure.
24. Detach the high-pressure hose. Vent the high-pressure hose by
009.05.
means of the opener (009.026) – see Work Card 009.05
25. Reconnect the high-presure hose.
26. Pump up the hydraulic tensioning tool to the tensioning pressure spe-
000.30). Retain the pressure for
cified for this screw (see Work Card 000.30
five minutes.
Important! Once the hydraulic tensioning tool is under pressure,
there must not be any detectable leakage during this period.
27. Release pressure, detach the high-pressure hose, and remove the
tensioning tool.
28. Slip protective cap onto the half of the quick--action coupling.

6641 009.16--01 E 02.00 L 58/64 106/ 07

 Figure 4. Squeezing a ring into a kidney shape

3 Piston
7 Turcon ring
20 Flat strip

Figure 5. Mounting the Turcon Z ring on the piston

3 Piston
6 O-ring seal
7 Turcon ring
24 Wooden rod or handle
of hammer

Figure 6. Pressing the Turcon Z ring into its final position (Left: prior to pressing in;
Right: after pressing it in)

6641 009.16--01 E 02.00 L 58/64 107/ 07

Hydraulic tensioning tool (single)
Use 009.17

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

the components to be connected. In this condition, the nuts can be
tightened or loosened without application of force.
The work/steps include:
untensioning and tensioning.

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.191 Standard
1 Tommy bars (set) -- Standard

Related work cards

Work card Work card Work card

000.30 009.03 009.18

Technical data

Tool No. 009.191

Effective piston area (cm2) 176.68
Delivery stroke (mm) 8
Nominal pressure (bar) 1400
Test pressure (bar) 1500
Thread diameter (mm) M72x4
Outer diameter (mm) 230
Height (mm) 106

6641 009.17--01 E 02.03 L 58/64 101/ 03

 1 Hydraulic tensioning tool
2 Tommy bar
3 Thrust pad
4 Nut
5 Bolt
6 Threaded stop ring
12 Return spring

A Gap

Figure 1. Attached hydraulic tensioning tool

Operating sequence 1 -- Untensioning

▲▲▲ Danger! During untensioning, make sure that there is no one

along the extended axis of the bolt to be untensioned!

Starting condition The thread of the bolt to be loosened has been cleaned.

Steps 1. Place the thrust pad (3) over the nut (4).
2. Screw the hydraulic tensioning tool (1) onto the bolt (5), making sure
that the thrust pad is centred by the hydraulic tensioning tool (refer to
Figure 1 ).
3. Turn the hydraulic tensioning tool back by the back-off angle (see
000.30).
work card 000.30
4. Connect the high-pressure hose (009.330) to the hydraulic tensioning
tool and high-pressure pump (009.338).
009.03) and close
5. Switch on the high-pressure pump (see work card 009.03
gap (A).
6. Pump up the hydraulic tensioning tool until the nut can be loosened.
▲ Attention! The pressure applied must not be more than 7% below
or max. 5% above the tensioning pressure (see work card 000.30)!
000.30

6 Threaded stop ring

7 Stroke gauge
8 Piston
10 Casing

M Marking on the stroke

gauge (max. stroke)
Figure 2. Marking on the stroke gauge

6641 009.17--01 E 02.03 L 58/64 102/ 03

 ▲▲ Caution! During pumping, watch the stroke gauge (7). The hy-
draulic tensioning tool may only be pumped up until the marking (M)
on the stroke gauge reaches the upper edge of the threaded stop
ring (6). Otherwise, the hydraulic tensioning tool will be damaged.
Refer to Figure 2 .
7. Using the tommy bar (2), slacken the nut through the opening in the
thrust pad (for back-off angle, see work card 000.30).
000.30
8. Release the pressure, disconnect the high-pressure hose from the
hydraulic tensioning tool and high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
9. Remove the hydraulic tensioning tool

Operating sequence 2 -- Tensioning

▲▲▲ Danger! During tensioning, make sure that there is no one

along the extended axis of the bolt to be tensioned!

▲ Attention! Correct tensioning of a bolted connection requires the

pressure gauge indication to be correct. In case of doubt, check the
pressure gauge against a reference pressure gauge.

Starting condition The thread of the bolt to be tensioned has been cleaned and the nut
screwed on all the way and tightened, hand-tight.

Steps 1. Place the thrust pad (3) over the nut (4).
2. Screw the hydraulic tensioning tool (1) onto the bolt (5), making sure
that the thrust pad is centred by the hydraulic tensioning tool (refer to
Figure 1 ).
3. Connect the high-pressure hose (009.330) to the hydraulic tensioning
tool and high-pressure pump (009.338).
009.03), and ten-
4. Switch on the high-pressure pump (see work card 009.03
sion the bolt applying the specified tensioning pressure (see work
000.30).
card 000.30
▲▲ Caution! During pumping, watch the stroke gauge (7). The hy-
draulic tensioning tool may only be pumped up until the marking (M)
on the stroke gauge reaches the upper edge of the threaded stop
ring (6). Otherwise, the hydraulic tensioning tool will be damaged.
Refer to Figure 2 .
5. Using the tommy bar (2), screw down the nut through the opening in
the thrust pad, hand-tight.
6. Release the pressure, disconnect the high-pressure hose from the
hydraulic tensioning tool and high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
7. Remove the hydraulic tensioning tool.

6641 009.17--01 E 02.03 L 58/64 103/ 03

Hydraulic tensioning tool (single)
Disassembling and assembling 009.18

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

whenever they are used. They must be vented, if necessary, and checked
for leaks occasionally. In case they leak, the sealing rings must be
replaced.
The work/steps include:
venting,
checking for leaks,
disassembly and assembly,
replacement of sealing rings/sealing elements.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 2

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Set of tools 009.134 Standard
1 Cross handle 001.891 Standard
1 Insert 22x12.5 009.134--3 Standard
1 Insert 19x12.5 009.134--4 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Hexagon screw driver 6 000.295 Standard
1 Hexagon screw driver 8 000.297 Standard
1 Hexagon screw driver 10 000.298 Standard
1 Side nippers 009.134--10 Standard
1 Screw driver 1x6.5 009.134--12 Standard
1 Screw driver 1.2x8 009.134--13 Standard
1 Marking pin 009.134--16 Standard
1 Hammer (wood/plastic) 009.134--18 Standard
2 Rope clamp 009.134--19 Standard

6641 009.18--01 E 02.03 L 58/64 101/ 07

 Qty Designation No. Availability
1 Wire rope 009.134--20 Standard
2 Mandril 009.134--25 Standard
1 Extractor 009.134--26 Standard
2 Flat strip (nylon) 009.134--27 Standard
1 Opener 009.026 Standard
1 Extension piece 12.5x125 001.911 Standard
1 Belzona Antiseize (lubricant) -- Inventory
1 Felt--tip pen/Marking pen -- Inventory
1 Anti--corrosion oil -- Inventory

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.17

Technische Daten

Tool No. 009.191

Effective piston area (cm2) 176.68
Delivery stroke (mm) 8
Nominal pressure (bar) 1400
Test pressure (bar) 1500
Thread diameter A (mm) M72x4
Outer diameter B (mm) 230
Height C (mm) 106

6641 009.18--01 E 02.03 L 58/64 102/ 07

 Tool No./Spare part No.

Item Designation Tool No.

- Hydr. tensioning tool, complete 009.191
1 Casing 009.191-1
2 Piston 009.191-2
3* Quick-acting-coupling half 009.191-3
4* TURCON ring 009.191-4
5* O-ring seal 009.191-5
6* TURCON ring 009.191-6
7* O-ring seal 009.191-7
12* Double nipple 009.191-12
13 Threaded stop ring 009.191-13
14* Compression spring 009.191-14
15 Screw plug 009.191-15
16 Stroke gauge 009.191-16
17 Screw plug (dial gauge connection) 009.191-17
18 Set screw 009.191-18
19 Protecting cap 009.191-19
- Set of spare parts 009.192
* jointly contained in the set of spare parts

1 Casing
2 Piston
3 Quick-acting-coupling
half
4 TURCON ring
5 O-ring seal
6 TURCON ring
7 O-ring seal
12 Double nipple
13 Threaded stop ring
14 Compression spring
15 Screw plug
16 Stroke gauge
17 Screw plug
18 Set screw
19 Protecting cap

A Thread diameter
B Outer diameter
C Height
M Marking on the stroke
gauge (max. stroke)

Figure 1. Hydraulic tensioning tool

6641 009.18--01 E 02.03 L 58/64 103/ 07

Operating sequence 1 -- Disassembly of the hydraulic tensioning tool

Steps 1. Mark the position of the casing (1)/threaded stop ring (13)/piston (2).
2. Unscrew the screw plugs (15), and take off the compression springs
(14).
3. Remove the stroke gauges (16) using the extractor (009.134-26)
(refer to Figure 2 ).

Figure 2. Removal of the stroke gauge

4. Take the protecting cap (19) off the quick-acting-coupling half (3).
5. Clamp the hydraulic tensioning tool into the vice (23), using braces
(22) and mandril (009.134-25) for this purpose (refer to Figure 3 ).
6. Screw off the quick-acting-coupling half, unscrew the double nipple
(12).
7. Remove the hydraulic tensioning tool from the vice.
8. Unscrew the set screw (18).
9. Screw the threaded stop ring (13) out by hand, turning it back oc-
casionally in order to prevent canting.
▲ Attention! In case there is any resistance, do not continue turning
the threaded stop ring but rather loosen it by a few taps with the
plastic hammer (009.134-18).
10. Remove the piston (2) from the casing by tapping on it with the plas-
tic hammer.
11. Cut the TURCON rings (4 and 6) open by means of the side nipper
(009.134-10) and take them out.
12. Remove the O-ring seals (5 and 7) using the marking pin
(009.134-16).
13. Clean all the individual components and check them for wear,
replacing them if necessary.

6641 009.18--01 E 02.03 L 58/64 104/ 07

 21 Hydr. tensioning tool
22 Brace
23 Vice
Figure 3. Clamping the hydr. tensioning tool into the vice

Operating sequence 2 -- Assembly of the hydraulic tensioning tool

Starting condition All individual components have been cleaned and checked for damage,
and replaced if necessary.

Steps 1. Check new O-ring seals (5 and 7) to see if they are intact.
2. Coat the running surface of the piston (2) and O-ring seal (7) with
anti-corrosion oil.
3. Insert the O-ring seal (7) into the respective groove, taking care that it
is evenly tensioned over the entire circumference, and not distorted.
4. Bend the O-ring seal (5) so that it becomes kidney-shaped and insert
it into the respective groove, taking care that it is not distorted (refer
to Figure 4 ).

Figure 4. Bending one of the O-ring seals so that it becomes kidney-shaped

5. Insert a new TURCON ring (4) into boiling water for five minutes, take
it back out, dry it, bend it so that it becomes kidney-shaped, and in-
sert it into the respective groove.
▲▲ Caution! Do not insert the TURCON rings into boiling water or
take them back out with the bare hand. Danger of scalding!
6. Clamp the piston into the vice (23), using braces (22) to do so.
7. Insert a new TURCON ring (6) into boiling water for five minutes, take
it back out, and dry it. Insert the ring into the respective groove on

6641 009.18--01 E 02.03 L 58/64 105/ 07

 one side of the piston, as far as possible. Put two flat strips
(009.134-27) around the ring at a distance of approx. 120ƒ , and care-
fully pull the ring over the rim of the piston and completely into the
groove using the flat strips. Remove the flat strips (refer to Fig-
ure 5 ).

2 Piston
6 TURCON ring

Figure 5. Pulling the TURCON ring onto the piston

▲▲ Caution! Do not insert the TURCON ring into boiling water or

take it back out with the bare hand. Danger of scalding!
8. Bring the TURCON ring back into its original shape.
Important! The TURCON ring was expanded during the fitting pro-
cess. In order to bring the ring back into its original shape, it has to be
pressed into the groove using a piece of round wood or the handle of a
hammer. Refer to Figure 6 .

2 Piston
6 TURCON ring
7 O-ring seal
24 Piece of round wood or
handle of a hammer

Figure 6. Bringing the TURCON ring into its final position (on the left: prior to pres-
sing in / on the right: after pressing in)
9. Coat the running surface of piston and casing (1) with Belzona
Antiseize lubricant.
10. Place the piston on the casing, check to ensure that the markings on
the piston/casing coincide (operating sequence 1, item 1), and press
the piston into the casing applying slight taps with the plastic hammer
(009.134-18) if necessary.
11. Screw the threaded stop ring (13) into the casing, until the top of the
threaded stop ring is flush with the casing top. Slightly turn the
threaded stop ring back occasionally in order to prevent canting.
▲ Attention! In case there is any resistance, do not continue turning
the threaded stop ring but rather loosen it by a few taps with the
plastic hammer (009.134-18).
12. Screw the set screw (18) in.

6641 009.18--01 E 02.03 L 58/64 106/ 07

 13. Check for flushness of the bores for the stroke gauges (16) between
casing and threaded stop ring.
14. Insert the stroke gauges by tapping on them until the top of the stroke
gauge is flush with the top of the threaded stop ring (refer to Fig-
ure 1 , detail Y).
15. Insert the compression springs (14) into the bores, screw the screw
plugs (15) in until the top of the screw plug is flush with the top of the
threaded stop ring (refer to Figure 1 , section K-K).
16. Clamp the hydraulic tensioning tool into the vice, using braces and
mandril (009.134-25) for this purpose (refer to Figure 3 ).
17. Screw a new double nipple (12) into the piston and tighten it.
18. Screw the quick-acting-coupling half (3) onto the double nipple and
tighten it.
19. Remove the hydraulic tensioning tool from the vice.
20. Attach the hydraulic tensioning tool at an appropriate place in such a
way that the quick-acting-coupling half points upwards.
21. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool and high-pressure pump (009.338).
22. Switch the high-pressure pump on (see work card 009.03009.03), and pump
up the hydraulic tensioning tool.
▲ Attention! Make sure that the tensioning pressure specified for
the chosen bolt is not exceeded (see work card 000.30).
000.30
23. Release the pressure.
24. Disconnect the high-pressure hose. Vent the high-pressure hose by
means of the opener (009.026) - see work card 009.05.
009.05
25. Reconnect the high-pressure hose.
26. Pump up the hydraulic tensioning tool applying the tensioning pres-
000.30). Retain the pres-
sure specified for this bolt (see work card 000.30
sure for five minutes.
Important! After pumping up the hydraulic tensioning tool, no leak-
age must be recognisable for this period of time.
27. Release the pressure, disconnect the high-pressure hose, remove
the tensioning tool.
28. Slip the protecting cap onto the quick-acting-coupling half.

6641 009.18--01 E 02.03 L 58/64 107/ 07

Operating values/Operating results

001 Operating media systems/pipes

002 Operating media/auxiliary agents
003 Machine elements
004 Hydraulic tensioning tools/high-pressure pump
005 Operating values/operating results

6682 005--01 E 08.97 101/ 01

Ignition and compression pressures
Determination 000.25

Purpose of jobs to be done

Record and assess operating data,

recognise problems on subassembly groups/systems (having an
influence).

Brief description

Ignition and compression pressures are a significant indicator for the

mechanical loading the engine is subjected to. They are closely correlated
with essential operating values and allow conclusions on the condition of
components and systems.
The work/steps include:
recording pressures,
recording operating data, and
evaluating results.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Ignition pressure measuring device, Baewert 419.019 Optional
make, type 250E
1 Protective gloves -- Inventory

Preliminary remarks

The ignition pressures are a significant indicator for the mechanical loading
the engine is subjected to. They are closely correlated with essential oper-
ating data and permit to draw conclusions on the condition of components
and the systems, and have therefore to be checked at regular intervals as
specified in the maintenance schedule, using an indicator (pressure
gauge). The evaluation of readings will have to make allowance for both
the absolute values and for differential values from cylinder to cylinder.
A calibration interval of one year is recommendable for the ignition pres-
sure measuring device.

6682 000.25--03 E 04.05 General 101/ 03

Operating sequence 1 -- Record pressures

Starting condition Stable engine operating condition at the desired output. Steady-state
condition of operating characteristics has been reached.

Steps 1. Prior to taking indicator diagrams, open the indicator valve and keep
it open for 2-3 firing strokes to expel soot and combustion residues
that may have deposited in the indicator valve pipe.
▲ Attention! Keep away from the fire burst!
2. Close the indicator valve.
3. Screw the pressure sensor of the measuring device onto the indicator
valve.
4. Record the ignition pressures according to the Operating instruction
manual for the 250E ignition pressure measuring device (419.019).
Tip! The compression pressures can be recorded in the same way as
described above for the ignition pressures, for which purpose the control
rod of the corresponding injection pump is during the process set to zero
against the force of the buckling lever spring.

▲ Attention! Measuring the compression pressure is only admis-

sible up to a load at which the cylinders, which remain in operation,
are capable of taking over the load of the cylinder, which has been
shut down.

Figure 1. Ignition pressure measuring device, Baewert make, type 250E

Operating sequence 2 -- Evaluation/valuation

The following limit values/requirements have to be observed:

- ignition pressures measured at rated output $ maximum value,
- cylinder-to-cylinder deviations $ mean value tolerance
(for the corresponding limit values, refer to the Operating instruction
manual, Section 2.5),
- equal control rod setting on all injection pumps.
It is recommended that the diagrams/results are compared with those of
the test run record and/or with those of previous measurements.

6682 000.25--03 E 04.05 General 102/ 03

 Too high ignition pressures occur if ignition is timed too early and the
amount of fuel injected is too small.
Too low ignition pressures on individual cylinders may be caused by the
following functional deficiencies:
- dripping/poor injection of the injection nozzle,
- damaged/worn injection pump, and
- untight inlet/exhaust valves.
Tip! The graphic and/or arithmetical evaluation of the measured data
can be effected by means of the delivered PC software.

6682 000.25--03 E 04.05 General 103/ 03

Charge air cooler/crankcase
Measuring the differential pressure 000.40

Purpose of jobs to be done

Record operating values,

ensure/restore operational reliability,
enable/support economic operation.

Brief description

Supplementary to the data provided in the maintenance schedule,

differential pressure measurements support the determination of the most
appropriate cleaning intervals for charge air coolers, and they enable the
assessment of operating values.
The work includes:
measurement by means of digital pressure gauge, and
measurement by means of U--pipe pressure gauge.

Tools/appliances required

Quant Denomination No. Availability

1 Digital pressure gauge ”Digima--Premo” 009.090 Optional
1 Ready--to--use bag 009.090--1 Optional
1 Accumulator 9V 009.090--2 Optional
1 Battery charger 009.090--3 Optional
1 PVC hose 009.030--4 Optional
4 Quick--lock coupling 009.030--5 Optional
2 Hose plug--in nipple 009.090--6 Optional
2 Filter 009.090--7 Optional
1 U--pipe pressure gauge/water--filled PVC hose -- Inventory
1 Measuring tape -- Inventory

Preliminary remarks

Clogged charge-air coolers adversely affect the cooling effect and the
engine operating performance. Measuring of the differential pressure in
addition to the cleaning intervals specified in the maintenance schedule
serve the purpose of determining the most appropriate times for cleaning
and to interprete operating data. A digital differential pressure gauge or a
U-pipe pressure gauge can be used for measuring.

6682 000.40--01 E 07.97 32/40, 40/54, 48/60, 58/64 101/ 04

Measuring set--up/unit

1 Casing in front of
charge-air cooler
2 Charge-air cooler
3 Charge-air pipe
4 Measuring connection
5 Measuring unit

Figure 1. Measuring points/measuring set--up (illustration shows L 40 / 54 engine with single--stage charge--air cooler)

1a ”ON” push button 4 ”Attenuation” push button 8 Battery shelf

1b ”OFF” push button 5a Pressure line connection 9 ”lo bat” display (battery
2a “0” push botton (measuring p1 condition)
range 0 -- 2 bar) 5b Pressure line connection 10a Output for recorder (+)
2b “/” Push button p2 10b Output for recorder (--)
(measuring range 0 - 6a Zero resetting for
10 bar) measuring range
3 Info field (display of 0 - 2 bar
measuring range - 6b Zero resetting for
attenuation) measuring range
0 - 10 bar
7 Display of the measured
value

Figure 2. ”Digima--Premo” measuring unit, make SI, special instruments

6682 000.40--01 E 07.97 32/40, 40/54, 48/60, 58/64 102/ 04

Safety instructions

The maximum pressure on the unit is 14 bar.

Only admit dry gases to connection p1, and only admit gases and fluids
which do not attack polyester, silicone and silicon to connection p2. Only a
measuring hose equipped with a water-repellent filter may be fitted to
connection p2.

In differential pressure measuring, p2 > p1 as a rule. Where p2 < p1, the

measured value sign becomes negative. In relative pressure measuring,
p1 = ambient air pressure, p2 = measuring pressure.

The hose couplings on the engine and the hoses upstream of the
meassuring unit are of the self--locking type.

Measuring using digital pressure gauge

Non--recurring preparations Equip PVC hoses with slip-in nipples and quick-lock coupling at both ends.
Cut one of the hoses approximately 30 cm upstream of the coupling and
fasten both ends to the connections on the water-repellent filter. Use this
hose also for connection p1.

Steps 1. Purge the measuring connections. For this purpose temporarily

connect the hose slip-in nipple which has a nominal diameter of 8 mm
and is fastened to the connection, to the coupling on the engine’s
side.
2. With the filter mounted, connect the PVC hoses to the measuring
points A and B. The securing rings of the hose couplings must be
made sure to engage.
3. Connect the measuring unit and press the ”0” push button for 0 -
2 bar measuring. In field 3, the simbol at ”D” turns up.
4. Press the ”ON” push button. Read the measured value from the
display.
5. Pressure pulsations result in instable displays. If this is the case,
press the ”Attenuation” push button. The simbol at ”D” will turn up in
field 3.
6. Switch the measuring unit off. Pull the measuring hoses off the unit
and the measuring points (making sure to lift the securing ring).
7. Compare the measured value with the reference value and valuate it.
The differential pressure in the as-new condition can be looked up in
the acceptance certificate of the engine. The charge-air cooler should
be cleaned when the differential pressure has reached the maximum
( see engine operating manual, section 2.5) at the latest.
Supplementary information If the battery or accumulator voltage is too low, this will be signalled in the
display field 9 by ”lo bat”. The unit can be further used as long as this
display does not start flashing. When it does, the measurements must be
expected to become incorrect.
The recorder outputs 10a/10b produce a DC of 1 mV/digit (max. 2 V) that
is proportional to the measured value.
Zero resetting is done by means of the potentiometers 6a/6b, with the unit
unloaded.

6682 000.40--01 E 07.97 32/40, 40/54, 48/60, 58/64 103/ 04

Measuring using U-pipe pressure gauge

Steps 1. Purge the measuring connections as described above.

2. Provide the PVC hose of 8 mm inside diameter with end fittings on
both ends, these fittings being connected to the measuring
connections on the engine.
3. Fill an adequate amount of water into the hose so that the water
column is approximately 300 mm high on both sides.
4. Take both ends of the hose and connect them simultaneously to the
couplings of the measuring points.
5. Measure the water differential level h, and evaluate the results as
described above.

ah = 100 mm WS =10
mbar differential
pressure

A Connection upstream
of charge-air cooler
B Connection down-
stream of charge-air
cooler

Figure 3. Measuring the pressure differential using a U-pipe pressure gauge

Checking the crankcase pressure

The crankcase also has a measuring connection (approximately at engine

centre line, exhaust side). It serves to measure the crankcase pressure
relative to the atmospheric, i.e. at connection p2. When interpreting the
measured data, allowance has to be made for the wear on pistons, piston
rings and cylinder liners, for sealing air possibly entering from the
turbocharger bearings into the crankcase, the operating condition of the
crankcase venting valve and other factors.

Figure 4. Measuring point on the crankcase (L 40/54)

6682 000.40--01 E 07.97 32/40, 40/54, 48/60, 58/64 104/ 04

Work cards,
arranged by subassembly groups

1 Introduction

2 Work cards,
arranged by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 3--02 E 08.97 101/ 01

Table of contents

: : : N 3.1 List of Assemblies

: : : N 3.2 Work cards, arranged by subassembly groups

N 009... Foundation/resilient mounting/ alignment of the engine

000.09 Position of the crankshaft flange in relation to the driven flange

: : N Determine/check

N 012 Crankcase/Bearing bolts/Cross tierods/ Cylinder head bolts

012.01 Foundation Bolt

: : N Checking
012.02 Main bearing bolts
: : N Untightening and tightening
012.03 Crankshaft locating bearing bolts
: : N Untightening and tightening

N 020 Crankshaft/Coupling bolts

000.10 Crankshaft
: : N Measure the crank web deflection
020.01 Crankshaft and balance weights
: : N Checking
020.02 Coupling bolts
: : N Checking, untightening and tightening
020.03 Gearwheel on the crankshaft
: : N Installing

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6722 10.07 L 58/64 CD 101 /07

 020.04 Oil bore of the crankshaft
: : N Blocking

N 021 Main bearing/ Thrust bearing/Flange bearing

021.01 Main bearing shell

: : N Removing and installing/checking
021.02 Main thrust bearing
: : N Measuring axial clearance/ checking locating bearing rings

N 027 Torsional vibration damper

027.02 Torsional vibration damper of the valve camshaft

: : N Checking
027.03 Torsional vibration damper of the crankshaft
: : N Removing and refitting

N 030 Connecting rod/Big--end bearing

030.01 Con--rod shank bolts

: : N Checking, untightening and tightening
030.02 Big--end bearing bolts
: : N Checking, untightening and tightening
030.03 Lower big--end bearing shell
: : N Removing and installing
030.04 Upper big--end bearing shell
: : N Removing and installing/checking
030.05 Connecting rod
: : N Removing and installing

N 034 Piston/Piston rings

034.01 Piston
: : N Removing and installing
034.02 Piston
: : N Checking and disassembling
034.03 Piston pin and piston pin bush
: : N Removing and installing/checking
034.04 Piston
: : N Assembling

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6722 10.07 L 58/64 CD 102 / 07

 034.05 Piston rings
: : N Assessing
034.07 Chromium--ceramic coated piston rings
N Assessing

N 050 Cylinder Liner/Top land ring

050.01 Cylinder liner with backing ring

: : N Removing and installing
050.02 Cylinder liner
: : N Measuring
050.03 Sealing face on cylinder head and sealing groove in top land ring
: : N Grinding
050.04 Cylinder liner (without backing ring)
: : N Removing and installing
050.05 Cylinder liner
: : N Honing

N 055... Cylinder head/Vave seat rings/ Saftey valve

055.01 Cylinder head bolts

: : N Checking, untightening and tightening
055.02 Cylinder head
: : N Removing and refitting
055.03 Cylinder head
: : N Grinding of seating faces
055.04 Valve seat rings
: : N Removing and installing
055.05 Cylinder head with turnover stand
: : N Machining

N 073 Crankcase cover/Saftey valve/ Coverings

073.01 Safety valve on the crankcase cover

: : N Checking, overhauling

N 100 Camshaft drive

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6722 10.07 L 58/64 CD 103 /07

 100.01 Camshaft drive
: : N Checking

N 102 Camshaft bearing

102.01 Camshaft bearing

: : N Removing and installing

N 111 Rocker arm/Rocker arm casing

111.01 Valve clearance

: : N Checking and adjusting
111.02 Rocker arm casing with rocker arms
: : N Removing and refitting

N 112 Cam follower/Push--rod

112.01 Push--rods
: : N Removing and installing
112.02 Cam follower
: : N Removing and installing/checking

113 Inlet and exhaust valves/Valve seat rings/ Valve guides/Valve

N rotators

113.01 Inlet and exhaust valve/valve rotator

: : N Removing and installing
113.02 Valve rotator
: : N Checking
113.03 Inlet and exhaust valve Valve cone and seat surface
: : N Checking and assessing
113.04 Valve seating surface
: : N Machining
113.05 Valve cone
: : N Grinding
113.06 Valve guide
: : N Checking, removing and installing
113.09 Valve plate Depth of burning marks and corrosion
: : N Checking

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6722 10.07 L 58/64 CD 104 / 07

 N 125 Operating device

125.02 Three--way valve

: : N Checking, overhauling
125.04 Three--way valve
: : N Checking, overhauling
125.05 3/2--way solenoid valve
: : N Checking, overhauling
125.08 4/2--way solenoid valve
: : N Checking, overhauling
125.08 5/2--way solenoid valve
: : N Checking, overhauling
125.09 Pressure reducing valve
: : N Checking, overhauling
125.10 Compressed air filter
: : N Checking, overhauling
125.12 Limit switch
: : N Checking, overhauling
125.14 2/2--way solenoid valve
: : N Checking, overhauling

N 140... Speed control

140.01 Woodward governor PGG 200/PGG--EG 200

: : N Maintaining and checking
140.02 Booster servomotor (2--stage)
: : N Maintaining and checking
140.03 Governor drive
: : N Checking

N 160... Starting air pilot valve/ Starting valve/Main starting valve

160.01 Starting air pilot valve

: : N Disassembling and assembling
161.01 Starting valve
: : N Checking, removing and installing
162.01 Main starting valve
: : N Disassembling and assembling

N 200... Fuel injection pump/Control linkage

200.01 Fuel injection pump

: : N Checking

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6722 10.07 L 58/64 CD 105 /07

 200.02 Fuel injection pump
: : N Removing and installing
200.03 Fuel injection pump
: : N Disassembling and assembling
200.05 Fuel injection pump Baffle screws
: : N Checking and replacing
200.06 Fuel injection pump
: : N Measuring the plunger lift
201.01 Drive of injection pump
: : N Removing and installing/checking
201.02 Cam follower of fuel injection pump
: : N Removing and installing by means of the dismantling tool
202.01 Injection timing adjusting device
: : N Adjusting
203.01 Control linkage
: : N Maintaining and checking

N 209 Camshaft

209.01 Camshaft
: : N Checking

N 221 Fuel injection valve

221.01 Fuel injection valve

: : N Removing and installing
221.02 Fuel injection valve
: : N Checking
221.03 Fuel injection valve
: : N Disassembling
221.04 Fuel injection valve
: : N Assembling
221.05 Fuel injection valve Sealing faces on the threaded piece
: : N Grinding

N 280... Charge air and exhaust pipe

280.01 Exhaust gas turbocharger/charge air pipe Emergency operation

: : N Guaranteeing
280.02 Charge air bypass device
: : N Disassembly and assembly, replacement of sealing elements
289.01 Exhaust pipe
: : N Checking

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6722 10.07 L 58/64 CD 106 / 07

 289.02 Exhaust gas blow--off device
: : N Disassembly and assembly, replacement of sealing elements

N 300... Lube oil and cooling water pump (attached to engine)

300.01 Lube oil pump

: : N Disassembling and assembling
300.02 Lube oil pump
: : N Assessing the individual components

N 322 Charge air cooler

322.01 Charge air cooler

: : N Checking and cleaning
322.03 Charge air cooler
: : N Checking, cleaning on the air side

N 434 Fuel injection pipe

434.01 Fuel injection pipe

: : N Removing and refitting
434.02 Fuel injection pipe Sealing faces on the delivery pipe
: : N Grinding
434.04 Buffer piston
: : N Checking

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6722 10.07 L 58/64 CD 107 /07

Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 3.1

6722 3.1--01 E 02.06 101/ 07

Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 3.1

6722 3.1--01 E 02.06 102/ 07

Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 3.1

D GB F E

011 Ölwanne Oil sump Carter à huile Cárter de aceite

012 Zylinderkurbelgehäuse Cylinder crankcase Carter du vilebrequin Cárter del cigüeñal
020 Kurbelwelle Crankshaft Vilebrequin Cigüeñal
021 Kurbelwellenlager Main bearing Palier du vilebrequin Cojinete del cigüeñal
(023) * Kurbelwellenverlängerung Crankshaft extension Prolongement du vilebrequin Prolongación del cigüeñal

027 Schwingungsdämpfer Vibration damper Amortisseur de vibrations Amortiguador de vibraciones

030 Pleuelstange Connecting rod Bielle Biela
034 Kolben Piston Piston Émbolo
050 Zylinderbuchse Cylinder liner Chemise de cylindre Camisa de cilindro
055 Zylinderkopf Cylinder head Culasse de cylindre Culata

(057) * Sicherheitsventil am Zylinderkopf Safety valve on cylinder head Soupape de sécurité dans la Válvula de seguridad en la culata
culasse de cylindre
071 Verschalung auf Kupplungsseite Covering on coupling end Revêtement du côté Revestimiento al lado del
d’accouplement acoplamiento
071 * Totpunktanzeiger Dead centre indicator Indicateur de point mort Indicador del punto muerto
072 Verschalung auf Covering on free end of engine Revêtement du côté opposé à Revestimiento al lado opuesto del
Kupplungsgegenseite l’accouplement acoplamiento
073 Sicherheitsventil am Safety valve on the crankcase Soupape de sécurité dans Válvula de seguridad
Kurbelraumdeckel cover le couvercle de carter en la tapa del cárter

077 Verschalung der Nockenwelle Covering of camshaft Revêtement d’arbre à cames Revestimiento del árbol de levas
100 Steuerungsantrieb Camshaft drive Commande de la distribution Accionamiento por ruedas dentadas
102 Nockenwellenlager Camshaft bearing Palier d’arbre à cames Cojinete del árbol de levas
(105) Einheitsantrieb Auxiliaries drive Commande des auxiliaires Accionamiento de los auxiliares
111 Kipphebel mit Lagerung Rocker arm with bearings Culbuteur avec logement Balancín con cojinete

112a Stoßstange mit Verschalung Push--rod with covering Tige de culbuteur avec Varilla de empuje con revestimiento
revêtement

6722 3.1--01 E 02.06 103/ 07

Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 3.1

D GB F E

112b Ein-- und Auslaßschwinghebel mit Inlet and exhaust cam follower Basculeur d’admission et Seguidor de leva de admisión y
Lagerung with bearing d’échappement avec logement escape con alojamiento
113 Einlaßventil Inlet valve Soupape d’admission Válvula de admisión
114 Auslaßventil Exhaust valve Soupape d’échappement Válvula de escape
125 * Bedienungseinrichtung Operating device Poste de commande Dispositivo de manejo

140 Drehzahlregler Speed governor Régulateur de vitesse Regulador de revoluciones

160 * Anlaßsteuerschieber Starting air pilot valve Vanne d’asservissement de Distribuidor de arranque
lancement
161 * Anlaßventil Starting valve Soupape de lancement Válvula de arranque
162 * Hauptanlaßventil Main starting valve Soupape de lancement Válvula de arranque principal
principale
200 Kraftstoffeinspritzpumpe Fuel injection pump Pompe d’injection de combustible Bomba de inyección de combustible

201 Einspritzpumpenantrieb Drive of injection pump Commande de pompe d’injection Accionamiento de bomba de
inyección
(202) * Einspritzzeitpunktverstellung Injection timing adjusting device Réglage de l’avance à l’injection Ajuste del momento de inyección
203 * Fernfüllungsgeber Fuel index transmitter Capteur de cran de combustible Transductor de llenado
203 Regelgestänge für Control linkage for fuel injection Tringlerie de réglage pour pompe Varillaje de regulación para bomba de
Kraftstoffeinspritzpumpe pump d’injection de combustible inyección de combustible
209 Nockenwelle Camshaft Arbre à cames Árbol de levas

221 Kraftstoffeinspritzventil Fuel injection valve Soupape d’injection de Válvula de inyección de combustible
combustible
280 Ladeluftleitung Charge air pipe Conduite d’air de suralimentation Tubería de aire de sobrealimentación
(280) * Turbinen Scheibenkühlung mit Turbine--disc cooling system with Refroidissement de turbine avec Turbinas de refrigeración de disco
Druckmeßumformer pressure transducer convertisseur de mesure de con convertidor de medición presión
pression
(280) * Luftumblaseleitung Air bypass pipe Tuyauterie de dérivation d’air Tubería de derivación de aire

6722 3.1--01 E 02.06 104/ 07

Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 3.1

D GB F E

280 * Druckmeßumformer Pressure transducer Convertisseur de mesure de Convertidor de medición de presión

pression

286 * Abgasturboladeranbau Mounting exhaust gas Montage turbocompresseur Montaje turbosobrealimentador

turbocharger
286 * Anbauteile für Wascheinrichtung Add--on parts for washing device Pièces pour dispositif de lavage Piezas de montaje del dispositivo de
lavado
289 Abgasleitung Exhaust pipe Tuyauterie d’échappement Tubería de escape
(289) * Abgas--Abblaseleitung Exhaust gas blow--off pipe Tuyauterie d’évacuation de gaz Tubería de purga de gas
d’échappement de escape
292 * Verschalung der Abgasleitung Covering of the exhaust gas pipe Revêtement du tuyauterie Revestimiento de la tubería de gas
d’échappement de escape

(300) Schmierölpumpe Lube oil pump Pompe à huile de graissage Bomba de lubricación
302 Schmierölpumpe für Lube oil pump for cylinder Pompe à huile de graissage pour Bomba de lubricación para la
Zylinderschmierung lubrication lubrification du cylindre lubrificación de cilindros
(302) * Schmierölpumpe für Lube oil pump for valve seat Pompe á huile de graissage pour Bomba de lubricante para lubricar
Ventilsitzschmierung lubrication le graissage des sièges de asientos de válvulas
soupapes
311 * Kurbelraumentlüftung Crankcase venting Ventilation du carter du Ventilación del cárter del cigüeñal
vilebrequin
322 Ladeluftkühler Charge air cooler Réfrigérant d’air de Refrigerador del aire de
suralimentation sobrealimentación

(350) Kühlwasserpumpe Cooling water pump Pompe à eau de refroidissement Bomba de agua de refrigeración
(400) * Impulsgeber / Impulsaufnehmer Pulse transmitter / Pulse pick--up Emetteur d’impulsions / Capteur Generador de impulsos / Receptor de
d’impulsions impulsos
(408) * Grundlagertemperatur-- Temperature monitoring of main Surveillance de température du Control de la temperatura del cojinete
überwachung bearing palier principal principal
409 * Abgastemperaturanzeige Temperature indication Indicateur de température Indicación de temperatura

6722 3.1--01 E 02.06 105/ 07

Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 3.1

D GB F E

409 * Abgas--Temperaturüberwachung Exhaust gas temperature Surveillance de température des Control de temperatura de gas de
monitoring gaz d’échappement escape

(413) * Ölnebeldetektor Oil mist detector Détecteur de brouillard d’huile Detector de neblina de aceite
413 * Splash--Oil--Temperaturüberwachu Splash Oil Temperature Surveillance de température des Control de temperatura del aceite
ng Monitoring projections d’huile de lubrification salpicado
419 * Indiziereinrichtung Indicating device Dispositif indicateur Dispositivo indicador
432 * Anlaßluftleitung Starting air pipe Tuyauterie d’air de lancement Tubería de aire de arranque
434 Kraftstoffeinspritzleitung Fuel injection pipe Tuyauterie d’injection de Tubería de inyección de combustible
combustible

434 * Kraftstoffleitungen Fuel pipes Tuyauteries de combustible Tuberías de combustible

440 * Schmierölleitungen Lubricating oil pipes Tuyauteries d’huile de graissage Tuberías de aceite lubricante
441 * Manometerleitung Pressure gauge pipe Tuyauterie du manomètre Tubería de manómetro
442 * Kondenswasserablauf Condensed water discharge Décharge d’eau de condensation Descarga del agua de condensación
443 * Zylinderschmierung Cylinder lubrication Lubrification des cylindres Lubrificación de cilindros

(443) * Ventilsitzschmierung Valve seat lubrication Graissage de siège de soupape Lubricación del asiento de
válvula
446 * Rohrleitungen zum Turbolader Pipes to the turbocharger Tuyauteries pour le Tuberías al turbosobrealimentador
turbocompresseur

6722 3.1--01 E 02.06 106/ 07

Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 3.1

D GB F E

447 Kühlwasserleitungen Cooling water pipes Tuyauteries d’eau de Tuberías de agua de refrigeración
refroidissement
* Diese Baugruppen sind in den Bildern nicht sichtbar
These assemblies are not shown in the figures
Ces sous--groupes ne sont pas illustrés sur les figures
Estos grupos constructivos no están visibles en las figuras
(...) falls vorhanden
if provided
s’il existe
si existe

6722 3.1--01 E 02.06 107/ 07

Work cards,
arranged by subassembly groups 3.2

See the following pages.

Auxiliary sheet for generating the table of contents

6629 3.2--01 E 08.97 General 101/ 01

Foundation/resilient mounting/
alignment of the engine

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 009...--04 E 06.98 101/ 01

Position of the crankshaft flange
in relation to the driven flange
Determine/check 000.09

Purpose of jobs to be done

Check alignment,
recognise problems on (influencing) components/systems,
ensure/restore operational reliability.

Brief description

The crankshaft flange/the engine must in cold condition show a certain

displacement relative to the driven flange/unit. The alignment is to be
measured during the installation, and to be checked at regular intervals.
This includes the following:
checking the alignment,
recording the measuring values, and
evaluating the results.

Tools/appliances required

Qty Designation No. Availability

2 Dial gauge -- Inventory
1 Micrometer (inside) -- Inventory
1 Micrometer (outside) -- Inventory

Related work cards

Work card Work card Work card

000.10 012.01

Preliminary remarks

The crankshaft flange, or strictly speaking the engine, must in the cold
condition show a certain axial displacement relative to the driven flange,
whereby it is ensured that under operating conditions the influences of
certain factors can be compensated. Such factors include:
- thermal expansion of the foundations,
- thermal expansion of the engine, the generator or the gearbox,
- thermal expansion of the rubber elements where resilient seating is
used,
- the settling behaviour of resilient mounting elements, and
- shaft displacement under load.
The position of both flanges is to be measured in the original state, and
later to be checked at regular intervals as specified in the maintenance
schedule.

6682 000.09--01 E 02.01 101/ 04

 Important! If required, special written instructions are drawn up for
certain propulsion systems, in which also the necessary alignment details
are given. These may deviate from those in the flywheel arrangement
drawing.

1 Driven shaft flange E Distance

2 Crankshaft flange of engine F Axis of engine crankshaft
A Radial displacement G Axis of shaft
B Axial displacement aA Difference, radial displacement
C Alignment control dimension, coupling ST Camshaft side
D Distance

Figure 1. Alignment of the crankshaft flange relative to the driven flange -- dimensions and terms

Operating sequence 1 -- Measure the flange alignment

Starting condition The crank web deflection is in compliance with specifications (see work
card 000.10).
000.10

Prerequisites/measuring To determine the exact alignment dimensions during assembly, it is

procedure necessary to manufacture a measuring jig with two dial gauges to be
attached to the flywheel. One of the dial gauges will measure the radial
axial displacements (A) for the vertical and horizontal deviations, while the
second one serves to measure the plane parallelity and/or the flange gap
(B). The measuring jig is also usable for later checks as are necessary on
resiliently mounted engines, in particular.
The axial distance (E) is measured by a micrometer, from the flange of the
crankshaft to the flange of the driven shaft; the control dimension (C) is
measured from the flywheel to the flange of the driven shaft. In that way,
the distance between the engine and the driven flange and the installation
dimension (C) of the flexible coupling with the possibly required preload
can be adjusted/checked.
▲ Attention! Emergency lubrication of the engine bearings may
possibly have to be provided for turning the crankshaft during the
alignment procedure.

6682 000.09--01 E 02.01 102/ 04

 The values measured should be noted down and entered in a log form
sheet (similar to that suggested on the following page). In this process, the
originally measured values should be compared with the desired values
calculated, and/or with the empirical values. Alignment will have to be
corrected once more, if necessary. A later comparison of measured values
permits to draw conclusions on the chronology, the amount and possible
causes of changes.

g
Alignment g sheet
log Date
E i Works
Engine W k No..:
N Time

1 driven shaft flange 2 engine crankshaft

* Enter values in table

** Enter values in illustration

Important! The effective radial displacement is only half the

difference (aA) calculated from the dial gauge readings.

1st measure- 2nd measure- 3rd measure- 4th measure-

ment ment ment ment
Radial displacement (A), dial gauge reading
Axial displacement (B), dial gauge reading

horizontally vertically
Difference (aA)
Effective radial displacement (aA/2)

Alignment control dimension (C), coupling

Distance (D)
Distance (E)
Distance between crankshaft flange and engine crankcase
Distance between flange and bearing of the driven shaft

6682 000.09--01 E 02.01 103/ 04

Engine coupled not coupled

Engine state cold warm •C

Engine room temperature •C

Remark: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...................................................................................................
...................................................................................................
...................................................................................................

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6682 000.09--01 E 02.01 104/ 04

Crankcase/Bearing bolts/Cross tierods/
Cylinder head bolts

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 012--04 E 06.98 101/ 01

Foundation Bolt
Checking 012.01

Purpose of jobs to be done

Tighten and untighten important bolted connections with correct values,

check state/wear condition of components,
recognise problems on subassembly groups/systems (having an
influence).

Brief description

Foundation bolts must be checked for correct preload at regular intervals,

the state and firm seat of fitting pieces and stops must be verified.
The work includes:
checking components.

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 Thrust pad 055.100 Standard
1 Tension nut 021.436 Standard
1 Open end inserting tool 012.037 Optional
1 High--pressure pump 009.341 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.301 Standard
1 Torque wrench 140--760 Nm 008.004 Inventory
1 Feeler gauge (set) 000.451 Standard
1 Tommy bar, 10 mm 000.263 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
16--22 Forcing--off bolt M56x4 -- Inventory
1 Depth gauge -- Inventory
1 Hammer (wood/plastic) -- Inventory

Related work cards

Work card Work card Work card

000.10 000.30 000.33
009.03

6722 012.01--01 E 11.06 L 58/64 CD 101/ 04

 1 Protection cap 7 Sleeve 12 Stud
2 Nut 8 O-ring seal
3 Clinder crankcase 9 Top plate A Bolt projection
4 Fitting stud bolt 10 Synthetic-casting-resin Minimum = 167mm
5 Wedge chocking
6 Guide ledger 11 Steel spring plate

Figure 1. Semi-resilient engine support (Figure shows marine engine viewed from the coupling end)

Preliminary remarks

After the intervals stated in the maintenance schedule, all studs (12, 15)
and fitting stud bolts (4, 14) of the engine support on the foundation are to
be checked for firm seat.
The synthetic-casting-resin chocking (10) is to be checked for cracks and
crumbling which might endanger the stability. Stoppers (16), guide ledgers
(6) and wedges (5) are to be checked for firm seat.
In case a new alignment of the engine is necessary, e.g. due to an imper-
000.10) or owing
missibly high crank-web-deflection value (see Work Card 000.10
to the replacement of defective resilient-casting-resin chocking, this has to
be done according to the instructions on the drawing Semi-resilient Sup-
port and MAN’s alignment instructions.

▲ Attention! After spells of bad weather, after collision or ground

touching (in the case of marine engines) or after natural disasters (in
the case of stationary engines), the position of the engine is to be
checked closely, and all the foundation bolts are to be retightened.
The foundation bolts on the coupling and free engine end are most
likely to be affected!
Mounting the engine on the foundation is effected differently, depending on
the plant (marine engine, stationary engine). Marine engines are bolted to

6722 012.01--01 E 11.06 L 58/64 CD 102/ 04

 the top plates (9) of the ship while stationary engines are bolted to the
foundation beams.

Operating sequence 1 -- Checking the hydraulically tightened foundation bolts

2 Nut
3 Cylinder crankcase
4 Fitting stud bolt
12 Stud

Figure 2. Hydraulic tensioning tool in mounted condition

Steps 1. Remove the protection caps (1). Start checking the bolts on the
coupling end. Refer to Figure 1 .
2. Slip the thrust pad (055.100) and the hydraulic tensioning tool
(009.301) over the stud (12) and fitting stud bolt (4) respectively.
Refer to Figure 2 .
3. Connect the high-pressure hose (009.330) to the hydraulic tensioning
tool (009.301) and the high-pressure pump (009.338) and open the
009.03).
relief valve (see Work Card 009.03
4. Using the tommy bar (000.263), screw the tension nut (021.436) onto
the stud (4 and/or 12), tighten them firmly and, in this way, press the
piston of the hydraulic tensioning tool completely into the tensioning
cylinder.
5. Turn the tension nut back by 450ƒ (1 1/4 revolutions).
6. Switch the high-pressure pump on (see Work Card 009.03009.03) and in-
crease the pressure slowly until the nut (2) can be loosened.
▲ Attention! The pressure applied must not be more than 5% above
000.30).
the tensioning pressure (see Work Card 000.30
7. Note down the loosening pressure and compare it with the tensioning
pressure (see Work Card 000.30).
000.30
8. Adjust the high-pressure pump to the specified tensioning pressure
and retighten the nut.
9. Release the pressure, remove the hydraulic tensioning tool.
10. Check the remaining studs in the same way.
11. Grease the threads of the studs to protect them against rust and
cover them by means of the protection caps.

6722 012.01--01 E 11.06 L 58/64 CD 103/ 04

Operating sequence 2 -- Checking the foundation bolts

3 Cylinder crankcase
9 Top plate
10 Synthetic-casting-resin
chocking
11 Steel spring plate
13 Hexagon nut
14 Fitting stud bolt
15 Stud
16 Stopper
Figure 3. Fastening the steel spring plates to the foundation

Steps 1. Check resp. tighten all nuts (13) of the fitting stud bolts (14) and
000.30). In
studs (15) applying the specified torque (see Work Card 000.30
this connection, the following is to be observed:
- Torque wrench (008.004) and open end inserting tool (012.037) are to
be arranged so that they are in alignment.
- The specified adjustment value (MA2) only applies if the original tool is
used. In case other tools are used, the relationship of the levers is to
be newly calculated by means of the formula shown below.

MA2
B  MA1
AB

A Lever arm: Length of the open end inserting tool (012.037)

B Lever arm: Length of the torque wrench (008.004)
MA1 Specified torque (see Work Card 000.30
000.30)
MA2 Adjustment value on the torque wrench 570 Nm

Operating sequence 3 -- Checking the cylinder crankcase

▲ Attention! Danger to life! Whenever doing work in the cylinder

crankcase, close the starting air bottle, remove the air from the start-
ing air pipe and engage the turning gear in order to prevent starting
of the engine and turning of the running gear. For supplementary
safety regulations, refer to sheet 3.2.

Steps 1. Thoroughly clean the cylinder crankcase and the oil sump when
doing overhaul work and on every oil change.
2. Inspect the cylinder crankcase for cracks on the inside and outside.
3. After completion of the work, check the inside of the cylinder crank-
case for tools or other loose parts which might have been left there.

6722 012.01--01 E 11.06 L 58/64 CD 104/ 04

Main bearing bolts
Untightening and tightening 012.02

Purpose of jobs to be done

Tighten and untighten important bolted connections at the correct values,

ensure correct execution of work.

Brief description

Main bearing bolts and cross tierods are to be checked at regular intervals.
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Tools/appliances required

Quant Denomination No. Availability

1 Suspension device 021.141 Standard
2 Nut 021.122 Standard
2 Sleeve 021.121 Standard
2 Intermediate ring 021.076 Standard
2 Tension nut 021.074 Standard
2 Tension screw 020.040 Standard
2 Sleeve 020.039 Standard
2 Tension nut 020.018 Standard
1 High--pressure pump 009.338 Standard
4 High--pressure hose 009.330 Standard
4 Hydraulic tensioning tool 009.301 Standard
2 Hydraulic tensioning tool (tandem) 009.030 Standard
2 Measuring device 009.051 Standard
2 Measuring device 009.029 Standard
1 Tommy bar 14 000.265 Standard
1 Tommy bar 12 000.264 Standard
1 Foot board (for oil sump) -- Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.06 009.09 009.13

6619 012.02--01 E 05.98 L 58/64 101/ 05

Operating sequence 1 -- Checking cross tierod

Starting condition Crankcase is open. Crankgear turned so that the bearing cap is readily
accessible. Protection caps on cross tierods are screwed off.

Steps 1. Clean threads of cross tierods (3) and mount tandem combinations
onto both cross tierods of a bearing, paying attention to centering
009.13).
(refer to work card 009.13
2. Back off tension nuts (020.018) and (021.074) by 270E (3/4 turn),
using tommy bar.
3. Connect high-pressure pump to tensioning tool (009.301) and switch
pump on. Eliminate gap formed between tension nuts and piston.
4. Pressurise tensioning tools until both nuts (4) can be loosened. Note
down loosening pressure for both nuts and compare with tightening
pressure.
▲ Attention! In the process, the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30
5. Adjust high-pressure pump to specified tightening pressure (refer to
000.30) and re-tighten both nuts (4).
work card 000.30
6. Release pressure and detach the complete tensioning tools.

3 Cross tierod
4 Nut

Figure 1. Hydraulic tandem combination mounted onto the cross tierod

Operating sequence 2 -- Checking main bearing bolts

Steps 1. Clean threads of main bearing bolts (2) and mount tandem type
tensioning tools (009.030) onto the two bolts of a bearing (refer to
Figure 2 ). In the process, watch for dimension of gap A (refer to
009.09). Fitting the sleeves (021.121) may be effected with
work card 009.09
the aid of suspension device (021.141).
2. Connect high-pressure pump, switch it on and close gap A.
3. Pressurise tandem type tensioning tools until both nuts (1) can be
loosened. Note down loosening pressure and compare with tightening
pressure.
▲ Attention! In the process the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30

6619 012.02--01 E 05.98 L 58/64 102/ 05

 4. Adjust high-pressure pump to specified tightening pressure and
re-tighten both nuts (1).
5. Release pressure and detach the tensioning tools.
Important! When dismounting main bearings, always release the
cross tierods first and the main bearing bolts thereafter.

1 Nut
2 Main bearing bolt

Figure 2. Self-resetting hydraulic tandem combination mounted onto the main bearing bolt

Operating sequence 3 -- Releasing cross tierods

Starting condition Crankcase is open. Crankgear turned so that the bearing cap is readily
accessible. Protection caps on cross tierods are screwed off.

Steps 1. Clean threads of cross tierods (3) and mount tandem combinations
onto both cross tierods of a bearing, paying attention to centering
(refer to Figure 1 ).
2. Back off tension nuts (020.018) and (021.074) by 270E (3/4 turn),
using tommy bar.
3. Connect high-pressure pump to tensioning tool (009.301) and switch
pump on. Eliminate gap formed between tension nuts and piston.
4. Pressurise tensioning tools until both nuts (4) can be loosened. Note
down loosening pressure for both nuts and compare with tightening
pressure.
▲ Attention! In the process, the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30
000.30.
5. Back off both nuts, for backing-off angle refer to work card 000.30
6. Release pressure and completely detach tensioning tools.

6619 012.02--01 E 05.98 L 58/64 103/ 05

Operating sequence 4 -- Releasing main bearing bolts

Starting condition Cross tierods have been released.

Steps 1. Clean threads of main bearing bolts (2) and mount tandem type
tensioning tools (009.030) onto the two bolts of a bearing (refer to
Figure 2 ). In the process, watch for dimension of gap A (refer to
009.09). Fitting the sleeves (021.121) may be effected with
work card 009.09
the aid of suspension device (021.141).
2. Connect high-pressure pump, switch it on and close gap A.
3. Pressurise tandem type tensioning tools until both nuts (1) can be
loosened. Note down loosening pressure and compare with tightening
pressure.
▲ Attention! In the process the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30
4. Back off both nuts (1). For backing-off angle refer to work
000.30.
card 000.30
5. Release pressure and detach tensioning tools.

Operating sequence 5 -- Tightening main bearing bolts and cross tierods

Starting condition Nuts (4 and 1) for cross tierods (3) (refer to Figure 1 ) and main bearing
bolts (2) (refer to Figure 2 ) have been tightened hand-tight with the
tommy bar. Gap between bearing cap and crankcase (5) (refer to
Figure 3 ) of equal width on both sides (1 mm max.).

Important! Tightening has to be effected in several steps. Observe

correct sequence of tightening. Prior to tightening the bearing bolts, ensure
that the bolt projection of 11á2 mm to the lower nut is adhered to (refer to
Figure 3 ) .

Steps 1. Completely mount tandem combination onto the two cross tierods,
paying attention to centering.
2. Mount hydraulic tandem device on the two main bearing bolts, paying
attention to centering.
3. Connect high-pressure pump to tensioning tools (009.301) of cross
tierods and tighten with 250 bar pressure. Tighten both nuts (4)
hand-tight, using tommy bar (refer to Figure 1 ).
4. Release pressure and uncouple high-pressure hoses (tensioning
tools remain in position).
5. Connect high-pressure pump to the already mounted tensioning
tools (009.030) for the main bearing bolts.
6. Pressurise to pressure of 250 bar and tighten both nuts (1)
hand-tight, using tommy bar.
7. Release pressure and uncouple high-pressure hoses (tensioning
tools remain in mounted position).
8. Connect high-pressure pump to tensioning tools (009.301) of cross
tierods once more and tighten the bolts to final pressure (refer to
000.30). Tighten nuts (4) hand-tight, using tommy bar.
work card 000.30
9. Release pressure and detach tensioning tools from the cross tierods.
10. Again connect high-pressure pump to the tensioning tools (009.030)
of the main bearing bolts and raise pressure to 250 bar. Place
measuring device (009.029 or 009.051) and set dial gauge to ”Zero”
009.06).
(refer to work card 009.06
11. Raise pressure in tensioning tool to final pressure (refer to work
card 000.30).
000.30 Tighten nuts (1) hand-tight and release pressure.

6619 012.02--01 E 05.98 L 58/64 104/ 05

 12. Again tighten the main bearing bolts with 250 bar. Take reading
of bolt elongation ol occurring between 250 bar and final pressure
from dial gauge and compare with specified value (refer to work
000.30).
card 000.30
13. Release pressure. Detach complete tensioning tools.
14. Refit protection caps on cross tierods and main bearing bolts.
Important! Always tighten the bolts on the basis of the specified
tightening pressure not according to elongation. Indication of elongation
ratings only serves the purpose of checking. In case of considerable
deviations, repeat the tightening process and closely check measuring
device or gauge.

5 Crankcase

Figure 3. Tandem combination mounted onto the main bearing bolt and cross tierod

6619 012.02--01 E 05.98 L 58/64 105/ 05

Locating bearing bolts
Untightening and tightening 012.03

Purpose of jobs to be done

Tighten and untighten important bolted connections at the correct values,

ensure correct execution of work.

Brief description

Locating bearing bolts and cross tierods are to be checked at regular

intervals.
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Tools/appliances required

Quant Denomination No. Availability

2 Sleeve 055.100 Standard
2 Tension nut 021.436 Standard
2 Intermediate ring 021.076 Standard
2 Tension nut 021.074 Standard
2 Tension screw 020.040 Standard
2 Sleeve 020.039 Standard
2 Tension nut 020.018 Standard
1 High--pressure pump 009.338 Standard
4 High--pressure hose 009.330 Standard
4 Hydraulic tensioning tool 009.301 Standard
1 Tommy bar 12 000.264 Standard
1 Tommy bar 10 000.263 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.01
009.03 009.13

6619 012.03--01 E 04.98 L 58/64 101/ 04

Operating sequence 1 -- Checking cross tierods

Starting condition Crankcase is open. Crankgear at cylinder No. 1 turned so that outer
crankshaft locating bearing cap is easily accessible. Protection caps on
cross tierods are removed.

Steps 1. Clean threads of cross tierods (3) and mount tandem combinations,
009.13).
ensuring centering in the process (refer to work card 009.13
2. Back off tension nuts (020.018 and 021.074) by 270• (3/4 turn), using
tommy bar.
3. Connect high-pressure pump to tensioning tools (009.301) and switch
on. Close gap formed between tension nuts and piston.
4. Pressurise tensioning tools until both nuts (4) can be loosened. Note
down loosening pressure for both nuts and compare with tightening
pressure.
▲ Attention! In the process, the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30
5. Adjust high-pressure pump to specified pressure and re-tighten both
nuts (4).
6. Relieve pressure and detach tensioning tools.

3 Cross tierod
4 Nut

Figure 1. Hydraulic tensioning tool mounted onto the cross tierod

Operating sequence 2 -- Checking outer locating bearing bolts

Steps 1. Clean threads of locating bearing bolts (2), mount sleeves (055.100),
tensioning tool (009.301) and tension nuts (021.436), connect
high-pressure hoses (refer to Figure 2 or work card 009.01
009.01).
2. Back off tension nuts (021.436) by 450• (1 1/4 turns), using tommy
bar.
3. Switch on high-pressure pump, close gap between tension nuts and
piston.
4. Pressurise tensioning tool until both nuts (1) can be loosened. Note
down loosening pressure and compare to tightening pressure.
▲ Attention! In the process, the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30

6619 012.03--01 E 04.98 L 58/64 102/ 04

 5. Adjust high-pressure pump to specified tightening pressure and
re-tighten both nuts (1).
6. Relieve pressure and remove tensioning tools.
Important! When dismounting the crankshaft locating bearing,
loosen the cross tierods first and the crankshaft bearing bolts thereafter.

1 Nut
2 Crankshaft locating
bearing bolt

Figure 2. Hydraulic tensioning tool mounted onto the outer locating bearing bolt

Operating sequence 3 -- Untightening cross tierods

Starting condition Crankcase is open. Crankgear at cylinder No. 1 turned so that outer
crankshaft locating bearing cap is easily accessible. Protection caps on
cross tierods are removed.

Steps 1. Clean threads of cross tierods (3) and mount tandem combinations,
ensuring centering in the process (refer to Figure 1 ).
2. Back off tension nuts (020.018 and 021.074) by 270• (3/4 turn),
using tommy bar.
3. Connect high-pressure pump to tensioning tools (009.301) and switch
on. Close gap formed between tension nuts and piston.
4. Pressurise tensioning tools until both nuts (4) can be loosened. Note
down loosening pressure for both nuts and compare with tightening
pressure.
▲ Attention! In the process, the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30
5. Back off both nuts (4), for backing-off angle refer to work
000.30.
card 000.30
6. Release pressure and remove tensioning tools.

Operating sequence 4 -- Untightening outer locating bearing bolts

Starting condition Cross tierods have been released.

Steps 1. Clean threads of locating bearing bolts (2), mount sleeves (055.100),
tensioning tool (009.301) and tension nuts (021.436), connect
high-pressure hoses (refer to Figure 2 ).
2. Back off tension nuts (021.436) by 450• (1 1/4 turns), using tommy
bar.
3. Switch on high-pressure pump, close gap between tension nuts and
piston.
4. Pressurise tensioning tool until both nuts (1) can be loosened. Note
down loosening pressure and compare to tightening pressure.

6619 012.03--01 E 04.98 L 58/64 103/ 04

 ▲ Attention! In the process, the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30
5. Back off both nuts (1), for backing-off angle refer to work
000.30.
card 000.30
6. Release pressure and remove tensioning tools.

Operating sequence 5 -- Tightening outer locating bearing bolts and cross tierods

Starting condition Nuts (4 and 1) of cross tierods (3) (refer to Figure 1 ) and locating
bearing bolts (2) (refer to Figure 2 ) are hand-tightened with use of
tommy bar. Gap between bearing cover and crankcase is equal on
both sides (1 mm max.).

Important! Tightening has to be done in several steps. Pay

attention to the correct sequence of tightening!

Steps 1. Tandem combinations completely mounted on both of the cross

tierods, ensure centering in the process (refer to Figure 3 ).
2. Raise pressure in tensioning tools to tightening pressure of 250 bar
and tighten both nuts (4) hand-tight, using tommy bar (refer
to Figure 1 ).
3. Release pressure. Detach each of the outer tensioning
tools (009.301) of the tandem combination and mount them
onto the locating bearing bolts, using sleeve (055.100) and tension
nut (021.436).
4. Raise pressure in tensioning tools for the locating bearing bolts to
final pressure (refer to work card 000.30)
000.30 and tighten nuts (1) hand
tight, using tommy bar (refer to Figure 2 ).
5. Release pressure. Remove tensioning tools and remount them to the
cross tierods.
6. Raise pressure in tandem combinations on cross tierods to final
pressure (refer to work card 000.30)
000.30 and tighten nuts (4) hand tight,
using tommy bar
7. Release pressure. Detach tensioning tools. Refit protection caps over
locating bearing bolts and cross tierods.
Important! On the outer locating bearings for the crankshaft,
checking the bolt elongation is not necessary.

2 Crankshaft locating
bearing bolt
3 Cross tierod

Figure 3. Tandem combination mounted onto the outer locating bearing bolts and cross tierods

6619 012.03--01 E 04.98 L 58/64 104/ 04

Crankshaft/Coupling bolts

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 020--04 E 06.98 101/ 01

Crankshaft
Measure the crank web deflection 000.10

Purpose of jobs to be done

Check alignment,
recognise problems on (influencing) components/systems,
ensure/restore operational reliability.

Brief description

The crank web deflection permits to draw conclusions on the alignment of

the main bearings and the bearings/the alignment of the driven shaft. It is
to be checked regularly.
This includes the following:
checking the alignment,
recording the measuring values, and
evaluating the results.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.15
1 Assistant 0.15

Tools/appliances required

Qty Designation No. Availability

1 Guide tube 021.032 Standard
1 Tools, basic scope 009.229 Optional
1 Dial gauge (measuring device) 008.171 Optional
1 Thickness gauges 0.05--1 000.454 Standard
1 Felt--tip pen/Marking pen -- Inventory

Related work cards

Work card Work card Work card

000.09

6682 000.10--03 E 09.06 32/40, L 40/54, 48/60, L 58/64 101/ 04

Preliminary remarks

The crank web deflection permits to draw conclusions on the alignment of

the main bearings and the bearings of the driven shaft. Should the mea-
sured values exceed the admissible maxima, the cause must be remedied/
the crankshaft has to be realigned. Possible causes include:
- Uneven wear of main bearings,
- the position of the driven shaft has changed, or
- the engine mounting on the foundation or the foundation as such has
changed.

The results of crank web deflection measurements have a coherence with

the alignment checks of the crankshaft flange relative to the driven flange.

Operating sequence 1 -- Measure the crank web deflection

Dial gauge readings should be taken at the points BDCR and BDCL if the
connecting rod is in place. With the connecting rod removed, readings are
to be taken in BDC position.
The designation refers to the position of the crank pin, but not that of the
dial gauge.
The sides and the sense of rotation are to be understood from the end
viewing onto the coupling flange.

Steps 1. Remove the crankcase doors.

2. Turn the crankshaft so that the number 1 cylinder comes to be in the
starting position; depending on the normal sense of rotation of the
engine, this is either the BDCL or the BDCR position.
3. Using the thickness gauges (000.454), check whether the crankshaft
rests on the bottom bearing shells.
Important! If this is not the case, wrong results of crank web deflec-
tion will be obtained.
4. Place the measuring instrument (008.171) in measuring point (2) and
set the dial gauge to ”0” approx. in the middle of the measuring
range.
▲ Attention! The measuring points for taking measurements with
the running gear installed are located in the balance weights!
Exception: 58/64 engine, here they are in the crank webs!

Important! If measurements are taken with the engine still warm,

the measuring instrument must previously have been in the crankcase for
approx. 15 minutes to adapt to the temperature prevailing.
5. Turn the crankshaft in the normal sense of rotation up to the desired
measuring positions (refer to Figure 2 ). At every position, take read-
ings of the magnitude and direction (+ or --) of the dial gauge excur-
sion in comparison with the initial setting, and enter in a table (similar
to the example/table 1).
▲ Attention! On a Vee engine, take care that the measuring instru-
ment is not damaged by the slave connecting rod while turning the
engine!
6. Measure the other crank throws in the same way.

6682 000.10--03 E 09.06 32/40, L 40/54, 48/60, L 58/64 102/ 04

 1 Crank web
2 Measuring point
(punch mark)
3 Crank pin

A Distance between
measuring points

Figure 1. Measuring the crank web deflection

OT Top dead center (TDC) ROT 90• right of TDC (RTDC) UTR right of BDC (BDCR)
UT Bottom dead center (BDC) LOT 90• left of TDC (LTDC) UTL left of BDC (BDCL)

Figure 2. Designations of measuring points

Operating sequence 2 -- Note down the measured values

Apart from the data shown in Table 1, the following information should be
entered in the measuring log sheet:
- Assembly condition (e.g. pistons/connecting rods in place/removed),
- condition of coupling and bearings (e.g. vessel in drydock/afloat),
- temperatures of oil and cooling water if measurements are taken with
the engine at operating temperature, and
- main sense of rotation of the engine if measurements are taken with
running gear components in place.

6682 000.10--03 E 09.06 32/40, L 40/54, 48/60, L 58/64 103/ 04

 Cylinder No.
C k web
Crank b position
iti 1 2 3
Crank web at BDCR 0 0
Crank web at RTDC -2 +1
Crank web at TDC -5 +3
Crank web at LTDC +1 +2
Crank web at BDCL +2 0
Crank web deflection TDC-BDC -6 +3
Crank web deflection RTDC-LTDC -3 -1

Difference in TDC values of

neighbouring cylinders 8
Table 1. Measuring log sheet (example) - Dimensions in 1/100 mm

Operating sequence 3 -- Evaluation/valuation

Crank web deflection is the maximum difference of measurements of two

crank web positions at an angle of 180• . The reference position for verti-
cal deflection is the BDC, that for horizontal deflection is LTDC. If crank
web deflection is to be measured with the running gear components in
place, the value for BDC is obtained from 0.5 (BDCL + BDCR), which then
permits to calculate the difference between TDC and BDC.
If the crank web distance increases as compared with the reference posi-
tion, plus values (+) are to be entered in the table; if the distance becomes
smaller, minus values ( -- ) are entered.
Table 2 contains the maximum deflection values and the measuring point
distances (A). The maximum values apply to all cylinders with the engine
either cold or at operating temperature, and whether rigidly or flexibly
coupled (exception for 32/40 engine; see below). In case the actual deflec-
tion values exceed the ones stated in the table, the crankshaft has to be
newly aligned.
Please also note the following:
The difference of TDC measurements of neighbouring cylinders should not
be larger than the maximum admissible deflection.

Engine type 32/40 40/54 L 48/60 V 48/60 58/64

L 48/60 B V 48/60 B
With the engine in Deflection in 1/100 mm á14 1) á18 á23 á26 á23
cold condition
With the engine at Deflection in 1/100 mm 14 á18 á23 á26 á23
operating tempera- 20
ture
Measuring point distance (A) 460 505 580 580 560
in mm
1) Applicable to crank No. 1 (coupling end) with rigid coupling and to all the other cranks in all cases.
For crank No. 1 (coupling end) the maximum value is -- 20 if the connection to the driving flange is by flexible coupling.
Table 2. Maximum admissible crank web deflections (differentials) and relevant measuring point distances

6682 000.10--03 E 09.06 32/40, L 40/54, 48/60, L 58/64 104/ 04

Crankshaft and balance weights
Checking 020.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure/restore operational reliability.

Brief description

Bolted connections which are tightened by means of hydraulic tensioning

tools must, according to the maintenance schedule, be checked for correct
tension.
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Safety requirements

- Engine shut--down
- Engine secured against starting

Tools/appliances required

Qty Denomination No. Availability

2 Sleeve 055.100 Standard
2 Tension nut 021.436 Standard
1 Foot board (for oil sump) 011.008 Standard
1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.330 Standard
2 Hydraulic tensioning tool 009.301 Standard
1 Tommy bar 12 000.264 Standard
1 Tommy bar 10 000.263 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.01
009.03 009.06

Technical details

Term Information
Balance weight 335 kg

6641 020.01--01 E 09.98 L 58/64 101/ 03

Operating sequence 1 -- Checking balance weight bolts

Starting condition Running gear has been opened, crankshaft turned so that the balance
weight (3) is pointing to the crankcase opening.

▲ Attention! In case of inspection and maintenace work inside the

crankcase place foot board (011.008) into oil sump, in order to
prevent accidents.
Remove foot board from inside crankcase after completion of work.

Steps 1. Completely mount the two tensioning tools (009.301) (refer to work
card 009.01).
009.01
Important! Close off with blind plugs the connections on the
high-pressure pump (009.338) which are not used.

▲ Attention! Crankshaft (4) must not be turned with the tensioning

tools mounted.

2 Stud
3 Balance weight
4 Crankshaft
5 Oil sump
(with attachments)
6 Oil sump
(standard version)

Figure 1. Crankshaft with haydraulic tensioning tool mouned onto the balance weight

1 Nut
2 Stud

Figure 2. Hydraulic tensioning tool mounted onto the stud

6641 020.01--01 E 09.98 L 58/64 102/ 03

 2. Using tommy bar, back off the tension nuts (021.436) by 450ƒ
(1 1/4 turns).
3. Switch on high-pressure pump and with it close the gap that has
fomed between tension nut and piston.
4. Pressurise tensioning tools until both nuts (1) may be loosened.
Note down loosening pressure for both nuts and compare with
tightening pressure
▲ Attention! In the process, the pressure must not be raised
higher than 5% in excess of the tightening pressure (refer to
000.30).
work card 000.30
5. Tighten, applying specified pressure and re-tighten nuts (1).
6. Release pressure and detach the two tensioning tools.
Important! For carrying out maintenance work, no removal and
refitting of any of the balance weights (3) is necessary. If repair work,
however, requires removal of the balance weights, ensure that on refitting,
the draw-in torque of the studs (2), the lubricant of the threads and the
specified tightening torque for tightening the nuts (1) are observed in
000.30. In the process, the elongation aL
accordance with work card 000.30
of the studs is to be measured and reading to be compared with the value
000.30. In case of considerable deviation, repeat
as per work card 000.30
tightening process and check measuring device or pressure gauge. The
studs are to be tightened with the specified tightening pressure, not
according to elongation. The elongation rating indicated merely serves
the purpose of checking.

Operating sequence 2 -- General checking

Steps 1. In case assembling/refitting work is to be carried out, all the screwed

fittings accessible of torsional vibration damper, balance weights,
shaft gear and two-piece drive gear for camshaft drive should be
checked for tight fit.
2. In case bearing shells of camshafts or big end bearings have been
removed, visually inspect the running surfaces of pins.
3. Crank journals and crank pins which have become rough must be
polished before refitting. Before doing so, close off the oil bores.

6641 020.01--01 E 09.98 L 58/64 103/ 03

Coupling bolts
Checking, untightening and tightening 020.02

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure operational reliability of bolted connections.

Brief description

Coupling bolts are to be checked at regular intervals for tight fit. Where
connections are found to have loosened, the cause must be determined.
The work/steps include:
checking the bolted connection,
untightening,
tightening.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.330 Standard
2 Hydraulic tensioning tool 009.191 Standard
2 Thrust pad 020.051 Standard
1 Tommy bar, 12 mm 000.264 Standard
1 Torque wrench 750--2000 Nm 008.005 Standard
1 Socket wrench (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Depth gauge -- Inventory
1 Lubricant -- Inventory

6641 020.02--03 E 02.03 L 58/64 101/ 06

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.17

Technical details

Term Information
Bolt projection (A) 150 mm
Flywheel 5170 kg

Operating sequence 1 -- Check the coupling bolts

Starting condition Coupling (8) removed, coupling bolts accessible, flywheel attached to the
crankshaft flange by means of four hexagon socket bolts (6).

Steps 1. Clean the threads of the coupling bolts (2 and 3).

2. Place the thrust pads (020.051) over two nuts (4) located opposite
each other.
3. Screw the hydraulic tensioning tools (009.191) onto the two coupling
bolts, making sure that the thrust pads are centred by the hydraulic
tensioning tools.
4. Turn the hydraulic tensioning tools back by the back-off angle (see
000.30).
work card 000.30
5. Connect the high-pressure hoses (009.330) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03), and close
6. Switch on the high-pressure pump (see work card 009.03
the gap between the thrust pads and flywheel (1), which was pro-
duced by turning back.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the coupling bolts!
7. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened. Note down the loosening pressure and compare it with the
tensioning pressure.
▲ Attention! The pressure applied must not be more than 7% below
or max. 5% above the tensioning pressure (see work card 000.30).
000.30

▲▲ Caution! During pumping, watch the stoke gauge of the hy-

draulic tensioning tools. Hydraulic tensioning tools may only be
pumped up until the marking on the stroke gauge (groove marked in
red) reaches the upper edge of the threaded stop ring. Otherwise,
the hydraulic tensioning tools will be damaged.
8. Adjust the high-pressure pump to the specified tensioning pressure
000.30).
(see work card 000.30
9. Using the tommy bar (000.264), screw down both nuts through the
opening in the thrust pad, hand-tight.
10. Release the pressure, disconnect the high-pressure hoses from the
hydraulic tensioning tools.

6641 020.02--03 E 02.03 L 58/64 102/ 06

 1 Flywheel 4 Nut 8 Coupling
2 Coupling bolt (fitting bolt) 5 Crankshaft 9 Coupling hub
3 Coupling bolt 6 Hexagon socket bolt
7 Hexagon bolt A Bolt projection

Figure 1. Fitting the hydraulic tensioning tool on the coupling bolts (overall view)

Important! The hydraulic tensioning tools are automatically reset to

zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
11. Remove the tensioning tools.
12. Screw the tensioning tools onto the next pair of bolts, and repeat the
procedure until all the coupling bolts have been checked.
13. After completion of the checks, disconnect the high-pressure hoses
from the high-pressure pump.

6641 020.02--03 E 02.03 L 58/64 103/ 06

 1 Flywheel
2 Coupling bolt (fitting bolt)
3 Coupling bolt
4 Nut

Figure 1. Attached tensioning tool

Operating sequence 2 -- Untension the coupling bolts

Starting condition Coupling (8) removed, coupling bolts accessible, flywheel attached to the
crankshaft flange by means of four hexagon socket bolts (6).

Steps 1. Clean the threads of the coupling bolts (2 and 3).

2. Place the thrust pads (020.051) over two nuts (4) located opposite
each other.
3. Screw the hydraulic tensioning tools (009.191) onto the two coupling
bolts, making sure that the thrust pads are centred by the hydraulic
tensioning tools.
4. Turn the hydraulic tensioning tools back by the back-off angle (see
000.30).
work card 000.30
5. Connect the high-pressure hoses (009.330) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03) and close
6. Switch the high-pressure pump on (see work card 009.03
the gap between the thrust pads and the flywheel (1), which was pro-
duced by turning back.
▲▲▲ Danger! During untensioning, make sure that there is no one
along the extended axis of the coupling bolt to be untensioned!
7. Pump up the hydraulic tensioning tool until the nuts can be loosened.
Note down the loosening pressure and compare it with the tensioning
pressure.
▲ Attention! The pressure applied must not be more than 7% below
or max. 5% above the tensioning pressure (see work card 000.30).
000.30

▲▲ Caution! During pumping, watch the stroke gauge of the hy-

draulic tensioning tools. Hydraulic tensioning tools may only be
pumped up until the marking on the stroke gauge (groove marked in
red) reaches the upper edge of the threaded stop ring. Otherwise,
the hydraulic tensioning tools will be damaged.
8. Using the tommy bar (000.264), slacken both nuts through the open-
ing in the thrust pad (for back-off angle, see work card 000.30).
000.30
9. Release the pressure, disconnect the high-pressure hoses from the
hydraulic tensioning tools.

6641 020.02--03 E 02.03 L 58/64 104/ 06

 Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
10. Remove the tensioning tools.
11. Screw the tensioning tools onto the next pair of bolts, and repeat the
procedure until all coupling bolts have been untensioned.
12. After untensioning all coupling bolts, disconnect the high-pressure
hoses from the high-pressure pump.
Important! Prior to removing the flywheel, check whether all fitting
bolts and the corresponding bores have been numbered and the position
flywheel - crankshaft flange has been marked. In case this has not yet
been done, it should be done immediately.

Operating sequence 3 -- Tensioning the coupling bolts

Starting condition Flywheel fitted to the crankshaft flange by means of four hexagon socket
bolts (6), coupling bolts cleaned and inserted into the bores.

Important! Make sure that the coupling bolts are fitted correctly
(number of coupling bolts, position of the fitting bolts (2), bolt projection (A)
of the coupling bolts).
The nuts have been screwed on, hand-tight. Works No. and markings of
engine and/or crankshaft flange and flywheel coincide.

Important! Always tension one pair of bolts (two coupling bolts lo-
cated opposite each other) at the same time. First, tension any pair, then
the pair which is located at a 90ƒ angle, after that again any pair, and so
on.

▲ Attention! Correct tensioning of a bolted connection requires the

pressure gauge indication to be correct. In case of doubt, check the
pressure gauge against a reference pressure gauge.

Steps 1. Check the bolt projection (A) of the coupling bolts (2 and 3).
2. Place the thrust pads (020.051) over the nuts (4).
3. Screw the hydraulic tensioning tools (009.191) onto both of the
coupling bolts, making sure that the thrust pads are centred by the
hydraulic tensioning tools.
4. Connect the high-pressure hoses (009.330) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03), and ten-
5. Switch the high-pressure pump on (see work card 009.03
sion the coupling bolts to the specified tensioning pressure (see work
000.30).
card 000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the coupling bolts to be tensioned!

▲▲ Caution! During pumping, watch the stroke gauge of the hy-

draulic tensioning tools. Hydraulic tensioning tools may only be
pumped up until the marking on the stroke gauge (groove marked in
red) reaches the upper edge of the threaded stop ring. Otherwise,
the hydraulic tensioning tools will be damaged.
6. Using the tommy bar (000.264), screw down both nuts through the
opening in the thrust pad, hand-tight.
7. Release the pressure, disconnect the high-pressure hoses from the
hydraulic tensioning tools.

6641 020.02--03 E 02.03 L 58/64 105/ 06

 Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
8. Remove the tensioning tools.
9. Screw the tensioning tools onto the next pair of bolts, and repeat the
procedure until all coupling bolts have been tensioned.
10. After all coupling bolts have been tensioned, disconnect the high-
pressure hoses from the high-pressure pump.
11. When fitting the coupling, make sure that the thread and the screw-
head seating face of the hexagon bolts (7) are coated with clean lu-
bricating oil, that the bolts are screwed in, hand-tight, and tightened
to the specified torque (see flywheel arrangement drawing of the re-
spective plant).

6641 020.02--03 E 02.03 L 58/64 106/ 06

Gearwheel on the crankshaft
Installing 020.03

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

If damage should be found on the gear wheel on the crankshaft, the gear
rim is to be replaced or renewed.
The work includes:
Installing components.

Tools/appliances required

Quant Denomination No. Availability

1 Torque wrench 750--2000 Nm 008.005 Standard
1 Socket wrench insert 55x25 001.804 Standard

Related work cards

Work card Work card Work card

000.30 100.01

Operating sequence 1 -- Fitting the gearwheel to crankshaft

Starting condition The bottom idler-gear pair of the camshaft drive, and the old gearwheel
from the crankshaft have been removed.

▲ Attention! Only turn the crankgear when the pushrods for

the inlet and exhaust valves have been removed. Otherwise, the
opened valves can be damaged by the rising pistons.

Steps 1. Insert the feather key (3) , fit the gearwheel halves (5) to the
crank- shaft, insert the bolts (2), screw on the nuts (1) and
tighten them by hand.
2. Determine the total length of the individual bolts, note these
values down and use them as a basis for checking the elongation.
3. Tighten the bolts (6 and 7) to pretightening torque
loading 1000 Nm.
4. Next tighten bolts (8 and 9) to the same torque loading.
5. Tighten the bolts (6 and 7) further until the specified bolt elongation
000.30), and then tighten to
has been reached (refer to workcard 000.30
the next pinhole.

6619 020.03--01 E 05.98 L 58/64 101/ 02

 6. Tighten the bolts (8 and 9) further until the specified bolt enlongation
has been reached, and then tighten to the next pinhole.
7. Refit the bottom idler-gear pair for the camshaft drive, taking the
correct positioning of the markings into account. The markings are
in alignment with each other when the piston of cylinder No. 1 is in
ignition TDC position.
Tip! It is recommended that overhaul work on the camshaft drive is
carried out in one of the service bases.

1 Castle nut
2 Bolt
3 Feather key
4 Parallel pin
5 Gearwheel
6--9 Sequence of tightening

Figure 1. Gearwheel fitted to crankshaft

6619 020.03--01 E 05.98 L 58/64 102/ 02

Oil bore of the crankshaft
Blocking 020.04

Purpose of jobs to be done

Ensure correct execution of work,

enable emergency operation.

Brief description

Should it be necessary in case of emergency, to continue engine operation

although one running gear (piston with connecting rod) has been removed,
the oil bores in the respective crankpin are to be blocked.
The work/steps include:
proper mounting
and, if necessary,
dismounting.

Tools/appliances required

Quant Denomination No. Availability

1 Blocking tool 020.038 Standard
2 Sealing plug 020.038--1 Standard
1 Threaded rod 020.038--2 Standard
2 O--ring seal 020.038--3 Standard
2 Open--jaw wrench 46 000.568 Standard

Related work cards

Work card Work card Work card

030.05 034.01 055.02
200.01

Operating sequence 1 -- Blocking the oil passages (engine emergency operation)

Starting condition Piston and connecting rod of one cylinder removed, engine must be
055.02).
maintained in operation (refer to work cards 034.01 and 055.02

Steps 1. Insert threaded rod (020.038-2) of blocking tool (020.038) into

oil passage (2) and screw on sealing plug (020.038-1) (refer to
Figure 1 ).
2. Tighten sealing plug and secure with split pin (3).
3. Install complete cylinder head, however, do not insert the valve
timing rods. Put swing lever out of operation and seal up the
lubricating passages.

6619 020.04--01 E 05.98 L 58/64 101/ 02

 4. Put injection pump of cylinder concerned out of operation (pull control
rod to zero delivery position and arrest in this position with a clamp,
200.01).
refer to work card 200.01
5. Block oil pipe for rocker arm lubrication.
6. Block starting control pipe leading to the cylinder which has been put
out of operation.
▲ Attention! With piston and connecting rod removed, the engine
should only be operated further in case of an emergency and with
output and speed reduced (note instructions contained in Operating
Manual/Section 3).
Operation with driving components removed is not possible in case
of engines with resilient mounting.

1 Crankshaft
2 Oil passage in
crank pin
3 Split pin 2x22

Figure 1. Blocking tool mounted with sealing plug

6619 020.04--01 E 05.98 L 58/64 102/ 02

Main bearing/
Thrust bearing/Flange bearing

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 021--04 E 06.98 101/ 01

Main bearing shell
Removing and installing/checking 021.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure operational reliability of bearings.

Brief description

Bearing shells must be checked at regular intervals. From the state of

wear and appearance of the bearing shell running surface, conclusions
can be drawn about the load conditions, lube oil care etc.
The work/steps include:
Checking bearing shells,
removing components,
attaching components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 3
1 Assistant 3

Tools/appliances required

Qty Designation No. Availability

1 Pilot rod 034.006 Standard
2 Guide tube 021.302 Standard
1 Cross tie 021.301 Standard
2 Guide tube 021.300 Standard
1 Cross tie 021.299 Standard
1 Lifting/lowering device 021.297 Standard
6 Tommy bar, 12 mm 021.297--17 Standard
1 Support 021.286 Standard
2 Support 021.280 Standard
1 Hydraulic hand pump with hose pipe 009.138 Standard
1 Telescopic cylinder 009.137 Standard

6641 021.01--01 E 04.05 L 58/64 101/ 11

 Qty Designation No. Availability
1 Turning stone 021.146 Standard
1 Centring template 021.145 Standard
1 Turning stone 021.137 Standard
1 O--ring seal 021.137--4 Standard
1 Guide tube 021.032 Standard
1 Foot board (for oil sump) 011.008 Standard
1 Thickness gauges 0.05--1 000.454 Standard
1 Eye bolt M6 000.023 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.10 000.11 000.30
012.02 012.03

Operating sequence 1 -- Removing and checking the lower bearing shell of the main bearings
and of the inner crankshaft locating bearing

▲ Attention! It is recommended to carry out the work mentioned

below with the engine at operating temperature.

Starting condition Crankcase is open, running gear has been turned to a position permitting
easy access to the main bearing cap.

Preliminary remark Prior to taking the hydraulic hand pump (009.138) and the telescopic cylin-
der (009.137) into operation, the operating instructions of the manufacturer
have to be read carefully.

Steps 1. Position the foot board (011.008) in the oil sump.

2. Remove the temperature sensor (if fitted).
3. Untighten the main bearing bolts (7) and the cross tierods (12) of the
012.02).
respective main bearing (see work card 012.02
4. Dismantle both cross tierods.
5. Untighten the cross tierods of the neighbouring main bearings and
loosen the nuts.
6. Put the cross tie (021.299) into the oil sump, position the guide tubes
(021.300) in the bores of the cross tie and push it underneath the
main bearing cap (2) and/or the main bearing bolts.
7. Screw the guide tubes into the main bearing bolts, hand-tight, lift the
cross tie and fix it by inserting one tommy bar (021.297-17) each into
the lower bore of the guide tubes. Refer to Figure 1 .
8. Place two supports (021.280) onto the cross tie and fasten them in
the crankcase by turning the hexagon nuts (3). The cross tie is
thereby forced against the tommy bars.
9. Place the drawn-in telescopic cylinder (009.137) on the cross tie and
attach it.

6641 021.01--01 E 04.05 L 58/64 102/ 11

 1 Lower bearing shell 6 Nut 12 Cross tierod
2 Main bearing cap 7 Bearing bolt 13 Hydraulic hose
3 Hexagon nut M24x2 8 Hexagon bolt M10x30 14 Cylinder crankcase
4 Hexagon bolt M12x45 9 Hexagon nut M10 16 Dipstick
5 Hexagon bolt M20x45 10 Stud 17 Pressure gauge
11 Hexagon nut 18 Lever
19 Lever

Figure 1. Main bearing with attached lifting/lowering device

6641 021.01--01 E 04.05 L 58/64 103/ 11

 13 Hydraulic hose 18 Lever A Connection for hydraulic
16 Dipstick 19 Lever hose
17 Pressure gauge B Connection for hydraulic
hose

Figure 2. Hydraulic hand pump and telescopic cylinder

(Illustration X: Lever (19) in centre position - Off-position)
(Illustration Y: Lever (19) in lower position - Lower the telescopic cylinder)
(Illustration Z: Lever (19) in upper position - Raise the telescopic cylinder)

6641 021.01--01 E 04.05 L 58/64 104/ 11

 ▲ Attention! Tighten the hexagon bolts (4) only to such an extent,
hand-tight, that the telescopic cylinder remains moveable enabling it
to align independently for further work.
10. Mount the support (021.286) to the side wall of the cylinder crank-
case.
11. Insert the hydraulic hand pump (009.138) into the guide on the sup-
port and secure it.
12. Connect the hydraulic hoses (13) to the telescopic cylinder.
▲ Attention! Make sure that the hydraulic hoses are properly con-
nected to the telescopic cylinder! Refer to Figure 2 .
13. Check the oil level in the hydraulic hand pump by means of the dip-
stick (16).
▲ Attention! The hydraulic hand pump has to be filled with a suffi-
cient amount of clean anti-corrosion oil at all times. Otherwise,
there is the risk that air enters the hydraulic system making it
necessary to evacuate the air from the complete hydraulic system of
the lifting/lowering device.
14. Shift the lever (19) upwards (position “Raising”).
15. Slip the pilot rod (034.006) onto lever (18). Actuate the hydraulic
hand pump by moving the lever upwards/downwards, raising the tele-
scopic cylinder in this way.
16. Raise the telescopic cylinder until it contacts the main bearing cap.
Bring the lever (19) into the centre position. Fasten the telescopic
cylinder to the main bearing cap.
17. Screw off the nuts (6) and put them down onto the cross tie.
18. Insert two further tommy bars into the bores of the guide tubes.
Refer to Figure 1 .
▲ Attention! Prior to lowering the main bearing cap (inner locating
bearing) located between the camshaft drive and cylinder 1, secure
the locating bearing ring. Otherwise there is the risk that, while turn-
ing the crankshaft, the locating bearing ring, too, is turned and falls
down.
19. Shift the lever (19) downwards (position “Lowering”).
20. Actuate the hydraulic hand pump by moving the lever upwards/down-
wards, lowering the telescopic cylinder in this way. Watch the pres-
sure gauge (17)!
▲ Attention! While lowering the main bearing cap, the pressure
must not rise above 100 bar.
▲▲ Caution! A severe pressure increase during lowering is an in-
dication that the main bearing cap has become tilted. Stop the
lowering process.
Do not continue the process of lowering the main bearing cap before
the tilting has been eliminated!
21. Lower the main bearing cap, down to the tommy bars.
22. Remove the bearing shell (1).
23. Carefully clean the running surface of the bearing shell, taking care
not to damage it.
000.11).
24. Check the condition of the running surface (see work card 000.11
▲▲ Caution! Do not remachine the bearing shell in any way!
▲ Attention! Replace bearing shells which have suffered damage or
pronounced scoring by dirt particles.
In case dirt scores are found on the bearing shell, the shaft journal
has to be checked and, if necessary, repolished (polishing cloth with
grain <15m).

6641 021.01--01 E 04.05 L 58/64 105/ 11

Operating sequence 2 -- Removing and checking the lower bearing shell on the outer crankshaft locating
bearing

▲ Attention! It is recommended to carry out the work mentioned

below with the engine at operating temperature.

Starting condition Casing cover of the camshaft drive as well as of the crankcase of the
neighbouring cylinders have been removed.

Preliminary remark Prior to taking the hydraulic hand pump (009.138) and the telescopic cylin-
der (009.137) into operation, the operating instructions of the manufacturer
have to be read carefully.

Steps 1. Put the foot board (011.008) into the oil sump.
2. Remove the temperature sensor (if fitted).
3. Untighten the main bearing bolts (21) and the cross tierods of the re-
012.03).
spective main bearing (see work card 012.03
4. Dismantle both cross tierods.
5. Untighten the cross tierods of the neighbouring main bearing and
012.02).
loosen the nuts (see work card 012.02
6. Put the cross tie (021.301) into the oil sump, position the guide tubes
(021.302) in the bores of the cross tie and push it underneath the
main bearing cap (20) and/or the main bearing bolts.
7. Screw the guide tubes into the main bearing bolts, hand-tight, lift the
cross tie and fix it by inserting two tommy bars (021.297-17) each
into the lower bores of the guide tubes. Refer to Figure 3 .
8. Place the drawn-in telescopic cylinder (009.137) on the cross tie and
attach it.
▲ Attention! Tighten the hexagon bolts (4) only to such an extent,
hand-tight, that the telescopic cylinder remains movable enabling it
to align independently for further work.
9. Mount the support (021.286) to the side wall of the cylinder crank-
case.
10. Insert the hydraulic hand pump (009.138) into the guide on the sup-
port and secure it.
11. Connect the hydraulic hoses (13) to the telescopic cylinder.
▲ Attention! Make sure that the hydraulic hoses are properly con-
nected to the telescopic cylinder. Refer to Figure 2 .
12. Check the oil level in the hydraulic hand pump by means of the dip-
stick (16).
▲ Attention! The hydraulic hand pump has to be filled with a suffi-
cient amount of clean anti-corrosion oil at all times. Otherwise,
there is the risk that air enters the hydraulic system making it
necessary to evacuate the air from the complete hydraulic system of
the lifting/lowering device.
13. Shift the lever (19) upwards (position “Raising”).
14. Slip the pilot rod (034.006) onto lever (18). Actuate the hydraulic
hand pump by moving the lever upwards/downwards, raising the tele-
scopic cylinder in this way.
15. Raise the telescopic cylinder until it contacts the main bearing cap.
Bring the lever (19) into centre position. Fasten the telescopic cylin-
der to the main bearing cap.
16. Screw off the nuts (22) and put them down onto the cross tie.
17. Insert two further tommy bars into the upper bores of the guide tubes.
Refer to Figure 3 .
021.02).
18. Secure the locating bearing ring (see work card 021.02

6641 021.01--01 E 04.05 L 58/64 106/ 11

 1 Lower bearing shell 9 Hexagon nut M10 19 Lever
4 Hexagon bolt M12x45 10 Stud 20 Main bearing cap
5 Hexagon bolt M20x45 11 Hexagon nut (external bearing)
8 Hexagon bolt M10x30 13 Hydraulic hose 21 Bearing bolt
16 Dipstick 22 Nut
17 Pressure gauge 23 Crankshaft
18 Lever 28 Crankshaft gearwheel

Figure 3. Main bearing (external bearing) with attached lifting/lowering device

▲ Attention! In case the locating bearing ring is not secured prior to

lowering the main bearing cap, there is the risk that, while turning

6641 021.01--01 E 04.05 L 58/64 107/ 11

 the crankshaft, the locating bearing ring, too, is turned and falls
down.
19. Shift the lever (19) downwards (position “Lowering”).
20. Actuate the hydraulic hand pump by moving the lever upwards/down-
wards, lowering the telescopic cylinder in this way. Watch the pres-
sure gauge (17)!
▲ Attention! While lowering the main bearing cap, the pressure
must not rise above 100 bar.
▲▲ Caution! A severe pressure increase during lowering is an in-
dication that the main bearing cap has become tilted.
Stop the lowering process.
Do not continue the process of lowering the main bearing cap before
the tilting has been eliminated!
21. Lower the main bearing cap, down to the tommy bars.
22. Remove the bearing shell (1).
23. Carefully clean the running surface of the bearing shell, taking care
not to damage it.
000.11).
24. Check the condition of the running surface (see work card 000.11
▲▲ Caution! Do not remachine the bearing shell in any way!

▲ Attention! Replace bearing shells which have suffered damage or

severe scoring by dirt particles.
In case dirt scores are found on the bearing shell, the shaft journal
has to be checked and, if necessary, repolished (polishing cloth with
grain <15m).

Operating sequence 3 -- Removing and checking the upper bearing shell

14 Cylinder crankcase
24 Upper bearing shell

Figure 4. Removal of the upper bearing shell

Starting condition Main bearing cap lowered (2 and/or 20), respective locating bearing ring
fixed (only crankshaft locating bearing).

Steps 1. Insert the turning stone (021.137) into the lube oil bore of the crank-
shaft (refer to Figure 4 ).
▲ Attention! The turning stone must fully contact the crankshaft!
2. Cautiously turn out the bearing shell (24), be careful not to damage it.

6641 021.01--01 E 04.05 L 58/64 108/ 11

 3. Using the eye bolt (000.023), pull the turning stone out of the crank-
shaft bore.
4. Carefully clean the running surface of the bearing shell, taking care
not to damage it.
5. Check the condition of the running surface (see work card 000.11).
000.11
▲▲ Caution! Do not remachine the bearing shell in any way!

▲ Attention! Replace bearing shells which have suffered damage or

pronounced scoring by dirt particles.
In case dirt scores are found on the bearing shell, the shaft journal
has to be checked and, if necessary, repolished (polishing cloth with
grain <15m).

Operating sequence 4 -- Installing the upper bearing shell

Starting condition The bearing shell has been cleaned.

Important! The new bearing shells supplied are ready to be fitted,

scraping or any other touching up is not permitted. The running points are
numbered (refer to the Operating Instructions, Section 5). If new shells
are fitted, the marking has to be transferred to these.

Steps 1. Position the centring template (021.145) at the cylinder crankcase

(14). For this purpose, insert the centring bolt (27) of the centring
template into bore (B) provided for bearing shell fixation (centring
template is held by magnetic force). Refer to Figures 5 and 6 re-
spectively.
2. Thoroughly oil the running surface of the bearing shell (24) (back of
the bearing shell to remain dry).
3. Position the bearing shell at the centring template and push it in by
hand as far as possible.
▲ Attention! Already prior to pushing the bearing shell in, pay
attention to the position of the groove provided for bearing shell fix-
ation.
4. Turn the crankshaft until the turning stone (021.146) can be inserted
into the oil bore of the crankshaft through one of the bores of the
bearing shell.
▲ Attention! To avoid deformation of the thin bearing shell in the
process of turning it in, place the turning stone as closely as poss-
ible to the parting line of the main bearing.
5. Turn the bearing shell in in several stages (corresponding to the pitch
of bore holes). For this purpose, pull the turning stone out after the
first turning step, turn the crankshaft back by one pitch of bore holes
and reinsert the turning stone. Repeat this process up to the last
bore.
6. Pull out the turning stone, turn the crankshaft back until the oil bore
comes free.
7. Insert the turning stone (021.137) directly into the oil bore of the
crankshaft and turn the bearing shell in completely.
▲ Attention! Make sure that the joint faces of bearing shells are in
uniform end position.
8. Take the centring template off and pull the turning stone out by
means of the eye bolt (000.023).

Operating sequence 5 -- Installing the lower bearing shell

Starting condition Bearing shell and cross tierods has/have been cleaned.

6641 021.01--01 E 04.05 L 58/64 109/ 11

 Important! The new bearing shells supplied are ready to be fitted,
scraping or any other touching up is not permitted. The running points are
numbered (refer to the Operating Instructions, Section 5). If new shells
are fitted, the marking has to be transferred to these.

Preliminary remark Prior to taking the hydraulic hand pump (009.138) and the telescopic cylin-
der (009.137) into operation, the operating instructions of the manufacturer
have to be read carefully.

Steps 1. Thoroughly oil the running surface of the bearing shell (1) (back of
the bearing shell to remain dry).
2. Place the bearing shell in the main bearing cap (2 and/or 20).
▲ Attention! During installation of the bearing shell, take note of the
position of the groove for bearing shell fixation. Refer to Figure 6 .
3. Shift the lever (19) on the hydraulic hand pump (009.138) upwards
(position “Raising”).
4. Slip the pilot rod (034.006) onto the lever (18). Actuate the hydraulic
hand pump by moving the lever upwards/downwards, raising the tele-
scopic cylinder (009.137) in this way. Watch the pressure gauge
(17)!
▲ Attention! While lifting the main bearing cap, the pressure must
not rise above 100 bar.

▲▲ Caution! Severe pressure rise during the lifting process is an

indication that the main bearing cap has become tilted.
Stop the lifting process.
Do not continue the process of lifting the main bearing cap before
the tilting has been eliminated!
5. Lift the main bearing cap until it contacts the cylinder crankcase (14).
Bring the lever (19) into centre position.
▲ Attention! When mounting the bearing caps on crankshaft locat-
ing bearings, make sure that the positioning pins in the crankcase
engage in the grooves of the bearing caps.
6. Remove the upper tommy bars (021.297-17) and screw the nuts (6
and/or 22) onto the main bearing bolts (7 and/or 21) until they contact
the main bearing cap, screwing them down hand-tight
▲ Attention! Take note of the specified projection of the main bear-
012.02).
ing bolt (see work card 012.02
7. Remove the hexagon bolts (5).
8. Shift the lever (19) downwards (position “Lowering”).
9. Actuate the hydraulic hand pump by moving the lever (18) upwards/
downwards, lowering the telescopic cylinder in this way.
Important! Actuate the lever until the telescopic cylinder has been
drawn in completely.
10. Disconnect the hydraulic hoses (13) from the telescopic cylinder and
remove the complete lifting/lowering device (021.297).
▲ Attention! Remove the fastening for locating bearing rings (crank-
shaft locating bearing only).
11. Apply MoS2 lubricant to the screw-in threads of the cross tierods and
screw them into the main bearing cap, hand-tight, down to contact.
12. Tighten the main bearing bolts and cross tierods (see work cards
012.02 and/or 012.03).
012.03
13. Screw down the nuts of the cross tierods of the neighbouring main
bearings, hand-tight. Tighten the cross tierods of the neighbouring
main bearings.
14. Check the main bearing clearance by means of guide tube (021.032)
and thickness gauge (000.454), inserting the thickness gauge approx.
25 mm deep from the coupling end and free engine end.

6641 021.01--01 E 04.05 L 58/64 110 / 11

 15. Measure the crank web deflection (see work card 000.10
000.10) and enter
the values in the engine operating record.
16. Fit the temperature sensor (if applicable).
17. Remove the foot board (011.008) from the oil sump.
▲ Attention! For running-in new bearing shells, please refer to the
running-in instructions in Section 3 of the Operating Instructions.

14 Cylinder crankcase 24 Upper bearing shell 27 Centering bolt

Figure 5. Installation of the upper bearing shell

1 Lower bearing shell

2 Bearing cap
14 Cylinder crankcase
24 Upper bearing shell
25 Locating piece
26 Hexagon socket bolt

B Bore for bearing shell

fixation

Figure 6. Bearing shell fixation on the main bearing (assembly)

6641 021.01--01 E 04.05 L 58/64 111 / 11

Main thrust bearing
Measuring end play/
checking locating bearing rings 021.02

Purpose of jobs to be done

Carry out work in time according to maintenance plan,

measure components,
assess wear pattern/condition.

Brief description

The end play as well as the locating bearing rings are to be checked at
regular intervals.

Tools/appliances required

Quant Denomination No. Availability

1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.330 Standard
2 Hydraulic cylinder 009.075 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Ratchet 001.521 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Magnetic post -- Inventory
1 Dial gauge -- Inventory
1 Hammer (wood/plastic) -- Inventory

Related work cards

Work card Work card Work card

000.11 000.33 009.03

Operating sequence 1 -- Measuring the end play of the crankshaft

Starting condition Crankcase window opened in the area of the camshaft drive.

Steps 1. Put two hydraulic cylinders (009.075) in position between crankcase

wall and balance weight in such a way that the crankshaft can axially
be shifted in one direction.

6619 021.02--02 E 03.98 L 58/64 101/ 03

 1 Crankcase
2 Locating bearing ring
3 Crankshaft gearwheel
4 Main bearing cap
5 Crankshaft
6 Main bearing cap
(outside bearing)

Figure 1. Crankshaft support

▲ Attention! Hydraulic cylinders must be put in position on various

cylinders.
2. Connect high-pressure hoses (009.330) to hydraulic cylinder and
high-pressure pump (009.338).
3. Switch on the high-pressure pump and shift the crankshaft (5) by
applying an adequate amount of pressure until contact is established.
▲▲ Caution! The pressure applied must not exceed a maximum of
500 bar. Reduce the pressure once the final position has been
reached.
4. Put the dial gauge in position on the coupling flange or at an other
accessible place and set it to “Zero”.
5. Release the pressure.
6. Reposition the hydraulic cylinder.
7. Switch on the high-pressure pump and shift the crankshaft in
opposite direction by applying an adequate amount of pressure until
contact is established.
▲▲ Caution! The pressure applied must not exceed a maximum of
500 bar. Reduce the pressure once the final position has been
reached.
8. Read the displacement path on the dial gauge.
9. Note down the end play and compare with the permissible value
(refer to the operating manual/technical data). Enter the end play in
the engine operating records.
Important! In case the permissible clearance is exceeded, the
locating bearing rings are to be removed and checked (refer to operating
sequence 2).
10. Release pressure, remove the hydraulic cylinders, take off the
magnetic post and the dial gauge.

6619 021.02--02 E 03.98 L 58/64 102/ 03

Operating sequence 2 -- Removal and installation of the locating bearing rings

Preliminary remarks Judging the locating bearing rings (2) is only possible after removal, by
assessing the wear pattern.

Steps 1. Remove the locating strip (8) of each locating bearing ring (2) -- refer
to Figure 2 .
2. Fix the crankshaft axially by means of two wooden wedges in such a
way that the locating bearing rings are accessible.
3. Turn out both locating bearing rings in direction of rotation, do not
turn the crankshaft while doing so.
000.11).
4. Check condition of the running faces (see work card 000.11
5. Prior to installing the locating bearing rings, clean them carefully and
oil them slightly.
6. Turn locating bearing rings in and place them onto the crankshaft.
7. Mount locating strips, paying attention to control dimension A = 0.05
to 1.17 mm, on both sides.
8. Measure the end play (refer to operating sequence 1) and enter the
value in the engine operating records.

1 Crankcase
2 Locating bearing ring
6 Main bearing cap
7 Hexagon head bolt
8 Locating strip

Figure 2. Mounting the locating bearing ring

6619 021.02--02 E 03.98 L 58/64 103/ 03

Torsional vibration damper

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 027--04 E 06.98 101/ 01

Torsional vibration damper
of the valve camshaft
Checking 027.02

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

The sleeve spring assembilies of the torsional vibration damper and the
locating bearings of the valve camshaft must be checked for
condition/wear in regular intervals.
The work includes:
checking components.

Safety requirements

- Engine secured against starting

- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Driving mandrel 027.025 Standard
1 Removing tool 027.024 Standard
1 Clamp 027.013 Standard
1 Lifting eye bolt M12 000.142 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hammer (wood/plastic) -- Inventory
1 Securing compound -- Inventory
(Loctite 243)
1 Lifting tackle with rope -- Inventory

Related work cards

Work card Work card Work card

000.11 000.19

Technical details

Term Information
Weight of side disc 89 kg

6641 027.02--04 E 10.00 L 58/64 101/ 03

Operating sequence -- Checking the sleeve spring assemblies

Preliminary remark The torsional vibration damper of the camshaft can be designed for
arrangement of the sleeve spring assemblies (4) in either one row or in
two rows.

Starting condition Damper covering (1) and camshaft covering removed on free end of
engine.

Steps 1. Using lifting eye bolt (000.142), attach one-piece side disc (2) to
lifting tackle and remove it.
Important! Number the sleeve spring assemblies and the
corresponding bores, as the sleeve spring assemblies are to be inserted
into their original bores when they are re-installed.
2. Pull the sleeve spring assemblies (4) out by means of the removing
tool (027.024).
Important! In case all sleeve spring assemblies are removed,
attention is to be paid to the marking between damper support (11) and
damper mass (3) during assembly.
3. Clean the sleeve springs in liquid cleaner, and check them.
▲ Attention! In case of broken springs, the complete sleeve spring
assembly has to be replaced.
4. Thoroughly clean the oil bores in the damper support and the inlet
holes in the camshaft (12) as well as in the bearing plate (6).
5. Oil the springs of the sleeve-spring assembly individually using lube
oil, compress the sleeve-spring assembly by means of the clamp
(027.013), and insert it into the bore. Loosen the clamp and press in
the sleeve-spring assembly in all the way using the driving mandrel
(027.025).
Important! Re-install the spring assemblies into the bore from which
they have been removed. Depending on the design, certain bores have to
remain empty. Make sure that there is the correct number of sleeve spring
assemblies per bore.
6. Fit the side disc, screw in the hexagon bolts using LOCTITE 243.
7. Check axial clearance (A) (for clearances refer to Operating Manual,
Volume B1 / Section Technical Data).
Important! Evaluation of the condition of the locating bearing is only
possible by checking the appearance of the contact faces of the butting
rings (8) and the bearing bush (10) (refer to work card 000.11).
000.11 For this
purpose, the two butting rings and the bearing bush are to be removed
after dismantling the torsional vibration damper, and to be checked. This is
only required if abnormal wear is detected in the course of the inspections
of the remaining camshaft bearings specified in the maintenance
schedule.

▲ Attention! Disassembly of the torsional vibration damper must be

carried out at a Service Centre, using the special tools available
there.

6641 027.02--04 E 10.00 L 58/64 102/ 03

 1 Damper covering
2 Outer side disc
3 Damper mass
4 Sleeve spring
assembly
5 Stop piece
6 Bearing plate
7 Taper sleeve
8 Butting ring
9 Shrink ring
10 Bearing bush
11 Damper support
12 Camshaft
13 Hexagon bolt
14 Hexagon bolt

A Axial clearance
B Lube oil inlet

Figure 1. Torsional vibration damper on the valve camshaft - model with two sleeve spring assemblies beside one another

6641 027.02--04 E 10.00 L 58/64 103/ 03

Torsional vibration damper
of the crankshaft
Removing and refitting 027.03

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

The torsional vibration damper on the crankshaft is to be replaced in

accordance with the intervals specified in the maintenance schedule.
The work/steps include:
dismounting components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 027.023 Optional
1 Pipe 027.023--1 Optional
1 Suspension plate 027.023--3 Optional
1 Slide piece 027.023--8 Optional
1 Bolt 027.023--13 Optional
1 Bracket 027.023--15 Optional
1 Adapter plate 027.023--19 Optional
1 Pipe 027.023--22 Optional
1 Pipe 027.023--23 Optional
1 Slide piece 027.023--24 Optional
6 Sleeve 027.023--36 Optional
2 Attachment swivel 027.035 Optional
1 Hydraulic cylinder 009.165 Optional
1 Ratchet hoist 002.552 Optional
1 Shackle A0.6 002.452 Standard
2 Shackle A1.6 002.454 Standard
1 Lifting eye bolt M10 000.141 Standard
1 Torque wrench 140--760 Nm 008.004 Standard
1 Ratchet 001.521 Standard

6641 027.03--02 E 10.03 L 58/64 101/ 07

 Qty Designation No. Availability
1 Extension piece 12.5x250 001.912 Standard
1 Socket wrench insert 36x20 001.771 Standard
1 Adapter 20x12.5 001.923 Standard
1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.330 Standard
2 Hydraulic tensioning tool 009.191 Standard
2 Thrust pad 020.051 Standard
1 Tommy bar, 12 mm 000.264 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Socket wrench insert (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lifting tackle with rope -- Inventory

Related work cards

Work card Work card Work card

000.30 009.03 009.17

Technical details

Term Information
Torsional vibration damper max. 3870 kg

Preliminary remarks

Every torsional vibration damper is a special component matched to suit

the respective plant. Improper installation may result in severe damage to
the plant and/or to the torsional vibration damper.

Operating sequence 1 -- Removal of the torsional vibration damper

Starting condition The crankcase cover and the covering on the free engine end have been
removed.

Steps 1. Screw the lifting eye bolt (000.141) into the cover (8). Attach the
rope to the lifting eye bolt by means of the shackle (002.452), and
suspend the rope in the lifting tackle.
2. Unscrew the hexagon socket bolts (7), and remove the cover. Put
the cover down onto an appropriate support (refer to Figure 1 ).
3. Turn the crankshaft (1) to a position in which the marking “Kur-
bel 1/Crank 1” on the torsional vibration damper (3) is up.
Untightening the bolts 4. Clean the threads of the bolts (4).
5. Mount the tensioning tools (009.191) together with the thrust pad
(020.051) onto two studs located opposite each other, paying atten-
tion to the centring (see work card 009.17).
009.17
6. Turn the tensioning tools back by the specified back-off angle (see
work card 000.30).

6641 027.03--02 E 10.03 L 58/64 102/ 07

 1 Crankshaft 6 Nut 8 Cover
3 Torsional vibration damper 7 Hexagon socket bolt 9 Hexagon socket bolt
4 Stud

Figure 1. Torsional vibration damper

1 Crankshaft
3 Torsional vibration damper
4 Stud
6 Nut

Figure 2. Mounting the hydraulic tensioning tools on the studs

6641 027.03--02 E 10.03 L 58/64 103/ 07

 7. Connect the tensioning tools to the high-pressure pump (009.338) by
means of the high-pressure hoses (009.330) - refer to Figure 2 .
8. Switch the high-pressure pump on (see work card 009.03009.03), and close
the gaps produced by turning back.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the studs to be untightened!
9. Increase the pressure until the nuts (6) can be loosened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the specified tensioning pressure (see work card
000.30)!
000.30
10. Note down the pressure required for loosening the two nuts and com-
pare it with the specified tensioning pressure.
11. Insert the tommy bar (000.264) through the opening in the thrust pad,
and slacken both nuts (6) - for back-off angle, refer to work card
000.30.
000.30
12. Release the pressure, remove the tensioning tools, and unscrew the
nuts (6) from the studs (4).
13. Reposition the tensioning tools onto a pair of bolts staggered by 90ƒ ,
and repeat the process (steps 4 to 12) until all the studs have been
untightened.

1 Crankshaft 10 Prop 14 Hexagon bolt M24x70

3 Torsional vibration damper 11 Countersunk bolt M12x40 15 Rope
4 Stud 12 Hexagon bolt M16x75
9 Hexagon socket bolt

Figure 3. Mounted fitting/unfitting tool (removal)

Removal of the torsional vibra- 14. Mount the suspension plate (027.023-3) and the adapter plate
tion damper (027.023-19) to the crankshaft using hexagon bolts (14) - refer to Fig-
ure 3 .
15. Slip the pipe (027.023-1) over the pin of the suspension plate, and
secure it in place by means of the hexagon bolt (027.023-13).

6641 027.03--02 E 10.03 L 58/64 104/ 07

 16. Place the bracket (027.023-15) under the pipe and fasten it to the
pipe using hexagon bolts (16) resp. nuts (17) - refer to Figure 5 .
17. Place a suitable prop (10) under the bracket.
18. Slip the slide piece (027.023-8) into the gap between the pipe
(027.023-1) and the torsional vibration damper (3), and fasten it to
the damper by means of hexagon bolts (12).
19. Screw the hexagon bolt (027.023-13) into the pin of the suspension
plate until the pipe (027.023-1) contacts the slide piece (027.023-8).
20. Unscrew the hexagon socket bolts (9).
21. Fasten the ratchet hoist (002.552) to the slide piece (027.023-8) and
the bracket (027.023-15).
22. Slightly oil the pipe, and pull the torsional vibration damper out (refer
to Figure 3 ). In this connection, pay attention to the centrings
taking care that they are not damaged.
23. Screw the attachment swivel (027.035) into the torsional vibration
damper and tighten it to the specified torque (350 Nm). Fasten the
ropes to the attachment swivel, possibly using the shackle (002.454),
and suspend the ropes from the lifting tackle (refer to Figure 3 ).
24. Slightly lift the torsional vibration damper up. Remove the prop (10),
the adapter plate (027.023-19), the suspension plate (027.023-3) with
the bracket (027.023-15) and the pipe (027.023-1).
25. Using the lifting tackle, move the torsional vibration damper out and
put it down onto an appropriate support. Remove the slide piece
(027.023-8).

Operating sequence 2 -- Fitting the torsional vibration damper

1 Crankshaft 9 Hexagon socket bolt 14 Hexagon bolt M24x70

3 Torsional vibration damper 10 Prop 20 Connecting pin
4 Stud 11 Hexagon bolt M12x40

Figure 4. Fitting/unfitting tool attached (removal)

6641 027.03--02 E 10.03 L 58/64 105/ 07

 For fitting the torsional vibration damper, proceed in the reverse order fol-
lowed for removal, paying attention to the following:
Fitting the torsional vibration 1. Prior to fitting the new torsional vibration damper, remove all of the
damper anti-corrosion agent from it.
2. Place the torsional vibration damper in front of the crankshaft flange
by means of the lifting tackle, and attach the slide piece (027.023-8).
3. Refit prop (10), adapter plate (027.023-19), suspension plate
(027.023-3) with bracket (027.023-15) and pipe (027.023-1).
4. Place the slide piece (027.023-24) on the pipe (027.023-1). Mount
the hydraulic cylinder (009.165) between slide piece (027.023-24)
and slide piece (027.023-8) - refer to Figure 4 .
5. Slip the pipes (027.023-23 and 027.023-22) through the bracket
(027.023-15) and onto the slide piece (027.023-24), and fix it in place
by means of the connecting pin (20).
6. Connect the hydraulic cylinder to the high-pressure pump (009.338)
by means of the high-pressure hose (009.330).
7. Using the hydraulic cylinder, gradually slide the torsional vibration
damper (3) towards the crankshaft.
8. When fitting the torsional vibration damper, pay attention to the cen-
tring and the marking crankshaft - torsional vibration damper, taking
care not to damage it.

1 Crankshaft 14 Hexagon bolt M24x70 18 Hexagon nut M30

3 Torsional vibration damper 16 Hexagon bolt M16x40 19 Threaded rod M30
9 Hexagon socket bolt 17 Hexagon nut M16 21 4x Reamed bore
12 Hexagon bolt M16x75 22 8x Through hole

Figure 5. Bolted connection for fixing crankshaft - torsional vibration damper in place
Tightening the studs 9. Using the sleeves (027.023-36), threaded rods (19) and nuts (18) fix
the torsional vibration damper (3) in place on three spots of the
crankshaft (1) respectively - refer to Figure 5 .
10. Screw the hexagon socket bolts (9) in.

6641 027.03--02 E 10.03 L 58/64 106/ 07

 11. Coat the thread and contact face of the studs (4) and nuts (6) with
MoS2 lubricant.
12. Insert the studs (4) into the reamed bores (21) and the through holes
(22) respectively, and screw the nut (6) on, hand-tight.
13. Mount the tensioning tools (009.191) with the thrust pad (020.051)
onto two studs located opposite each other, paying attention to the
009.17).
centring (see Work Card 009.17
14. Connect the tensioning tools to the high-pressure pump (009.338) by
means of the high-pressure hoses (009.330) - refer to Figure 2 .
▲ Attention! Correct tightening of a bolted connection requires the
pressure gauge to work properly! In case of doubt, check the pres-
sure gauge against a reference pressure gauge!
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the stud to be tightened!
15. Switch the high-pressure pump on, adjust it to the specified pressure
000.30), and tighten both nuts until they are seated
(see Work Card 000.30
009.03).
(see Work Card 009.03
16. Release the pressure, and remove the tensioning tools.
17. Reposition the tensioning tools onto a pair of bolts staggered by 90ƒ ,
remove the bolted connections (consisting of sleeves, threaded rods
and nuts) for fixing the torsional vibration damper in place, and repeat
the process (steps 12 to 16), until all the studs have been tightened.
18. Remove the complete fitting/unfitting tool.
19. Attach the cover (8) by means of hexagon socket bolts (7).
20. Prior to taking the engine into operation, the torsional vibration
damper is to be supplied with hydraulic oil by means of the prelubri-
cating pump, until oil emerges from the oil circulation bores of the
side discs.

Operating sequence 3 -- Transport of the torsional vibration damper

3 Torsional vibration damper

15 Rope

sa max. 60ƒ
Figure 6. Lifting and transport of the torsional vibration damper
Transport of the torsional vibration damper is only permissible in horizontal
position. In this connection, only the auxiliary means provided for this pur-
pose, i.e. the lifting eye bolts, are to be used. Both for removal and trans-
port, the torsional vibration damper is at least to be attached at two points
(refer to Figure 6 ).

6641 027.03--02 E 10.03 L 58/64 107/ 07

Connecting rod/Big end bearing

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 030--04 E 06.98 101/ 01

Conrod shank bolts
Checking, untightening and tightening 030.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure operational reliability of bolted connections.

Brief description

Conrod shank bolts are to be checked at regular intervals by means of

hydraulic tensioning tools.
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Safety requirements

- Driving shaft secured against turning

- Engine secured against starting

Tools/appliances required

Quant Denomination No. Availability

3 Sleeve 030.167 Standard
1 Measuring device 030.212 Standard
1 Gauge mandrel 030.212--1 Standard
3 Nut 012.010 Standard
3 Hydraulic tensioning tool 009.346 Standard
1 High--pressure pump 009.338 Standard
3 High--pressure hose 009.330 Standard
1 Tommy bar 6 000.261 Standard

Related work cards

Work card Work card Work card

000.30 009.03 009.07

6619 030.01--02 E 04.98 L 58/64 101/ 04

 1-6 Identification for bolt
tightening
7 Nut
8 Conrod shank bolt

L Length of bolt
355 -0.05 mm
(new condition)

Figure 1. Hydraulic tensioning tool mounted onto the conrod shank bolts

6619 030.01--02 E 04.98 L 58/64 102/ 04

Operating sequence 1 -- Checking conrod shank bolts

Starting condition Crankcase opened, crankgear in BDC position.

Steps 1. Mount three complete hydraulic tensioning tools (009.346) with

sleeves (030.167) and nuts (012.010) onto conrod shank bolts (8)
(refer to Figure 1 ). Mount first on rods identified 1-3-5 (refer to work
009.07) and pay attention to centering and gap width A.
card 009.07
2. Connect high-pressure pump (009.338), switch on and determine
loosening pressure for the three nuts (7), note it down and compare
000.30).
with tightening pressure (refer to work card 000.30
▲ Attention! In the process, the pressure must not exceed the
000.30).
tightening pressure by more than 5% (refer to work card 000.30
3. Adjust high-pressure pump to specified pressure and re-tighten
nuts (7).
4. Release pressure and remove tensioning tools.
5. Repeat process in the same manner with conrod shank bolts (8),
identified as 2-4-6.

Operating sequence 2 -- Releasing conrod shank bolts

Starting condition Crankcase opened, crankgear in BDC position.

Steps 1. Mount three complete hydraulic tensioning tools (009.346) with

sleeves (030.167) and nuts (012.010) onto conrod shank bolts (8)
(refer to Figure 1 ) identified 1-3-5 (refer to work card 009.07
009.07), pay
attention to centering and gap width A.
2. Connect high-pressure pump (009.338) and pressurise until nuts (7)
become loose.
▲ Attention! In the process, the pressure must not exceed the
000.30).
tightening pressure by more than 5% (refer to work card 000.30
3. Back off all nuts (7) (refer to work card 000.30
000.30).
4. Release pressure and remove tensioning tools.
5. Repeat procedure in the same manner with conrod shank bolts (8)
identified as 2-4-6.

Operating sequence 3 -- Tighten conrod shank bolts

Starting condition Conrod shank bolts (8) have been drawn in at the specified draw-in torque
000.30). Connecting rod head placed on connecting
(refer to work card 000.30
rod. Thrust pieces (9) laid in, nuts (7) tightened hand-tight.

Important! Tightening has to be done in two steps. Attention has to

be paid to correct sequence of tightening.

Steps 1. Clamp gauge mandel (030.212-1) in measuring device (030.212)

and set scale of gauge to ”Zero”. Remove gauge mandel.
2. Hook in measuring device between centerings of conrod shank
bolt (8) (refer to Figure 2 ), take reading and note down.
3. Measure all remaining conrod shank bolts in the same manner
and note down.
Tip! It is recommended to prepare a special measuring record for the
tightening of the conrod shank bolts.

6619 030.01--02 E 04.98 L 58/64 103/ 04

 4. Mount three complete hydraulic tensioning tools (009.346) with
sleeves (030.167) and nuts (012.010) onto conrod shank bolts (8)
identified as 1-3-5. When doing so, pay attention to the centering.
5. Connect high-pressure pump and tighten at the specified pressure
000.30). Tighten nuts (7) handtight, using tommy
(refer to work card 000.30
bar.
6. Release pressure, remove tensioning tools and place them onto the
conrod shank bolts (8) identified as 2-4-6.
7. Tighten these bolts as well, in the manner as described under item 5.
8. Release pressure and remove tensioning tools.
9. Measure length of bolts (L) once more, calculate bolt elongation oI
000.30).
and compare with specified value (refer to work card 000.30
Important! The bolts are to be tightened at the specified tightening
pressure, not according to elongation. Elongation is only indicated for
checking purposes. In case of considerable deviations, repeat tightening
procedure and/or check gauge.

As a consequence of overstretching the bolts, a permanent elongation

may occur. The maximum admissible elongation rate is 1 mm over the
measurement in new condition. If this rate is exceeded, the bolt must be
replaced.

8 Conrod shank bolt

9 Thrust piece

Figure 2. Measuring device mounted onto the conrod shank bolt

6619 030.01--02 E 04.98 L 58/64 104/ 04

Big-- end bearing bolts
Checking, untightening and tightening 030.02

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure operational reliability of bolted connections.

Brief description

Big--end bearing bolts are to be checked at regular intervals using

hydraulic tensioning tools.
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Safety requirements

- Engine secured against starting

- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

2 Tension screw 030.166 Standard
2 Sleeve 030.165 Standard
2 Tension nut 020.018 Standard
1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.330 Standard
2 Hydraulic tensioning tool 009.301 Standard
1 Sliding caliper 009.069 Standard
1 Sliding caliper 009.039 Standard
1 Tommy bar, 12 mm 000.264 Standard
1 Tommy bar, 10 mm 000.263 Standard

Related work cards

Work card Work card Work card

000.30 009.01 009.03

6619 030.02--01 E 05.98 L 58/64 101/ 04

Operating sequence 1 -- Checking big end bearing bolts

Starting condition Crankcase has been opened, crank position 45•... 60• after TDC (exhaust
side or control/timing side).

9 Nut
10 Big end bearing bolt
L Length of bolt
(new condition)
828 +0.1 mm or
850 +0.1 mm

Figure 1. Hydraulic tensioning tool mounted onto the big end bearing bolt

Steps 1. Mount two tension screws (030.166), sleeves (030.165) and hydraulic
tensioning tools (009.301) with tension nuts (020.018) diagonally
opposed onto big end bearing bolts (refer to Figure 1 ) and connect
tools with the high-pressure pump.

6619 030.02--01 E 05.98 L 58/64 102/ 04

 ▲ Attention! Do not turn crankshaft with hydraulic tensioning
tools mounted.
2. Using tommy bar, turn back the tension nuts (020.018) through
009.01).
450• (1 1/4 turn) (refer to work card 009.01
3. Switch on the high-pressure pump. Close the gap between tension
nuts and pistons and ascertain release pressure for the two nuts (9),
note it down and compare with tightening pressure (refer to work
000.30).
card 000.30
▲ Attention! In the process, the pressure must not exceed the
000.30).
tightening pressure by more than 5% (refer to work card 000.30
4. Regulate high-pressure pump to specified pressure and retighten the
two nuts (9).
5. Relieve the system and detach hydraulic tensioning tools.
6. Repeat this procedure in the same manner with the two remaining
bolts.

Operating sequence 2 -- Releasing the big end bearing bolts

Starting condition Crankcase has been opened, crank position 45•... 60• after TDC (exhaust
side or control/timing side).

Steps 1. Mount two tension screws (030.166), sleeves (030.165) and

hydraulic tensioning tools (009.301) with tension nuts (020.018)
diagonally opposed onto big end bearing bolts (refer to Figure 1 )
and connect tools with the high-pressure pump.
2. Using the tommy bar, turn back the tension nuts (020.018)
009.01).
through 450• (1 1/4 turn) (refer to work card 009.01
3. Switch on high-pressure pump. Close the gap between tension nuts
and pistons and continue pumping until the two nuts (9) are freed.
▲ Attention! In the process, the pressure must not exceed the
000.30)
tightening pressure by more than 5% (refer to work card 000.30
000.30).
4. Slacken back the two nuts (9) (refer to work card 000.30
5. Relieve system from pressure and detach hydraulic tensioning tools.
6. Repeat this procedure in the same manner with the two remaining
bolts.

Operating sequence 3 -- Tightening big end bearing bolts

Starting condition Big end bearing has been preassembled so that only a small gap is left at
the split joints of the loose bearing shells.

Important! The tightening has to be done in several steps. Pay

attention to the correct sequence of tightening.

Steps 1. Using the sliding caliper (009.039 or 009.069), ascertain lengths L of

all bolts and note these values down. These values will be used as a
basis for figuring out bolt elongation oI after tightening has been
completed (check).
2. Mount two tension screws (030.166), sleeves (030.165) and hydraulic
tensioning tools (009.301) with tension nuts (020.018) diagonally
opposed onto the big end bearing bolts (refer to Figure 1 ). When
doing so, pay attention to the centering.
3. Connect hydraulic tensioning tools with high-pressure pump and
start pumping to an initial pressure of 500 bar. Tighten nuts (9)
hand-tight.
4. Relieve system from pressure, detach hydraulic tensioning tools
and mount on remaining two bolts.

6619 030.02--01 E 05.98 L 58/64 103/ 04

 5. Raise pressure in system to final pressure (refer to work
000.30). Tighten nuts (9) hand-tight.
card 000.30
6. Release pressure, detach the hydraulic tensioning tools once
more, remount them onto the two bolts pretightened first.
7. Raise pressure in hydraulic tensioning tools to final pressure.
Tighten the nuts (9) hand-tight.
8. Relieve hydraulic tensioning tools from pressure and detach them.
9. Again measure length of bolts (L), figure out bolt elongation oI and
000.30).
compare with the prescribed value (refer to work card 000.30
Important! Tighten the bolts on the basis of the specified tightening
pressure, never apply tighten to comply with the specified elongation!
Quotation of elongation figures serves for checking purposes only. In case
of greater deviations, repeat the tightening process and/or check/calibrate
the pressure gauge.

Due to overstretching, permanent elongation of the bolts may take place.

The maximum permissible value of elongation is limited to 1 mm beyond
the length of new bolts. In case this value has been exceeded, the bolt
must be renewed.

6619 030.02--01 E 05.98 L 58/64 104/ 04

Lower big end bearing shell
Removing and installing 030.03

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure operational reliability of bearings.

Brief description

Big end bearing shells are to be checked at regular intervals. For this
purpose, the big end bearing cap must be lowered and the big end bearing
bolts removed.
The work/steps include:
Checking bearing shells,
removing components,
attaching components.

Tools/appliances required

Quant Denomination No. Availability

1 Fitting/unfitting tool 030.214 Standard
1 Wire rope 030.216 Standard
1 Rope guide 030.215 Standard
2 Rope guide 030.200 Standard
2 Support 030.188 Standard
2 Support 030.181 Standard
1 Ratchet hoist 002.552 Standard
2 Shackle A0.6 002.452 Standard
1 Feeler gauge (set) 000.451 Standard
1 Hexagon screw driver 8 000.297 Standard
1 Tommy bar 10 000.263 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Hammer (wood/plastic) -- Inventory

Related work cards

Work card Work card Work card

000.11 030.02 030.04

6619 030.03--06 E 04.98 L 58/64 101/ 05

Technical details

Term Information
Big end bearing cap 215 kg

Preliminary remarks

Important! If only the lower big end bearing shell is to be

checked or removed, the connecting big end bearing bolts may
remain in place (refer to Operating sequence 1). If, in addition, the
upper big end bearing shell or possibly even the connecting rod shank
are to be removed, it is necessary to turn the crankshaft and this means
that the big end bearing bolts have to be removed (refer to Operating
sequence 2).

Operating sequence 1 -- Removing lower big end bearing shell

Starting condition Crankcase opened. Big end bearing bolts released. Crank gear in
BDC position.

Steps 1. Using the hexagon bolts (3), screw the two supports (030.181)
onto connecting rod shank (12) and big end bearing cap (9) so that
supports remain still movable.
2. Fasten rope guides (030.200) to balance weights (1). To do so, the
bolts of the rope guides must be screwed fully home into the balance
weights.
3. Fasten rope guide (030.215) to the crankcase (4).
4. Hook ratchet hoist (002.552) into catwalk support.
5. Lay wire rope (030.216) over rope guides and fasten to supports,
using shackles (002.452). Hook wire rope to ratchet hoist and attach
wire rope clamp (14) (refer to Figure 1 ).Tighten wire rope.
6. Screw nuts (5) off big end bearing bolts (6).
7. Slightly slacken rope. Detach big end bearing cap (9) with bolt (10)
from connecting rod shank (12) by alternate hammer blows onto both
of the supports in direction A.
8. Screw two hexagon bolts (3) out from connecting rod shank and,
using the ratchet hoist, lower big end bearing cap (9) with bearing
shell (8) into oil sump (7). In the case of V-type oil sump, secure big
end bearing cap against skidding.
▲ Attention! Do not turn the engine at this stage of disassembly
(rope guides).
000.11), remove if
9. Inspect big end bearing shell (refer to work card 000.11
required.

Operating sequence 2 -- Removing big end bearing bolts and lower big end bearing shell

Important! Proceed with this Operating sequence if it is necessary

030.04) or
to remove the upper big end bearing shell (refer to work card 030.04
030.05).
to remove the connecting rod shank (refer to work card 030.05

6619 030.03--06 E 04.98 L 58/64 102/ 05

 1 Balance weight 6 Big end bearing bolt 10 Bolt
2 Nut 7 Oil sump 11 Crankshaft
3 Hexagon bolt M20x40 8 Lower big end bearing 12 Connecting rod shank
4 Crankcase shell 13 Hexagon nut M16
5 Nut 9 Big end bearing cap 14 Wire rope clamp

Figure 1. Removing the lower big end bearing cap. Normal oil sump (left), V-type oil sump (right)

Starting condition Crankcase opened, big end bearing bolts released, crankgear in
position BDC.

Steps 1. Screw on two supports (030.181) with hexagon bolts (3)

to connecting rod shank (12) and big end bearing cap (9) in
a manner ensuring that the supports still remain movable.
2. Back-off nuts (5) far enough to ensure that the supports can
be moved into center position by alternate hammer blows onto
both of the supports in direction A (refer to Figure 1 ).Tighten
hexagon bolts (3).
▲ Attention! The supports must be moved to center position
to avoid their brushing or hitting the balance weights.

6619 030.03--06 E 04.98 L 58/64 103/ 05

 2 Nut
3 Hexagon bolt M20x40
5 Nut
6 Big end bearing bolt
7 Oil sump
9 Big end bearing cap
11 Crankshaft
12 Connecting rod shank

Figure 2. Removing the big end bearing bolts

3. Rotate crankshaft (11) to position 45• before/after TDC. Screw
off nut (5) of the big end bearing bolt (6) located inside (refer to
Figure 2 ).
4. Screw off nut (2), hold on to big end bearing bolt in the process.
Remove big end bearing bolt.
5. Rotate crankshaft 90• and remove second big end bearing bolt in
the same manner (items 3 and 4).
6. Rotate crankshaft to BDC position.
7. Fasten rope guides (030.200) to balance weights (1), to accomplish
this, the bolts of the rope guides must be screwed fully home into
balance weights.
8. Fasten rope guide (030.215) to crankcase (4).
9. Hook ratchet hoist (002.452) into catwalk support.
10. Lay wire rope (030.216) over rope guides and fasten to supports,
using shackles (002.452). Hook wire rope on to ratchet hoist, attach
wire rope clamp (14) (refer to Figure 1 ).Tighten wire rope.
11. Loosen hexagon bolts (3) far enough so that supports will again be
movable. Slightly slacken wire rope. Detach big end bearing cap with
bolt (10) from connecting rod shank (12) by alternate hammer blows
onto both of the supports in direction A.
12. Screw two hexagon bolts (3) out of connecting rod shank and lower
big end bearing cap with bearing shell (8) into oil sump (7), using
ratchet hoist. In the case of V-type oil sump, secure big end bearing
cap against skidding.
13. Remove supports, rope guides and bearing shell.
14. Screw in two supports (030.188) to locate upper bearing shell (refer
030.05).
to work card 030.04 or 030.05

Operating sequence 3 -- Installing lower big end bearing shell

Starting condition Bearing shell cleaned, back dry, running surface oiled well, crankgear in
position BDC.

6619 030.03--06 E 04.98 L 58/64 104/ 05

 Important! The bearing shells are numbered consecutively
when first installed. When fitting new bearing shells, these are to be
marked in the same manner accordingly.
New bearing shells are delivered in ready-for-installation condition.
No attempt must be made on either new bearing shells or upon
shells that have already run, to reduce play by filing the joint surfaces
on the parting line or by processing them in any way mechanically. It
is true that this will reduce the clearance, but it also means that the
shells are no longer clamped sufficiently in the connecting rod and
in the bearing cap. Furthermore, under no circumstances must any
re-scraping be made on the running surface.
Installing is a reversal of the the sequence of the removal process
according to Operating sequence 1 or 2. The following points are
to be observed in the process:

Steps 1. Place lower big end bearing shell (8) so that positioning pin is
located in recess of big end bearing cap (9).
2. If supports (030.188) for upper bearing shell are fitted,
remove same.
3. When joining big end bearing cap with connecting rod shank (12),
alternately apply hammer blows to both of the supports (030.181)
in direction B until connecting rod shank and big end bearing cap
abut or, in case of dismounted connecting rod bearing bolts (6),
until the supports have been moved to center position. In the
process of joining, watch out for bolt (10).

Operating sequence 4 -- Installing big end bearing bolt

Steps 1. Rotate crankshaft (11) to position 45• before/after TDC.

2. Install big end bearing bolt located inside from below through
the big end bearing cap and screw on nut (2) loosely.
3. Draw in big end bearing bolt hand-tight until collar is seated
on connecting rod shank, in the process, counterhold nut (2) by
using tommy bar (000.263).
Important! Use tommy bar for counterhold only, nut must
not be re-tightened with tommy bar.
4. Rotate crankshaft 90• and install second big end bearing bolt
in the same manner.
5. Screw on nuts (5) until seated on big end bearing cap.
6. After pretensioning the big end bearing bolts, measure bearing
clearance, using feeler gauge (000.451), in the process, insert
feeler gauge approx. 10 mm from fly-wheel end and from free
engine end. Enter readings in engine log.

6619 030.03--06 E 04.98 L 58/64 105/ 05

Upper big end bearing shell
Removing and installing/checking 030.04

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure operational reliability of bearings.

Brief description

Big end bearing shells are to be checked at regular intervals. For this
purpose, the big end bearing cap must be lowered and the big end bearing
bolts removed.
The work/steps include:
Checking bearing shells,
removing components,
attaching components.

Tools/appliances required

Quant Denomination No. Availability

2 Support 030.188 Standard
2 Supporting device 030.177 Standard
1 Shackle A1.0 002.453 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Ratchet 001.521 Standard
1 Hexagon screw driver 8 000.297 Standard
1 Eye bolt M20 000.155 Standard
1 Lifting tackle with rope -- Inventory

Related work cards

Work card Work card Work card

000.11 030.03

Technical details

Term Information
Weight of connecting rod shank 400 kg

6619 030.04--04 E 05.98 L 58/64 101/ 03

Operating sequence 1 -- Removing upper big-end bearing shell

Starting condition Crankcase opened, big-end bearing bolts removed, big-end bearing cap
deposited in oil sump (secured against skidding in case of V-type oil
sump), position of crank gear 60ƒ before/after TDC (crank pin on exhaust
side), holers (030.188) are fitted.

Steps 1. Screw one supporting device (030.177) for the piston (15) to the
fly-wheel side and to engine free end side of cylinder liner (16).
2. Carefully lower the piston until seated.
▲ Attention! When turning, ensure that the connecting rod shank
is following the crankshaft movements.
3. Screw eye bolt (000.155) into connecting rod shank (12), attach
rope (17) with shackle (002.453) to eye bolt and hook into lifting
tackle. Tighten rope.
4. Carefully turn the crankpin downwards until the bearing shell (18) is
well accessible.
5. Screw off holders (030.188). When doing so, hold the bearing shell in
place first and finally take it out.
000.11). Renew
6. Check condition of bearing shell (refer to work card 000.11
bearing shell if necessary.

7 Oil sump 12 Connecting rod shank 17 Rope

9 Big-end bearing cap 15 Piston 18 Upper bearing shell
11 Crankshaft 16 Cylinder liner 19 Hexagon bolt M16x30

Figure 1. Removing upper big-end bearing shell (right-hand side of drawing showing V-type oil sump, left-hand side of drawing
showing normal oil sump

6619 030.04--04 E 05.98 L 58/64 102/ 03

Preliminary remarks

New bearing shells are delivered in ready-for-installation condition. No

attempt is allowed on either new bearing shells or upon shells that have
already run, to reduce play by filing the joint surfaces on the parting line or
by processing them in any way mechanically. It is true that this will reduce
the clearance, but it also means that the shells are no longer clamped
sufficiently in the connecting rod and in the bearing cap. Furthermore,
under no circumstances may any rescraping be made on the running
surface.

Important! The bearing shells are numbered consecutively when

first installed. When fitting new bearing shells, these are to be marked in
the same manner accordingly.

Operating sequence 2 -- Installing upper big-end bearing shell

Starting condition Big-end bearing shell cleaned, back dry, running surface oiled well.

Steps 1. The installation takes place in reverse order to that of removal. In the
process of placing the big-end-bearing shell (18), ensure that the
locating pin engages in the recess at the connecting rod shank (12).
▲ Attention! When turning the crankshaft to BDC position, it must
be ensured that the supporting devices (030.177) have been removed
and the connecting rod with piston is following the crankshaft
movements.

6619 030.04--04 E 05.98 L 58/64 103/ 03

Connecting rod
Removing and installing 030.05

Purpose of jobs to be done

Enabling emergency operation,

remachining crank pin in case of slighter damages.

Brief description

Disassembling the connecting rod is necessary:

when operating the engine during emergency operation,
when remachining slighter damages on crank pins.

The work/steps extend to:

removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Holder 030.191 Standard
2 Support 030.188 Standard
1 Strap 030.187 Standard
1 Fitting/unfitting tool 030.185 Standard
1 Holder 030.185--4 Standard
2 Collar nut M30 030.185--9 Standard
2 Hexagon bolt 030.185--38 Standard
2 Hexagon bolt 030.185--52 Standard
1 Link 030.185--54 Standard
1 Support 030.185--90 Standard
1 Guide piece 030.185--101 Standard
4 Hexagon nut 030.185--109 Standard
1 Locating clamp 030.176 Standard
1 Protecting tape for crank pin 020.041 Standard
1 Blocking tool 020.038 Standard
2 Sealing plug 020.038--1 Standard
1 Threaded rod 020.038--2 Standard
2 O--ring seal 020.038--3 Standard
1 Open--jaw and ring spanner (set) -- Standard

6619 030.05--05 E 05.98 L 58/64 101/ 04

Related work cards

Work card Work card Work card

030.01 030.02 030.03
034.01

Technical details

Term Information
Weight connecting rod shank approx. 390 kg

Operating sequence 1 -- Removing the connecting rod

Starting condition Crankcase has been opened. Connecting rod is secured to counterweight
by locating clamp (030.176). Piston has been removend (refer to work
card 034.01).
034.01 Connecting rod big end bearing bolts have beend removed,
030.03).
bearing cap has been lowered (refer to work cards 030.02 and 030.03
Crankpin at BDC. Step on crankshaft covering has been removed.

Steps 1. Install two supports (030.188) to secure the upper bearing shell.
2. Mount the holder (030.191) on the exhaust side of the connecting rod
and secure by means of hexagon bolt (030.185-38).
3. Attach the strap (030.187) to the holder (030.191) and secure the
other end to the other side of the connecting rod by means of the
hexagon bolt (030.185-38).
4. Mount the holder (030.185-4) and the link (030.185-54) on the
connecting rod and secure the guide piece (030.185-101) on the
exhaust side by means of hexagon nuts (030.185-109).
5. Turn the crankshaft until the connecting rod is approx. 5ƒ from the
horizontal (refer to Figure 1 ).
6. Insert the support (030.185-90) into the holdes (030.185-4
and 030.191) such that the rollers or studs are in contact with
the lower flange of the support beam.
7. Secure the support beam on the camshaft side. If necessary, slightly
turn the crankshaft to align the connecting rod.
8. On the exhaust side, adjust the hexagon bolts (030.185-52) to align
the support beam in such a way that the rollers are resting on the
lower flange.
9. Remove the strap and the locating clamp and attach lifting tackle to
the link (030.185-54).
10. Withdraw the connecting rod as far as possible toward the camshaft
side.
11. Using the lifting tackle, raise the connecting rod until the second
holder permits no further movement.
12. Raise the connecting rod further, disengage the second holder
from the support beam and carefully lower the connecting rod onto
wooden blocks.
13. Once the connecting rod has been removed, particularly if work is to
be carried out on the cylinder liner or inside the crankcase, wrap
protective tape (020.041) around the crankpin.
▲ Attention! If the lube oil pump will be in operation before the
connecting rod is reinstalled, insert the blocking tool (020.038) to
seal the crankpin oilway. Insert a split pin (2x22) to secure the
sealing plug (020.038- 1) (refer to Figure 2 ).

6619 030.05--05 E 05.98 L 58/64 102/ 04

 1 Connecting rod
2 Bore for big end bearing bolt

Figure 1. Removing connecting rod

Figure 2. Blocking tool for crankshaft

6619 030.05--05 E 05.98 L 58/64 103/ 04

Operating sequence 2 -- Installing the connecting rod

Steps 1. Installation is the reverse of the removal procedure.

6619 030.05--05 E 05.98 L 58/64 104/ 04

Piston/piston rings

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 034--04 E 06.98 101/ 01

Piston
Removing and installing 034.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Pistons are to be disassembled within the scope of maintenance and

repair work.
The work/steps include:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Angular screw driver 050.121 Standard
1 Fitting/unfitting tool 050.117 Standard
1 Support 050.117--1 Standard
3 Hexagon bolt 050.117--14 Standard
1 Tapered sleeve for inserting the piston rings 034.099 Standard
1 Tap wrench 034.098 Standard
1 Tap 034.080 Standard
1 Suspension device 034.147 Standard
1 Support 034.147--1 Standard
2 Hexagon bolt 034.147--2 Standard
1 Pilot rod 034.006 Standard
2 Guide tube 030.180 Standard
1 Extension pipe 030.180--1 Standard
1 Guide tube 030.180--2 Standard
1 Locating clamp 030.176 Standard
1 Support 030.176--1 Standard
1 Thrust pad 030.176--7 Standard
1 Foot board (for oil sump) 011.008 Standard
1 Foot board (for oil sump) 011.005 Standard

6641 034.01--04 E 07.05 L 58/64 101/ 06

 Qty Designation No. Availability
1 Foot board (for oil sump) 011.004 Standard
1 Shackle A2.0 002.455 Standard
1 Shackle A1.0 002.453 Standard
1 Feeler gauge (set) 000.451 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Tommy bar, 6 mm 000.261 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

030.01 055.02

Technical details

Term Information
Top land ring 147 kg
Piston with connecting rod small end 811 kg

Operating sequence 1 - Removing piston

5 Rope
6 Cylinder head bolt
7 Hexagon bolt
M20x2x140
8 Sealing ring
9 O-ring seal
10 Top land ring
11 Backing ring
12 Cylinder crankcase
13 Cylinder liner

Figure 1. Removing the top land ring

6641 034.01--04 E 07.05 L 58/64 102/ 06

 Important! Prior to dismounting piston, the top land ring (10) must
be removed as its diameter is smaller than that of the cylinder liner (13).

Starting condition Cylinder cooling water completely drained. Cylinder head removed,
crankcase opened, foot board placed into oil sump, conrod shank bolts
released, piston approximately 60• before/after TDC.

Tip! Do not drain cooling water into bilge or into the sewage system.
Pump cooling water into separate receptacle and reuse (cooling water
treatment additive).

Steps 1. Remove coke residues from top land ring (10) and from upper region
of cylinder Iiner (13), if any. In the process, cover up gap between
piston (17) and cylinder liner, to avoid dropping of foreign matter in
between.
2. Clean the three pocket bores at inner diameter of the top land ring
and remove loose dirt particles from piston top.
3. Place support (050.117-1) onto top land ring (branch socket for pilot
rod located on timing side) (refer to Figure 1 ).
4. Screw three hexagon bolts (050.117-14) into pocket bores of top land
ring hand tight. Screw hexagon bolts (7) into support until they
contact backing ring (11).
5. Screw pilot rod (034.006) into support. Attach support with shackle
(002.453) and rope (5) to lifting tackle.
6. Press off top land ring, using hexagon bolts and carefully pull out
towards the top, in the process, guide it with pilot rod.
7. Deposit top land ring on wooden support and remove device.
8. Loosen sealing ring (8), to do so, insert angular screw driver
(050.121) into groove at outer diameter. Take out sealing ring.
9. Turn piston to TDC and clean threaded bores on piston top, using
manual tap (034.080).
10. Place support (034.147-1) on piston, screw hexagon bolts
(034.147-2) into piston until seated and fasten support, using
hexagon nuts (18). Attach rope with shackle (002.455) to support
(refer to Figure 2 ).
11. Turn piston to exact BDC position and attach rope to lifting tackle.
12. Mount locating clamp (030.176) to balance weight (21) and thus
locate conrod shank (20) (refer to Figure 3 ).
13. Screw off nuts from conrod shank bolts (14) and remove thrust rings.
14. Cautiously pull piston out of cylinder liner, ensure not to damage
cylinder head bolts (6) in the process.
15. Deposit piston onto wooden support in a manner to ensure that
conrod shank bolts are not damaged.
16. Secure luboil bore in conrod shank against penetration of dirt.
17. The aperture at cylinder liner exposed thereby must covered up.
▲ Attention! Fastening of the conrod shank with the use of the
locating clamp is only valid if the engine is not running or for
turning the crankgear. With that condition prevailing, the engine
must not be operated.

6641 034.01--04 E 07.05 L 58/64 103/ 06

 5 Rope
6 Cylinder head bolt
11 Backing ring
13 Cylinder liner
14 Conrod shank bolt
15 Positioning pin
16 Connecting rod big end
17 Piston
18 Hexagon nut M16
20 Conrod shank
21 Balance weight
22 Hexagon bolt M20x35
Figure 2. Removing the piston

20 Conrod shank
21 Balance weight
22 Hexagon bolt

Figure 3. Locating clamp mounted onto the balance weight

Operating sequence 2 - Installing piston

Starting condition Piston cleaned, checked, overhauled if necessary and assembled with
connecting rod big end. Cylinder liner, top land ring as well as parting
surfaces at connecting rod big end and conrod shank cleaned. Connecting

6641 034.01--04 E 07.05 L 58/64 104/ 06

 rod shank mounted to balance weight and exactly in position BDC.
Thread of the cylinder head screw protected against damage.

Steps 1. Fasten support (034.147-1) to piston (17) (refer to Operating

sequence 1, Item 10), attach rope (5) to support, using shackle
(002.455) and hook rope into lifting tackle (refer to Figure 2 ).
2. Oil piston rings and running surface of piston with clean lubricating
oil.
3. For piston rings (1-4) arrange that joint gaps are pointing towards
timing side (ST) (refer to Figure 4 ).

1-4 Position of piston ring

joint gaps
St Timing side
(Exhaust side)

Figure 4. Drawing of the position of piston ring joint gaps

4. Lift piston, screw extension pipes (030.180-1) and guide tubes
(030.180-2) onto both of the centrally located conrod shank bolts (14)
until seated (refer to Figure 2 ).
5. Remove cover of cylinder liner, place tapered sleeve (034.099) onto
cylinder liner (13) and oil internally.
6. Open lube oil bore in conrod shank (20).
7. Using lifting tackle, move piston over cylinder liner and cautiously
lower it into same, in the process, guide piston until piston skirt slides
into cylinder liner.
Important! Turn piston so that mark (ST) on piston top is pointing
towards timing side.
8. Cautiously lower piston further, in the process, the piston rings are
gliding into the cylinder liner with the help of the tapered sleeve. Align
piston and connecting rod big end in time so that guide tubes
(030.180) are pointing towards corresponding bores in conrod shank.
9. Lower piston until connecting rod big end (16), is guided in conrod
shank by means of extension pipes (030.180-1). Screw out guide
tubes (030.180-2), ensuring in the process that conrod shank bolts do
not revolve along with the screwing motion.
10. Cautiously lower piston further until seated, in the process watch out
for positioning pins (15) at the parting surface. If necessary, loosen
locating clamp (030.176) to some extent in order to facilitate the
inserting process.
11. Using feeler gauge (000.451), check and ensure that parting gap is
equalling <0.05 mm over entire circumference.
12. Screw off extension pipes, ensuring in the process that conrod shank
bolts do not revolve along with the screwing motion.
13. Plug thrust rings onto conrod shank bolts and screw on nuts
hand-tight.
14. Remove locating clamp and preload conrod shank bolts (refer to work
030.01).
card 030.01
15. Turn piston into position TDC, unhook rope, remove tapered sleeve
and support.
16. Turn piston to position of approximately 60• before/after TDC.
17. Check O-ring seals (9) for damage. If necessary, place new O-ring
seals, which have been greased with clean lube oil, into grooves,
ensure in the process, that O-ring seals are uniformly tensioned over
the entire circumference and are not twisted.
18. Place support (050.117-1) onto top land ring (10) (refer to Figure 1 ).

6641 034.01--04 E 07.05 L 58/64 105/ 06

 19. Screw three hexagon bolts (050.117-14) into pocket bores of top land
ring hand-tight. Screw pilot rod (034.006) into support. Attach support
to lifting tackle, using shackle (002.453) and rope.
20. Cautiously insert top land ring into backing ring (11) and lower onto
cylinder Iiner.
21. Remove device.
22. Place new sealing ring (8) into groove.
23. Remove foot board from oil sump.
24. Remount engine parts that had been detached, mount pipings and
screw connections, fill cooling water into engine.

6641 034.01--04 E 07.05 L 58/64 106/ 06

Piston
Checking and disassembling 034.02

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Pistons and piston rings are to be checked with regard to the appearance
of their contact faces as well as the lubricating and wear condition.
The work/steps include:
disassembly of components,
checking of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Piston ring expander 034.074 Standard
1 Piston ring expander 034.114 Standard
1 Adapter 20x12.5 001.923 Standard
1 Extension piece 20x400 001.914 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 36x20 001.796 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Ratchet 001.521 Standard
1 Feeler gauge (set) 000.451 Standard
1 Honing stone -- Optional
1 Dial gauge -- Inventory
1 Lifting tackle with rope -- Inventory
1 Memo pad -- Inventory
1 Marking pen -- Inventory
1 Emery paper -- Inventory
1 Oil stone -- Inventory

6619 034.02--02 E 12.04 L 58/64 101/ 05

Related work cards

Work card Work card Work card

034.01 034.03 034.04
034.05

Operating sequence 1 -- Checking

Starting condition Piston has been removed and placed on an appropriate wooden support.

1 Nut
2 O-ring seal
3 Coolant pipe
4 Snap ring
5 Piston crown
6 Clamping sleeve
7 Compression ring
8 Compression ring
9 Compression ring
10 Oil control ring
11 Guide shoe
12 Piston skirt
13 Piston pin
14 Retaining ring
15 Thrust pad
16 Stud

A Shoulder clearance
B Part No. stamped on
piston crown

Figure 1. Piston (sectional view)

Steps 1. Check condition of piston and piston rings.

Important! The running surface of the piston should present a uni-
form contact pattern without scores and other signs of damage. Pro-
nounced scoring or fretting marks suggest overloading of the engine, un-
satisfactory cooling, inadequate lubrication, or foreign particles having
entered between the piston and cylinder liner.
2. Clean piston of carbon deposits, taking care not to roughen the sur-
face of the piston crown. Carefully clean the running surface.
Important! The graphite layer on the piston skirt (12) must have
been preserved after cleaning!
3. Measure and note down the axial clearance of the piston rings in their
grooves and enter the values in the engine operating log. For this
purpose, determine the axial clearance at four points (on the exhaust
and exhaust counter side, as well as on the coupling and the free en-
gine end), at a quarter depth of the piston ring groove (refer to Fig-
ure 2 . Use the feeler gauge (000.451) to do so.

6619 034.02--02 E 12.04 L 58/64 102/ 05

 Regarding assessment of piston rings, refer to work cards
034.07.
034.05 and 034.07

10 Piston crown
17,18,19 Compression ring

A Depth of piston ring

groove
B Measuring point (¼A)

Figure 2. Measuring the axial clearance of the piston rings

4. Measure shoulder clearance between piston crown (5) and piston
skirt (12) at four points evenly distributed over entire circumference
and note them down. Regarding admissible shoulder clearances and
permissible deviation of of the clearances measured at the various
034.04.
measuring points, refer to work card 034.04

Operating sequence 2 -- Removal and installation of the piston rings

Starting condition Normally, piston rings are not to be removed for checking the piston, as
they are subjected to considerable stresses while being removed/fitted.
Should piston rings have to be removed because of advanced wear or dirt
accumulation, proceed as follows:

Steps 1. Using piston ring expander (034.074 or 034.114), remove piston

rings (7-10) one by one, clean them and mark them with marking pen
(cylinder No. and number of piston ring groove).

7-9 Compression ring

17 Locking lever

Figure 3. Removal and installation of piston rings using the piston ring expander

6619 034.02--02 E 12.04 L 58/64 103/ 05

 ▲ Attention! Marking the piston rings is necessary so as to avoid
mixing them up (piston rings which have already been in use must
be refitted to the same piston and into the same piston ring groove
as before).

▲ Attention! The piston ring expander has in any case to be used

for removing and fitting the piston rings (refer to Figure 3 ).

Important! The piston ring expander (034.074) must not be used

for gas-tight piston rings (overlap at the gap). The piston ring expander
(034.114) with closed locking lever (17) is to be used for this purpose. With
the locking lever open this tool can also be used for normal piston rings.
The locking lever is spring loaded. In closed position a smaller spanner
clearance is released than in open condition.
2. Check piston rings thoroughly, renew if necessary.
3. Carefully clean the ring grooves in the piston and check them for
wear. For this purpose, check the depth of the piston ring groove by
means of a suitable dial gauge (30), taking measurements at four
points (on the exhaust and exhaust counter side, as well as on the
coupling and the free engine end), at a quarter depth of the piston
ring groove, and determine the wear (refer to Figure 4 ).

5 Piston crown
30 Dial gauge

A Depth of piston ring

groove
B Measuring point (¼A)

Figure 4. Measure the piston ring groove (determine the wear)

▲ Attention! Conically worn piston ring grooves suggest excessive

wear of the cylinder liner. Ring grooves affected by pounding can be
reconditioned. We recommend that in such cases MAN B&W be con-
sulted. Replacement piston rings fitting the reconditioned ring
grooves have to be installed, and the new ring height has to be en-
tered in the engine operating logs.
4. Using the ring expander, mount the piston rings on the piston, making
sure that the rings are positioned correctly, in accordance with the
marking. Measure the axial clearance of the piston rings in the
grooves and enter the measured values in the engine operating logs
(refer to operating sequence 1, item 3).
Important! If a piston that has already been in use is going to be
fitted in another cylinder liner, it is absolutely necessary to replace the
compression rings and the oil control ring, and to rehone the cylinder liner.
New running in of the engine will then be necessary (refer to engine oper-
ating instructions, Section 3).
Regarding dimensions and clearances of pistons and piston rings, refer to
the engine operating instructions, Section 2.5.4. Concerning the arrange-
034.04.
ment of piston rings (in new condition), see work card 034.04

Operating sequence 3 -- Disassembly

Starting condition Piston has been removed and cleaned on the outside, shoulder clearance
(A) has been measured.

6619 034.02--02 E 12.04 L 58/64 104/ 05

Steps 1. Remove piston pin (13) and connecting rod small end (refer to work
034.03).
card 034.03
2. Loosen four nuts (1) and unscrew them (refer to Figure 1 ).
3. Suspend the piston skirt (12) by means of the rope which has been
slipped through the piston pin bore, remove it and put it down care-
fully. When lifting the piston skirt, pay attention to the studs (16) and
thrust pads (15).
4. If required, unscrew studs from piston crown.
5. Carefully clean piston crown (5) and piston skirt (12). The inside of
the cooling spaces and the cooling passages in the piston crown
must be cleaned down to the bare metal (using rotating wire brushes
or emery belts). Oil bores are to be purged by means of compressed
air. Check parts for damage (cracks).
Important! Operation of engine with intensely contaminated lubri-
cating oil results in increased coke deposits in the cooling spaces of the
piston.
6. Check the contact face between piston crown (5) and piston
skirt (12), and smooth material elevations (see Operating Se-
quence 4).

Operating sequence 4 -- Smoothing the contact face between the piston crown and the piston skirt

Preliminary remark During engine operation, punctual welding may occur locally on the con-
tact faces between piston crown and piston skirt, which cause material
elevations on the contact faces when the piston is disassembled.
As the precise starting position cannot be reached when the piston is reas-
sembled, the material elevations are to be removed and smoothed re-
spectively.

Starting condition The piston has been disassembled and cleaned.

Arbeitsschritte 1. Check the contact face of piston crown (5) and piston skirt (12) for
material elevations.
2. Remove the material elevations in several stages using emery paper
with increasingly finer grain size every time (100 --180).
3. Smooth the contact faces by means of an oil stone or honing stone.
▲ Achtung! Particular care is to be taken in this connection that
the material elevations on the contact faces of the piston crown and
piston skirt are removed completely, as remaining elevations may
result in high compressive stresses at certain points.

6619 034.02--02 E 12.04 L 58/64 105/ 05

Piston pin and piston pin bush
Removing and installing/checking 034.03

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Piston pin and piston pin bush are to be checked at regular intervals, and
are hence to be dismounted.
The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Fitting/unfitting tool 034.077 Standard
1 Suspension device 030.189 Standard
1 Pliers for retaining ring 002.165 Standard
1 Open--jaw wrench 13x17 000.604 Standard
1 Lifting tackle with rope -- Inventory

Related work cards

Work card Work card Work card

034.02

Operating sequence 1 -- Removing

Starting condition Piston with conrod head removed and settled on a wooden support with
piston crown facing downwards (refer to Figure 1 ). Piston inside free
of oil and oilcoke.

Steps 1. Mount suspension device (030.189) to conrod head (19), hang

device onto lifting tackle and raise slightly in order to relieve the
piston pin (13).
2. Remove the retaining rings an push out piston pin that far as shown
in the illustration. Before doing so, secure the piston against canting.

6619 034.03--01 E 05.98 L 58/64 101/ 02

 Tip! Piston pin may easily be pushed out at a temperature difference
of 30-40ƒ C compared with the piston. For doing so, carefully warm up
the piston in the area of the pin using a gas torch (keep torch in circular
motion, inner flame cone not too close with piston).
3. Carefully lift out conrod head from the piston and lower it with care
onto a suitable support.
4. Install tool (034.077) in piston pin and clamp it with hexagon bolt (20).
5. Hang tool onto the lifting tackle and carefully push out the piston pin
the full way.
6. Clean piston pin and bush and check them for wear (for maximum
permissible clearance, refer to Operating Manual/Technical Data).
▲ Attention! In case replacement of the bush is required, this work
should be carried out in a Service Workshop as the bush is to be
cooled down before being installed. In the meantime and if possible,
install spare conrod head. Rescraping the running surface must
neither be made with new nor with used bushes.

Operating sequence 2 -- Installing

Steps 1. Check to see that the guide shoe is free to move and supply pipe fully
pressed into the piston crown.
2. Installing the piston pin is a reversal of the removal procedure. When
installing, attention should be paid not to damage the piston with the
tool (034.077) during insertion.

12 Piston crown
13 Piston pin
19 Conrod head
20 Hexagon bolt M10x40

Figure 1. Removing and installing piston pin

6619 034.03--01 E 05.98 L 58/64 102/ 02

Piston
Assembling 034.04

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

Pistons are to be disassembled within the scope of maintenance and

repair work.
The work includes:
reassembling components.

Tools/appliances required

Qty Designation No. Availability

1 Piston ring expander 034.074 Standard
1 Piston ring expander 034.114 Standard
1 Torque wrench 20--200 Nm 008.002 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Standard
1 Extension piece 20x400 001.914 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 36x20 001.796 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Ratchet 001.521 Standard
1 Feeler gauge (set) 000.451 Standard
1 Lifting tackle with rope -- Inventory
1 Memo pad -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

034.01 034.03

Operating sequence 1 -- Assembling the piston

Starting condition Piston components have been cleaned, checked and renewed if required.
Piston crown deposited on suitable wooden support. Coolant pipe (3) with

6619 034.04--02 E 10.00 L 58/64 101/ 04

 guide shoe (11) mounted movably in piston skirt (12), snap ring (4)
inserted (refer to Figure 1 ).

1 Nut
2 O-ring seal
3 Coolant pipe
4 Snap ring
5 Piston crown
6 Clamping sleeve
7 Compression ring
8 Compression ring
9 Compression ring
10 Oil control ring
11 Guide shoe
12 Piston skirt
13 Piston pin
14 Retaining ring
15 Thrust pad
16 Stud

A Shoulder clearance
B Part No. stamped onto
piston crown

Figure 1. Piston (sectional view)

Steps 1. Coat threads of studs (16) with Molykote Paste HSC or Copaslip and
screw them into piston crown (5), applying a torque of 150 Nm.
2. Hang piston skirt (12) with rope slipped through piston pin bore, insert
clamping sleeve (6) and O-ring seal (2) and lower piston skirt
carefully onto the piston crown, watching out for clamping sleeve and
studs.
Important! Prior to lowering the piston skirt onto the piston crown,
ensure that the seating surfaces are spotlessly clean and dry. Use new
O-ring seal (2) whenever a piston is assembled.
3. Insert the thrust pads (15) in the bores over the studs.
Important! Insert the thrust pads correctly! Spherical end is to seat
on the piston skirt.

A Shoulder clearance

Figure 2. Measuring of the shoulder clearance with the feeler gauge

6619 034.04--02 E 10.00 L 58/64 102/ 04

 4. Coat threads and seating surfaces of the nuts (1) with Molykote
Paste D or Optimoly Paste White T, and screw nuts down until
seated.
5. Assembly with new parts: Using feeler gauge (000.451), measure
shoulder clearance (A) between piston crown and piston skirt over
the entire circumference (refer to Figure 2 ), and note down. The
difference between maximum and minimum dimensions must not
exceed 0.01 mm.

Assembly with used parts: Measure shoulder clearance (A) between

piston crown and piston skirt over the entire circumference (refer to
Figure 2 ), and note down. The difference between maximum and
minimum dimensions must not exceed 0.03 mm.
Important! The shoulder clearance (A) depends on the part
number stamped onto the piston crown (5) at point (B). Refer to Table 1.

Part No. on piston crown Shoulder clearance (A) in mm

11.03455-2443 0.23 ... 0.29 mm
11.03455-2719
11.03455-2881 0.28 ... 0.34 mm
11.03455-2881-1
11.03455-2881-2
11.03455-3511 0.38 ... 0.44 mm
Table 1. Shoulder clearance (A) for new and used parts, bolts not tightened
6. Pre-tighten nuts in the order 1-2-3-4 to a torque of 60 Nm (refer to
Figure 3 ).

1-4 Order of tightening

Figure 3. Order of tightening the studs

7. Tighten nuts in the order 4-3-2-1 to a torque of 260 Nm and release
them again.
8. Check studs for correct draw-in, applying a torque of 150 Nm.

Perform procedure of final tightening in 3 steps:

9. Pre-tighten nuts in the order 1-2-3-4, applying torque of 20 Nm.
10. Tighten nuts in the order 4-3-2-1, applying torque of 60 Nm.
11. In the order 1-2-3-4, continue tightening the nuts at a torsion angle of
180•.
Check: At a torque of 260 Nm, it must not be possible to turn the nuts any
further.
12. Check and ensure that the coolant pipe (3) is fully pressed into
piston skirt and that the guide shoe (11) is free to move.
13. Refit piston pin (13) and connecting rod head (refer to work
card 034.03).
034.03

6619 034.04--02 E 10.00 L 58/64 103/ 04

Arrangement of piston rings

Fitted in the top-most groove of the piston crown (5) is a

chromium-ceramic or a plasma-coated compression ring (7) (refer to
Figure 4 ).
Fitted in the second groove from top is a plasma-coated or chromium-
plated compression ring (8).
Fitted in the third groove from top is a chromium-plated compression
ring (9).
Fitted in the fourth groove from top is an oil control ring (10).

5 Piston crown
7 Compression ring
8 Compression ring
9 Compression ring
10 Oil control ring
12 Piston skirt

Figure 4. Arrangement of the piston rings

Important! The inclination at the inner diameter or rather the

designation ”TOP” on the piston ring flank must always point upwards
to the combustion chamber.

When removing and installing piston rings, use piston ring

expander (034.074 or 034.114) in any case.

When installing already used piston rings, watch for position according to
034.02).
marking (refer to work card 034.02

When removing and installing normal piston rings (canted or perpendicular

gap), depress locking lever of piston ring expander (034.114) to tension
piston rings. The locking lever is spring-loaded. When released it returns
to its original position.

▲ Attention! When removing and installing gas-tight piston

rings (overlap at the gap), the locking lever of piston ring expander
(034.114) must not be depressed as, otherwise, the piston rings are
overstretched.

6619 034.04--02 E 10.00 L 58/64 104/ 04

Piston rings
Assessing 034.05

Purpose of jobs to be done

Carry out work in time according to maintenance plan,

measure components,
assess wear pattern/condition.

Brief description

Piston rings are to be diagnosed at regular intervals on the basis of the

wear pattern.
The work includes:
checking components.

Related work cards

Work card Work card Work card

034.07

Preliminary remarks

Piston rings have to be replaced after they have been in use for the time
periods given in the maintenance schedule. Replacement will also be
necessary if interim checking reveals damage to the running surface or
excessive clearances.
The rings being in use are compression rings with chromium-plated,
plasma-coated or (the most recent solution) chromium/ceramic-coated
running surfaces, and chromium-plated oil scraper rings. Please refer to
Table 1.

Ring Running surface Appearance

Compression rings
Groove1 chrome/ later network of cracks
ceramic-coated
Grooves 1/2 plasma-coated uniformly grey
Grooves 2/3 chromium-coated uniformly grey
Oil scraper ring
Groove 4 chromium-coated uniformly grey
Table 1. Piston rings/coating
On plasma-coated and chrome-plated rings, the appearance of the coating
does not change, or changes but slightly, under steady wearing conditions.
The behaviour of chromium/ceramic-coated rings is different. The running
surface of these rings has a polished metal appearance of uniformly grey
colour when not yet worn. After several hundreds of operating hours, a

6682 034.05--01 E 07.97 101/ 03

 network of cracks will appear on the surface. This is the normal
appearance.
It is the result of hard metal oxide/ceramic particles embedded in the
reticular structure of the chromium layer.
The ring type can be sun from the code number on the top side of the
piston ring.

Wear appearance of plasma-coated, chrome-plated or chromium/ceramic-coated piston rings

Due to its shape, the running face of new compression rings does not
have contact across its full width but only the width of the actual contact
surface A. With the progress of wear, the actual contact surface width will
increase.

A Actual contact surface B Ring width

width

Figure 1. Running face of plasma-coated and chrome-plated piston rings

(time in use > 1000 hrs)

Figure 2. System of cracks on chromium/ceramic-coated piston rings

(time in use approx. > 8000 hrs)
At the end of the useful life, the actual contact surface extends up to the
chamfers or radii of the ring sides, please see Figure 3.

Figure 3. Piston ring of good running pattern at the end of the useful life.
The chamfers or radii are still distinctly visible on the piston ring shown in
Figure 3. Coated compression rings have to be replaced when the actual
contact surface extends over the entire piston ring width, i.e. when the
chamfers or radii are hardly visible any more. In this condition, the residual

6682 034.05--01 E 07.97 102/ 03

 thickness of the coating will not safely endure the subsequent
maintenance interval.
Burns (C) produce local discoloration of the piston ring face. Such rings
have to be replaced. (See Figure 4).

Figure 4. Piston ring with burns on the face

Coated compression rings and oil scraper rings have also to be replaced if
the coating has worn through at one spot.

Figure 5. Piston with worn-through coating

Figure 5 shows a chrome-plated compression ring. Turn chromium layer
has completely worn spotwise at (D).
Broken-off particles or cracks in the coating of a piston ring also call for its
replace.

Figure 6. Piston ring with broken-off particles in the face

Figure 6 shows a plasma-coated compression ring. Parts of the coating
have broken off at (E).
Chromium/ceramic-coated compression rings have to be replaced when
the continous, micro-cracked surface has decayed to a crazed cracke
appearance. The cracks will then have extended down to the base
material, which involves the danger of particles breaking away.

6682 034.05--01 E 07.97 103/ 03

Chromium-- ceramic coated
Piston rings
Assessing 034.07

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

Piston rings are to be diagnosed at regular intervals on the basis of the

wear pattern.
The work includes:
checking components.

Related work cards

Work card Work card Work card

034.05

Preliminary remarks

Piston rings have to be replaced after they have been in use for the time
periods specified in the maintenance schedule. Replacement will also
become necessary if interim checking reveals damage to the running
surface or excessive wear.
Piston rings with a chromium-ceramic coating on the running surface are
fitted in the topmost groove. The ring specification is defined by the code
number applied to the top side of the piston rings.
Contrary to plasma-coated or chromium-plated rings, the appearance of
the coating on chromium-ceramic rings changes distinctly as wear
proceeds. In the new condition, the face of these rings has a polished
metal appearance of uniform silvery grey colour. After several hundreds of
operating hours, a network of cracks or individual longitudinally and
transversely oriented cracks will appear. This is the normal appearance. It
is the result of hard metal oxide/ceramic particles embedded in the
reticular structure of the chromium layer and offers the advantage of very
high resistance to wear and a distinctly improved resistance to thermal
loads and simultaneously minimised cylinder liner wear. The characteristic
crack network serves as a lube oil reservoir.
The illustrations following below show piston rings in approximately 5-fold
magnification. They are thought as an aid in diagnosing the condition of
used chromium-ceramic coated piston rings and as supplementary
information to work card 034.05.
034.05

6682 034.07--01 E 07.97 101/ 04

1. Normal wear pattern. The piston ring can be used without any restrictions.

1. Wide network of cracks

This appearance of the running face is representative for the normal
wear condition of a chromium-ceramic coated ring.
Result: The piston ring is available for further use without any restriction.

2. Narrow network of cracks

This appearance of the running face also reflects the normal state of
wear. The surface is smooth throughout. No bulging of the running
layer towards the cracks can be seen. Surfaces of such appearance
do not suggest separation of layers.
Result: The piston ring ring is available for further use without any
restriction.

6682 034.07--01 E 07.97 102/ 04

 3. Narrow longitudinal cracks in the running direction
This appearance of the running face also reflects normal wear
conditions. The surface is smooth throughout.
Result: Provided the cracks have a width of < approx. 0.1 mm, the piston
ring is available for further use without any restriction.

2. Wear is critical -- Piston ring has to be replaced.

1. Burn
This appearance of the running face reflects a condition which is
actually to be diagnosed as normal, but the burn spot that is visible
will not recover. Besides, there is a potential risk of blow-by.
Result: The piston ring cannot be used any longer and has to be replaced.

2. Pronounced crazed cracking

This appearance of the running face shows pronounced crazed
cracking of relatively large crack width. The surface is no longer
continuously smooth but bulged near the cracks.
Result: The piston ring cannot be used any longer and has to be replaced.

6682 034.07--01 E 07.97 103/ 04

 3. Longitudinal cracks of large width in the running direction
This appearance of the running face, showing longitudinal cracks of
considerable width, is indicative of the danger of separation even
though the surface may be smooth throughout.
Result: As the cracks have a width of > approx. 0.1 mm, the piston ring
cannot be used any longer and has to be replaced.

3. Total damage. Piston ring has to be replaced.

Piston rings that have suffered total damage such as, e.g.:
- breakage
- separation of the running layer
- pieces of material broken off, etc.
require replacement. Neighbouring components such as the cylinder liner,
piston, cylinder head should be checked for damage.

6682 034.07--01 E 07.97 104/ 04

Cylinder Liner/Top land ring

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 050--04 E 06.98 101/ 01

Cylinder liner with backing ring
Removing and installing 050.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check components for condition/wear,
assess the contact pattern/wear.

Brief description

Cylinder liners are to be removed and cleaned at regular intervals.

The work/steps include:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems drained

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5
1 Assistant 0.5

Tools/appliances required

Qty Designation No. Availability

1 Suspension device 050.203 Standard
1 Plate 050.203--1 Standard
2 Thrust screw 050.203--3 Standard
2 Thrust pad 050.203--4 Standard
1 Attachment swivel 050.203--10 Standard
2 Lifting eye bolt M36x3 000.147 Standard
1 Suspension device 050.125 Optional
1 Clamping piece (two--part) 050.125--1 Optional
2 Shackle A1.6 002.454 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricating oil, clean -- Inventory

6722 050.01--01 E 03.06 L 58/64 CD 101/ 06

Related work cards

Work card Work card Work card

034.01 050.02 055.01

Technical details

Term Information
Cylinder liner with backing ring 2000 kg

1 Hexagon bolt
3 Backing ring
4 Cylinder liner
7 Hexagon bolt
10 Cylinder crankcase
11 Cylinder head bolt

M Marking on the cylinder

liner and backing ring

Figure 1. Suspension device for cylinder liner with backing ring

Operating sequence 1 -- Removal of the cylinder liner with backing ring

Starting condition The cooling water has been drained completely.

▲ Attention! Do not drain the cooling water into the bilge or the
sewage system! Pump the cooling water into a separate tank, and
re-use it (because of the cooling-water conditioning agent)!

The cylinder head has been dismantled; the top land ring and the piston
with connecting rod small end have been removed; the connecting rod
shank has been affixed to the balance weight by means of the locating
clamp.

6722 050.01--01 E 03.06 L 58/64 CD 102/ 06

Steps 1. Clean the cylinder liner (4).
2. 050.02.
Measure the cylinder liner (4) - see Work Card 050.02
3. Remove all pipes and pipe unions from the backing ring (3).
4. Unscrew two hexagon bolts (7) from the backing ring (3). Refer to
Figure 2 .
5. Back off the thrust screws (050.203-3) with thrust pad (050.203-4) in
the plate (050.203-1).
6. Place the plate (050.203-1) on the backing ring (3) and attach it to the
latter by means of hexagon bolts (1). Refer to Figure 2 .
7. Screw the thrust screws (050.203-3) in as far as the top edge of the
cylinder liner (4).

1 Hexagon bolt
3 Backing ring
4 Cylinder liner
7 Hexagon bolt
10 Cylinder crankcase
11 Cylinder head bolts
12 Rope

Figure 2. Fitting the suspension device for cylinder liner with backing ring

Important! This prevents the backing ring from falling down, if it has
become loose, when the removed cylinder liner is set down.
8. Screw two lifting eye bolts (000.147) into the backing ring (3).
9. Fasten two ropes (12) to the lifting eye bolts (000.147) and attach
them to the lifting tackle.
10. Cover the crankcase by appropriate means, especially on the sides,
in order to prevent that dirt from the cooling spaces penetrates into
the big-end and main bearings.
11. Pull cylinder liner (4) and backing ring (3) out of the cylinder crank-
case (10) towards the top, parallel to the centre axis of the cylinder.
Refer to Figure 3 .
▲ Attention! When removing the cylinder liner, be careful not to
damage the cylinder head bolts (11)!
12. Put the cylinder liner (4) and the backing ring (3) down onto a wooden
support. Tighten the ropes (12).
13. Back off the thrust screws (050.203-3) by a few turns; slightly slacken
the lifting tackle, and loosen the backing ring (3) by careful tapping
(use a wooden or copper support).

6722 050.01--01 E 03.06 L 58/64 CD 103/ 06

 14. Remove the suspension device (050.203), and lower the backing ring
(3) onto a wooden support.
▲ Attention! Secure the cylinder liner against overturning!
15. Put the clamping piece (050.125-1) around the cylinder liner (4) and
screw it together. Refer to Figure 5 .
16. Fasten two ropes (12) to the suspension device by means of
shackles (002.454), and attach them to the lifting tackle.
17. Lift the cylinder liner (4) out of the backing ring (3) and place it on a
wooden support.
18. Remove the tools.
19. Take the O-ring seals (5 and 13) off. Refer to Figure 4 .
20. Clean the cylinder liner (4).
21. Purge the oil bores with compressed air.

1 Hexagon bolts
3 Backing ring
4 Cylinder liner
8 Fixation sleeve
10 Cylinder crankcase
11 Cylinder head bolts
12 Rope

Figure 3. Removal of the cylinder liner with backing ring

Operating sequence 2 -- Installation of the cylinder liner with backing ring

Starting condition The cylinder liner has been thoroughly cleaned on the inside and outside.
050.02).
The cylinder liner has been measured (see Work Card 050.02

▲ Attention! In case of deep scoring in the piston running surface

or extensive wear, the cylinder liner must be replaced, especially if
the maximum permissible wear has been reached in the region of the
topmost compression ring at TDC or if the ovality is too severe (see
Volume B1 / Operating Instructions)!

The lubricating oil bores have been purged; the sealing faces have been
cleaned thoroughly and are not damaged; the crankcase has been cov-
ered by appropriate means.

6722 050.01--01 E 03.06 L 58/64 CD 104/ 06

Steps 1. Put the clamping piece (050.125-1) around the cylinder liner (6) and
screw it together. Refer to Figure 5 .
2. Fasten two ropes (12) to the suspension device (050.125) by means
of shackles (002.454), and attach them to the lifting tackle.
3. Lift the cylinder liner (4).
4. Oil new O-ring seals (5 and 13) with clean lubricating oil and insert
them into the ring grooves of the cylinder liner (4), making sure that
they are uniformly tensioned over the entire circumference and not
twisted. Refer to Figure 4 .
5. Place the cylinder liner (4) into the backing ring (3).

3 Backing ring
4 Cylinder liner
5 O-ring seal
6 Leakage-check bore
hole
10 Cyliinder crankcase
11 Cylinder head bolts
13 O-ring seal

Figure 4. Cylinder liner with backing ring

Important! Already when inserting the cylinder liner into the back-
ing ring make sure that the markings (M) of cylinder liner and backing ring
are facing one another.
6. Remove the shackle (002.454) from the suspension device (050.125)
and dismantle the clamping piece (050.125-1).
7. Screw two lifting eye bolts (000.147) into the backing ring (3).
8. Fasten two ropes (12) to the lifting eye bolts (000.147) and attach
them to the lifting tackle.
9. Pull the backing ring (3) over the cylinder liner (4) from below, paying
attention to the O-ring seals (5 and 13) in the process.
▲ Attention! Make sure that the markings (M) on the backing ring
and the cylinder liner coincide!
10. Back off the thrust screws (050.203-3) with the thrust pad
(050.203-4) in the plate (050.203-1).
11. Place the plate (050.203-1) on the backing ring (3) and attach it to the
latter by means of the hexagon bolts (1). Refer to Figure 2 .
12. Screw the thrust screws (050.203-3) in as far as the top edge of the
cylinder liner (4).

6722 050.01--01 E 03.06 L 58/64 CD 105/ 06

 13. Lift the backing ring (3) together with the cylinder liner (4) and posi-
tion them over the locating bore in the cylinder crankcase (10).
14. Carefully insert the backing ring (3) with the cylinder liner (4) into the
cylinder crankcase (10).
▲ Attention! Make sure that the fixation sleeve (8) is positioned cor-
rectly relative to the bore in the cylinder crankcase (10) / backing
ring (3)! Do not damage the cylinder head bolts (11) during installa-
tion!

3 Backing ring
4 Cylinder liner
12 Rope
14 Hexagon bolt
15 Hexagon nut

M Marking on the cylinder

liner and backing ring

Figure 5. Suspension device for cylinder liner

15. Remove the tools.
16. Screw two hexagon bolts (7) through the backing ring (3) and into the
cylinder crankcase (10) and tighten them.
17. Remove the cover from the crankcase.
18. Measure the cylinder liner (4) - see Work Card 050.02.
050.02
19. Fit all pipes and pipe unions.
20. After installation/fitting of all engine components (piston, cylinder
head etc.), fill cooling water into the engine and vent the cooling
water pipes.
21. Upon completion of assembly work, check at operational cooling
water pressure whether the O-ring seals (5) are in order and no water
is emerging from the check bore holes (6). Refer to Figure 4 .
22. With the engine running, check the cylinder for gas tightness at the
check bore holes (6). Refer to Figure 4 .
▲ Attention! If a new cylinder liner has been installed, it must be
run in according to the instructions (see Volume B1 / Operating In-
structions)!

6722 050.01--01 E 03.06 L 58/64 CD 106/ 06

Cylinder liner
Measuring 050.02

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Cylinder liners are to be checked within the scope of maintenance and

repair work.
The work/steps include:
Measuring components and
assessing contact pattern/wear.

Tools/appliances required

Qty Designation No. Availability

1 Gauge bar 32/40 050.097 Standard
1 Gauge bar 40/54 050.096 Optional
1 Gauge bar 48/60 050.095 Optional
1 Gauge bar 58/64 050.094 Standard
1 Micrometer (inside) 58/64 050.107 Standard
1 Micrometer (inside) 48/60 050.062 Optional
1 Micrometer (inside) 32/40 050.038 Optional
1 Micrometer (inside) 40/54 050.002 Optional

Preliminary remarks

Cylinder liners are not worn out completely evenly on the circumference
and along the running face. The wear values are limited and that for both
the ovality and the maximum wear. This way, sealing problems and over-
loading of the piston rings are to be avoided.
Regular checks provide a basis for optimising the operating conditions and
for decisions concerning a possible replacement of the cylinder liner.

Operating sequence 1 - Measure the cylinder liner

Starting condition Cylinder head, top land ring (if existing) as well as piston and connecting
rod removed. Cylinder liner thoroughly cleaned, especially in the upper
area and in the area of the gauge bar stop, on the top face.

6682 050.02--01 E 09.06 32/40, 40/54, 48/60, 58/64 101/ 03

Steps 1. Insert the gauge bar in the cylinder liner. See Figure 1. The measur-
ing bar is held magnetically on the running face and on the top face
of the collar. The number and positions of the measuring points are
fixed by means of the bores in the bar.
Important! Measuring point 1 is only relevant for cylinder liner de-
signs without top land ring. For measuring, the spacer (8) is to be re-
moved. For cylinder liner designs with top land ring, measuring is started
at measuring point 2.
2. Heat up the inside micrometer to the temperature of the cylinder liner
and insert it successively into all of the bores of the gauge bar. De-
termine the dimensions in longitudinal direction of the engine and
transversely to it and note them down.
3. Determine the temperature of the cylinder liner during measurement
and note it down.
4. Enter dimensions in engine log book and compare with the max. per-
missible values (refer to operating manual, Section 2.5).
▲ Attention! In case the values measured exceed the max. permis-
sible values for wear or ovality, the cylinder liner must be renewed.
The wear is the difference from the values measured minus nominal di-
mension. The ovality is the difference from the values measured (in trans-
verse and in longitudinal direction) of each plane.

1-6 Measuring point

7 Knurled screw
8 Spacer
9 Cylinder liner
10 Gauge bar
11 Inner screw gauge

Figure 1. Measuring the cylinder liner

6682 050.02--01 E 09.06 32/40, 40/54, 48/60, 58/64 102/ 03

 Cylinder diameter (mm)

Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

M
Measuring
i plane
l trans- longitu- trans- longitu- trans- longitu- trans- longitu- and
d so
verse dinal verse dinal verse dinal verse dinal on
1 -- --
2 580.82 580.75
3 580.76 580.60
4 580.30 580.30
5 580.20 580.20
6 580.83 580.75
Cylinder liner
temperature during 30ƒ &
measuring
Condition of running perfect
surface
Table 1. Measuring log (example: L 58/64 engine)

6682 050.02--01 E 09.06 32/40, 40/54, 48/60, 58/64 103/ 03

Sealing face on cylinder head
and sealing groove in top land ring
Grinding 050.03

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

The sealing face on the cylinder head and the sealing groove in the top
land ring are to be checked every time the cylinder head is removed, and
remachined if necessary.
The work includes:
grinding the sealing face and the sealing groove.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Grinding tool 050.210 Optional
1 Disk support 050.210--1 Optional
1 Grinding wheel 050.210--2 Optional
1 Turnover stand 055.131 Optional
1 Angular screw driver 050.121 Standard
1 Crow bar 001.391 Standard
1 Grinding paste (silicone--free) -- Inventory
1 Depth gauge -- Inventory
1 Micrometer (outside) -- Inventory

Related work cards

Work card Work card Work card

055.02 055.05

6722 050.03--01 E 03.06 L 58/64 CD 101/ 04

Preliminary remarks

The grinding tool (050.210) can be used for the top land ring and the cylin-
der head. The correct side for each case is shown in Figures 1 and 2 .

1 Cylinder head A Sealing face on the cylinder head

5 Wing screw

Figure 1. Grinding tool - Grinding the sealing face on the cylinder head

Operating sequence -- Grinding the sealing face on the cylinder head and the sealing groove
in the top land ring

Starting condition The cylinder head has been removed and clamped into the turnover stand
(055.131).

Steps 1. Loosen the sealing ring (6) - see Figure 3 - by means of an angular
screw driver (050.121) which has been inserted at the inner diameter
or a crow bar (001.391), and remove it from the top land ring.
Important! Depending on the application (grinding the sealing
groove in the top land ring or the sealing face on the cylinder head), use
the side of the grinding wheel which is suitable for the operation (refer to
Figures 1 and 2 ).
2. Grind the sealing groove (B) in the top land ring (see Figure 2 ) or
the sealing face (A) on the cylinder head (see Figure 1 ) using grind-
ing paste and the grinding tool so as to obtain a plain surface. For
this purpose move the grinding tool to and fro and lift it in between so
as to permit the grinding past to redistribute.

6722 050.03--01 E 03.06 L 58/64 CD 102/ 04

 Important! Grinding should be kept to the required minimum, as it is
difficult to obtain a plain surface by grinding. If necessary, the cylinder
head has to be machined on a lathe.

2 Cylinder liner 4 Top land ring B Sealing groove on the top

3 Backing ring 5 Wing screw land ring

Figure 2. Grinding tool - Grinding the sealing groove on the top land ring
3. After completion of the work, remove the remainders of the grinding
paste thoroughly.
4. By measuring the difference, determine the gap dimension (C) be-
tween the cylinder head and the top land ring on several spots.
Important! In the case of reground sealing faces, the gap dimension
(C) between cylinder head and top land ring must be at least 0.5 mm (see
Figure 3 ). If the gap dimension is smaller, oversize rings can be ordered
from MAN B&W Diesel AG Augsburg or the service bases.
5. If an oversize ring is installed, this has to be entered in the service
records, stating also the cylinder concerned.

6722 050.03--01 E 03.06 L 58/64 CD 103/ 04

1 Cylinder head
2 Cylinder liner
3 Backing ring
4 Top land ring
6 Sealing ring
A Sealing faces on the
cylinder head
B Sealing groove in the
top land ring
C Gap dimension

Figure 3. Gap between cylinder head and top land ring

6722 050.03--01 E 03.06 L 58/64 CD 104/ 04

Cylinder liner (without backing ring)
Removing and installing 050.04

Purpose of jobs to be done

Carry out work in time according to maintenance plan,

measure components,
assess wear pattern/condition.

Brief description

Cylinder liners are to be removed and cleaned at regular intervals.

The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Suspension device 050.125 Standard
1 Clamping piece (two--part) 050.125--1 Standard
1 Fitting/unfitting tool 050.091 Standard
1 Support (upper) 050.091--1 Standard
1 Support (lower) 050.091--10 Standard
1 Support (upper) 050.091--15 Standard
4 Stop piece 050.091--30 Standard
2 Stop piece 050.091--31 Standard
2 Threaded rod 050.091--32 Standard
2 Hexagon nut 050.091--34 Standard
2 Shackle A1.6 002.454 Standard
1 Grease (acid--free) -- Inventory
1 Lifting tackle with rope -- Inventory

Related work cards

Work card Work card Work card

034.01 055.01

6619 050.04--03 E 04.98 L 58/64 101/ 04

Operating sequence 1 -- Removing

1 Leakage check bores 3 Backing ring

2 Cylinder liner 4 Sealing rings

Figure 1. Removing cylinder liner

6619 050.04--03 E 04.98 L 58/64 102/ 04

Starting condition Cylinder head removed. Top land ring and piston with connecting
rod head removed. Connecting rod shaft fastened to crankshaft.

▲ Attention! Do not turn crankshaft with fitting/unfitting

tool in-situ.

Steps 1. Secure rope to bow of lower support (050.091-10) and

fasten to lifting tackle through cylinder liner. Cautioulsy
insert support through crankcase opening and pull it up to
the position as per illustration (transversely to engine axis).
2. Align upper support (050.091-15) with lower support and
replace upper support in this position. Screw threaded
rods (050.091-32) into lower support hand-tight.
3. Screw hexagon nuts (050.091-34) onto threaded rods until
seated on upper support, raise cylinder liner until it abuts with
upper travese by alternately tightening the nuts (refer to
right-hand half of Figure 1 ).
4. Unhook rope from lower travese, attach lifting tackle to
crosspiece of upper support, pull out cylinder liner vertically
towards the top and deposit on wooden support.
Important! Do not deposit cylinder liner on lower support.
For removal of lower travese supports of 160 mm in height are
required.
5. Dismount fitting/unfitting tool.
6. The suspension device (050.125) can be used for transport
(refer to Figure 2 ).

2 Cylinder liner
5 Rope
6 Hexagon bolt M20x60
7 Hexagon nut M20

Figure 2. Suspension device with cylinder liner

Operating sequence 2 -- Installing

Starting condition Cylinder liner cleaned thoroughly inside and outside, liner bore measured.
Deep scores in piston running surfaces or excessive wear require
replacement of cylinder liner, particularly so, if in the region of the topmost
compression ring in TDC the maximum wear rate has been reached or in
case of excessive ovality (refer to Operating Manual/Technical Data). Blow
lubrication bores through, sealing faces carefully cleaned and undamaged.
Suspension device (050.125) mounted.

Steps 1. Scrutinize sealing rings (4). If necessary, place new sealing rings
coated with acid-free grease in ring grooves, ensure in the process
that rings are uniformly tensioned over entire circumference and not
twisted.
2. Place cylinder liner on wooden support which is at least 160 mm
high.
3. Disassemble suspension device, in its place mount the
fitting/unfitting tool (050.091) with lower support (050.091-10)
and upper support (050.091-1) (refer to Figure 3 ).

6619 050.04--03 E 04.98 L 58/64 103/ 04

 4. Cautiously insert cylinder liner into backing ring and
crankcase/cylinder block. In the process, watch out for alignment of
marks (M) at cylinder liner and backing ring.
5. Dismount fitting/unfitting tool, measure cylinder liner bore once more.
Tip! For installing the top land ring refer to work card 034.01.
034.01
6. After termination of assembling work and with the cooling water
pressure prevailing, check leakage-free condition of sealing rings at
the leakage check bores (1).
Important! If new cylinder liners were installed, they are to
be run-in in accordance with instructions (refer to Operating Manual/
Section 3).

1 Leakage check bores

2 Cylinder liner
3 Backing ring
4 Sealing rings
M Marks on cylinder liner
and backing ring in
longitudinal extension
of engine

Figure 3. Installing cylinder liner

6619 050.04--03 E 04.98 L 58/64 104/ 04

Cylinder liner
Honing 050.05

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of components,
restore running face,
ensure correct execution of work.

Brief description

Cylinder liners are to be checked at regular intervals, and the original

running face geometry is to be restored.
The work/steps include:
honing of the reversing zone of the piston rings,
honing of the complete running face.

Tools/appliances required

Qty Denomination No. Availability

1 Honing device 050.114 Optional
1 Rope tackle with remote control 050.114--1 Optional
1 Cross tie 050.114--2 Optional
2 Extension pipe 050.114--3 Optional
2 Extension pipe 050.114--4 Optional
2 Adapter 050.114--5 Optional
4 Stop for stroke limit 050.114--6 Optional
1 Guide arm with control valve 050.114--7 Optional
1 Extension 050.114--8 Optional
1 Drive unit 050.114--9 Optional
1 Air connection with universal joint 050.114--10 Optional
1 Honing head 050.114--11 Optional
1 Tank 050.114--12 Optional
1 Funnel 050.114--13 Optional
1 Additional mass 050.114--14 Optional
2 Tension spring strip 050.114--16 Optional
1 Air supply station 050.114--17 Optional
1 Spray nozzle 050.114--20 Optional
3 Cleaning brush 050.114--21 Optional
1 Oil for air oiler 050.114--23 Optional
1 Support 050.114--24 Optional
1 Honing stone (set) for laser--hardened cylinder -- Optional
liners

6641 050.05--01 E 11.98 L 58/64 101/ 08

 Qty Denomination No. Availability
1 Honing stone (set) for unhardened cylinder liners -- Optional
1 Lifting tackle with rope -- Inventory
1 Cleaning agent (Diesel oil/petroleum) -- Inventory
1 Collecting tank -- Inventory

Related work cards

Work card Work card Work card

034.01 050.02 055.02

1 Rope tackle
2 Cross tie
3 Extension pipe
4 Stop for stroke limit
5 Remote control
6 Extension pipe
7 Guide arm with control
valves
8 Threaded piece
9 Additional mass
10 Adaptor
11 Extension
12 Support
13 Cylinder head bolt
14 Cylinder liner
15 Drive unit
16 Air connection with
universal joint
17 Spray nozzle
18 Grinding bar with
honing stones
19 Cleaning brushes
20 Honing head
21 Tension spring strip
22 Funnel
23 Air supply station
24 Tank

Figure 1. Pneumatic honing tool as mounted

6641 050.05--01 E 11.98 L 58/64 102/ 08

Preliminary remarks

Cylinder Iiners are to be rehoned when piston rings are replaced or the
maintenance interval has expired. Honing restores the original roughness
of the cylinder liner running surface. This roughness is required to ensure
a sufficiently thick and adhesive lubrication film. Whereas the original
micro geometry can largely be restored an influence on the wear profile,
i.e. the macro geometry of the cylinder liner is not possible.
Usually the TDC range of the piston rings is honed during the first, and the
complete running surface of the piston rings during the second operation.

Honing of the cylinder liners is not very time consuming. The operation of
the device and the work itself, as well as the evaluation of the results
require, however, attention and a certain amount of experience. We
therefore recommend to have this work carried out by
MAN B&W Diesel AG personnel, at least once for instruction.

Technical/functional description

The honing device essentially consists of:

- the rope tackle (1) (refer to Figure 1 ),
- the drive unit (15),
- the honing head (20),
- the lubricator (17 and 24),
- the guide elements (2-4, 6-8 and 10) and
- the portable air supply station (23).

Drive and control of the device are effected by compressed air

(pmax = 18 bar).
The fittings of the air supply station (23) serve for air filtration and drainage
as well as the adding of oil (refer to Figure 2 ).
The presetting of the stroke speed and the speed of the honing head (20)
as well as the presetting of the contact pressure of the grinding bars (18)
are carried out with the control valves at the compressed air outlets. The
rope tackle motor for the up-and-down movement is actuated by buttons at
the remote control (5).
The drive unit (15) is switched on and off by means of the ball cock at the
guide arm (7). The regulation of the contact pressure of the grinding basis
effected with the slide valve placed next to it. The grinding area can be
lubricated and cleaned from abrasion particles by means of the lubricator,
consisting of container (24) and spray nozzles (17). The lubricant/cleanser
is collected in a funnel (22) at the lower edge of the cylinder liner (14) and
led to the outside. If the grinding bars are replaced by cleaning brushes
(19) mechanical cleaning of the cylinder liner (14) is possible.
The device can be set to different diameters and adapted to different
stroke lengths by extension pipes and adaptors.

6641 050.05--01 E 11.98 L 58/64 103/ 08

 23 Air supply station
26 FiIter/water separator
27 Oiler
28 Pressure control valve
29 Pressure gauge

A Compressed air supply

B Compressed air to
rope tackle motor
(stroke speed)
C Compressed air to
drive unit (speed)
D Compressed air to
guide arm/honing head
(contact pressure)

Figure 2. Air supply station (viewed from the side and from top)

14 Cylinder liner
22 Funnel
31 Hose
32 Collecting tank

§ Honing angle

Figure 3. Honing the cylinder liner (starting position)

Operating sequence 1 -- Honing of the reversing range of the piston rings in the TDC (nip area)

Starting condition Cylinder head removed. Piston with connecting rod head removed. Using
the locating clamp, the connecting rod shank is attached to the balance
weight and turned aside so that the funnel (22) can be mounted (refer to

6641 050.05--01 E 11.98 L 58/64 104/ 08

 Figure 3 ). Cylinder liner cleaned (free from coke and lube oil) and exactly
measured (cylinder liner has not yet reached the max. wear values, for
limit values please refer to Operating Manual/Technical Data). Bore outlets
for the cylinder lubrication closed with plasticine or viscous grease. Crank
drive covered with appropriate means. Funnel mounted to the lower end of
the cylinder liner and the hose (31) connected towards the outside into the
collecting tank (32). Honing device mounted and set according to the
separate description.

Important! Honing of the reversing range of the piston rings is to

be carried out with the short honing stones prior to the later honing of the
complete running surface of the piston rings.

Steps 1. Honing stones, approx. 20 mm long, to be clamped in each grinding

bar (18) at the same level in center area of the grinding bar.
Tip! Short honing stones can be prepared from broken, long honing
stones. For this purpose, cut a notch into the stone using a steel sew
blade, mount the stone in the vice and break it.
2. Carefully introduce honing head (20) into the cylinder liner (14).
3. Using the stops (4), limit the reciprocating movement of the honing
head in the cylinder liner so that the top edge of the honing stones
projects approx. 10 mm beyond the top dead centre of the top piston
ring and a reciprocation path of 60-80 mm results.
4. Adjust the spray nozzles (17) so that the issuing lubricant is
distributed over the honing area.
5. Close the shut-off cock at the tank (24) and top up the same with
lubricant (Diesel oil, gas oil or petrol).
▲▲ Caution! Do not smoke, do not use open flames - fire hazard!
6. Open the shut-off cock at the tank. Check whether lubricant leaks at
spray nozzles and distributes over the honing area. Check whether
the lubricant is supplied, without leakages, to the collecting tank (32)
via the funnel (22).
Important! For honing a cylinder liner, approx. 4 -- 6 litres of
lubricant are required.
Make sure to use an adequate amount of lubricant for the honing process,
as it is desirable to wash off the grinding dust immidiately. Provided the
lubricant is supplied via a fine-meshed formed fabric to the collecting tank
it can be used several times. A clean lubricant/cleanser is to be used for
the final cleaning of the cylinder liner after the actual honing process.
7. Start the honing device with the previously tested setting. Provide
contact of the honing stones.
Hone with short up-and-down movements (approx. 20-30 double
strokes each ) until the short honing stones are used up. This
requires approx. 1-1.5 minutes. Speed of the honing head approx. 35
rpm; contact pressure 2.5 bar. The short stroke permits a small
honing angle only. If honing scores become visible in the TDC area of
the first piston ring, the honing procedure is to be stopped. A rounded
shoulder still existing at the point of reversal of the first piston ring is
permitted. A further set of short honing stones is to be used and the
procedure to be repeated, if necessary.
8. As soon as a satisfying grinding pattern is obtained, the honing
process is to be stopped and the supply of the lubricant to be shut
off.
9. Remove honing head from cylinder liner and secure in top position.

6641 050.05--01 E 11.98 L 58/64 105/ 08

Operating sequence 2 -- Honing of the complete running surface of the cylinder liner

Starting condition Zone of reversal of the piston rings honed in the TDC resp. cylinder liner
shows but slight incipient wear traces in the TDC zone.

Important! This work is to be done to roughen the upper zone of

the cylinder liner which does not have any honing scores after a longer
operating period. The lower range is to be honed as little as possible; at
the end of this procedure, however, two double strokes are to be made
over the complete running surface of the piston rings. On laser-hardened
cylinder liners, it should be made sure that there is a gradual transition
from the hardened parts of the cylinder liner to the soft section below.

Steps 1. Equip the honing head (20) with six long honing stones.
2. Cautiously introduce the honing head into the cylinder liner (14).
3. Adjust the reciprocation of the honing head by means of stops (4)
so that the honing stones work in the upper half of the piston stroke
zone (the zone contacted by the piston rings), i.e. the honing stones
should with their top and bottom edges move approx. 100 mm
beyond these Iimits.
4. Adjust the spray nozzles (17) so that the issuing lubricant distributes
over the honing area. Top up the container (24) with lubricant (Diesel
fuel, gas oil or kerosene).
▲▲ Caution! Do not smoke, do not use open flames - fire hazard!
5. Open the shut-off cock at the tank. Check whether lubricant leaks at
spray nozzles and distributes over the honing area. Check whether
the lubricant is supplied, without leakages, to the collecting tank (32)
via the funnel (22).
Important! For honing a cylinder liner, approx. 10 litres of
lubriacant are required.
Make sure to use an adequate amount of lubricant for the honing process,
as it is desirable to wash off the grinding dust immediately.
6. Start the honing device with the previously tested setting. Make the
honing stones contact the cylinder liner surface. Honing of a cylinder
Iiner requires 75-80 up-and-down movements at a reciprocating
speed of approx. 10 double strokes per minute (refer to Table 1).The
total honing time for a cylinder liner is usually 4-8 minutes, the higher
values applying to the laser-hardened cylinder liners.
Speed of the honing head (refer to Table 1), contact pressure 2.5 bar.
The stroke movement is to be controlled so that a honing angle (§) of
45-60• (22. 5-30• as against the horizontal line) is obtained (for
template refer to Figure 4 ). For laser-hardened cylinder liners as
well as for normal cylinder liners a roughness depth Rz of 10-15 ³m is
to be aimed at.
7. Stop device. Evaluate roughness, honing angle and honing pattern.
Please refer to Table 2. Provided the evaluation is satisfying, two
double strokes are to be made over the whole running surface of the
piston rings. For this purpose, the stops (4) are to be adjusted so that
the honing stones are partly moving out of the cylinder liner. During
this process, the honing head must, however, not hit the funnel (22).
8. After honing, the cylinder liner is to be measured (refer to work
050.02). If the max. permissible wear in the TDC of the first
card 050.02
piston ring or the max. permissible ovality are exceeded (for limit
values refer to Operating Manual/Technical Data) the cylinder liner
has to be replaced.
9. Replace the grinding bars by hard cleaning brushes (19).
10. Introduce honing head and carefully remove (loosen, wash off) all
grinding residues with reduced contact pressure of 0.5-1 bar at
unchanged speed and stroke speed. Repeat this procedure with soft

6641 050.05--01 E 11.98 L 58/64 106/ 08

 cleaning brushes, if required. Cleaning should be carried out using a
lot of lubricant. In total, approx. 50 double strokes are to be made.
The last stroke is to be made with fresh lubricant. Grinding particles
must not be left. Check with finger tips!
11. Detach the honing device. Place on next cylinder or, on termination of
the cleaning, store at a safe place or in a box.
12. Completely remove plasticine or grease plug from the bores for the
cylinder lubrication. Wash away residues in the oil ducts by actuating
the cylinder Iiner Iube oil pump. For this purpose, adjust the cylinder
lubrication device to full amount (notch 9) and switch on the electric
motor.
13. Remove the funnel (22) taking care that no impurities get into the
crankcase.
14. Finally clean the cylinder liner manually.
▲ Attention! After the pistons have been installed and the cylinder
covers mounted in place, the instructions of the Operating Manual
(refer to Section 3/Engine Running-in) are to be observed for putting
into operation.

Number of Time per Number of

Type Length of Speed double strokes double stroke* double strokes
stroke (rpm) per min (s) required
(mm)
58/64 750 19 10 6 75-80
Table 1. Parameters for the honing of cylinder liners

* Applicable for a honing angle (§) of 45E

Alternative
Feature Checking/Measuring

1 2
Surface roughness Rz, Measuring instrument Technovit impression Finger nail test and visual
measured in the TDC (thermosetting synthetic) -- examination
zone for the top piston permits later evaluation of
ring and the middle of all three parameters
top piston ring lift
Honing angle Goniometer Angle template
Honing pattern, i.e. profile Examination of Examination using a
and distribution faxfilm impressions pocket lense, visual
of honing lines, (celluloseacetate film) checking -- requires
occurrance of “metall under the microscope empirical skill
jackets” (glazing and (50-fold magnification)
“pitting” along the
honing lines), unhoned
“holes” being left.
Table 2. Examining the running surface of cylinder liners after honing

6641 050.05--01 E 11.98 L 58/64 107/ 08

 X 135ƒ 45ƒ Honing angle Y 120ƒ 60ƒ Honing angle

Figure 4. Aid for making a honing angle template

6641 050.05--01 E 11.98 L 58/64 108/ 08

Cylinder head/Saftey valve

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 055...--04 E 06.98 101/ 01

Cylinder head bolts
Checking, untightening and tightening 055.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure operational reliability of bolted connections.

Brief description

Cylinder head bolts are to be checked at regular intervals by means of

hydraulic tensioning tools.
The work/steps include:
checking bolted connection,
untightening,
tightening.

Safety requirements

- Engine shut--down
- Engine secured against starting

Tools/appliances required

Quant Denomination No. Availability

4 Hydraulic tensioning tool 009.301 Standard
4 Tension nut 021.436 Standard
4 Sleeve 055.100 Standard
1 High--pressure pump 009.338 Standard
4 High--pressure hose 009.330 Standard
2 Tommy bar 10 000.263 Standard
2 Tommy bar 12 000.264 Standard
1 Open--jaw and ring spanner (set) -- Standard

Related work cards

Work card Work card Work card

000.30 009.01 009.03

6619 055.01--01 E 04.98 L 58/64 101/ 03

Operating sequence 1 -- Checking

Starting condition Rocker arm casing completely removed. Protection caps for cylinder head
bolts taken off. Threads, seats and nuts cleaned.

Steps 1. Mount four complete hydraulic tensioning tools onto bolts (2,4,6,8)
(refer to Figure 1 ), paying attention to centering (refer to work
card 009.01).
009.01

1-8 Position of the cylinder

head bolts

Figure 1. Hydraulic tensioning tool mounted on the cylinder head bolts

2. Using the tommy bar 450• turn back the tension nuts (1 1/4 turns).
3. Switch on high-pressure pump and tighten carefully until the nuts (2)
are free (refer to Figure 2 ). Ascertain the loosening pressures,
note them down and compare with preloading pressure as per work
card 000.30.
000.30

1 Cylinder head bolt

2 Nut
3 Cylinder head

Figure 2. Sectional view of a hydraulic tensioning tool mounted

4. Preload to specified pressure and tighten the nuts (2) with the tommy
bar.
5. Release pressure and detach all tensioning tools.
6. Change over the tensioning tools onto bolts (1,3,5,7) and carry out
the check as described in items 2-5.

Operating sequence 2 -- Releasing

Steps 1. Mount four complete hydraulic tensioning tools onto bolts (2,4,6,8),
paying attention to centering.
2. Back off the four tension nuts through 450• (1 1/4 turns), using the
tommy bar.
3. Carefully raise pressure in tensioning tools until the nuts (2) get
free.

6619 055.01--01 E 04.98 L 58/64 102/ 03

 4. Using the tommy bar (2), turn back the nuts (2), (refer to work
000.30).
card 000.30
5. Release pressure and detach all tensioning tools.
6. Change over the tensioning tools to bolts (1,3,5,7) and release them
as described in 2-4.
7. Release pressure and detach tensioning tools.

Operating sequence 3 -- Preloading

Steps 1. Mount four complete hydraulic tensioning tools onto bolts (1,3,5,7),
paying attention to centering. Using the tommy bar, tighten the
hydraulic tensioning tools so that the lower nuts of the cylinder head
bolts are seating on the cylinder crankcase.
2. Carefully raise pressure in tensioning tools to 1000 bar.
3. Tighten four nuts (2) hand-tight with the tommy bar.
4. Release pressure and detach all tensioning tools.
5. Change tensioning tools over to bolts (2,4,6,8) and preload them
000.30).
to 900 bar as described in item 2-4 (refer also to work card 000.30
6. Release pressure and detach tensioning tools.
Tip! There is no need to preload the bolts (1,3,5,7) once more. When
bolts (2,4,6,8) are preloaded, bolts (1,3,5,7) are released to such an extent
that all bolts are equally preloaded.

Important! When exchanging/replacing a cylinder head bolt

and preloading it hydraulically in subsequence, attention must be paid
that its temperature is equal to that of the other bolts. This is of special
importance in case of exchange/replacement of a cylinder head bolt with
the engine at operating temperature.
For removal and installation of the cylinder head bolt, refer to Figure 3 .
After having exchanged/replaced a cylinder head bolt (1), always secure
the hexagon bolt (5) with locking wire.

1 Cylinder head bolt

2 Sealing ring
3 Ring, 2-part
4 Clamping ring
5 Hexagon bolt, locking
wire
6 Holder

Figure 3. Exchanging of the cylinder head bolt

6619 055.01--01 E 04.98 L 58/64 103/ 03

Cylinder head
Removing and refitting 055.02

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Cylinder heads are to be disassembled within the scope of maintenance

and repair work.
The work/steps include:
dismounting components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems drained
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Suspension device 055.228 Standard
1 Support 055.228--1 Standard
1 Pilot rod 034.006 Standard
1 Shackle A2.5 002.456 Standard
1 Suspension link 002.484 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Hexagon screw drivers (set) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

000.08 000.30 055.01
111.02 289.01 434.01

6722 055.02--01 E 12.05 L 58/64 CD 101/ 06

Technical details

Term Information
Cylinder head with valves 2000 kg

1 Cylinder head bolt

2 Nut
5 Cylinder head
10 Backing ring
11 Push-rod covering
13 Cylinder crankcase
23 Hexagon socket bolt
Figure 1. Cylinder head with suspension device

Operating sequence 1 -- Removing the cylinder head

Starting condition Cooling water has been drained completely and cooling water for injection
valve cooling system (if fitted) has been drained.

▲ Attention! Do not drain cooling water into the bilge or into the
sewage system! Pump cooling water into a separate tank and reuse
it (cooling water reconditioning agent)!

The running gear has been turned so that the piston of the cylinder con-
cerned is in the ignition-TDC position (all valves closed). The rocker arm
casing has been dismantled, and the push-rods have been removed.

Steps 1. Loosen or remove all pipes and pipe unions from the cylinder head
concerned (5).
2. Partly remove the covering of the exhaust pipe.

6722 055.02--01 E 12.05 L 58/64 CD 102/ 06

 3. Open the clamp on the exhaust pipe connection (see Work Card
289.01).
289.01
434.01).
4. Dismantle the fuel injection pipe (see Work Card 434.01
055.01.
5. Untighten the cylinder head bolts (1) - see Work Card 055.01
6. Unscrew the nuts (2). Refer to Figure 2 .
7. Place the support (055.228-1) on the cylinder head (5), and attach it
by means of hexagon socket bolts (23). Refer to Figure 1 .
8. Screw the pilot rod (034.006) into the support.
9. Attach the suspension link (002.484) to the support using the shackle
(002.456) and fasten it to the lifting tackle.
10. Carefully remove the cylinder head (5), guiding it by means of the
pilot rod. Refer to Figure 3 .
▲ Attention! Do not damage the cylinder head bolts (1) and the cyl-
inder head sealing face during removal!
11. Place the cylinder head (5) on a clean support.
12. Remove the tools.
13. Remove the sealing ring (8).
14. Remove the O-ring seals (18 and 21) from the sleeves (19 and 20).
15. Cover all openings on the engine by suitable means, including the
openings of the push-rod covering (11).
16. Close the exhaust pipe connection on the exhaust pipe by means of
the closing cover.
17. Remove the O-ring seals (4, 6 and 7).
18. Clean the cylinder head (5) - see Operating Sequence 2.

1 Cylinder head bolt

2 Nut
5 Cylinder head
10 Backing ring
11 Push-rod covering
13 Cylinder crankcase

Figure 2. Cylinder head - Fitting the suspension device

6722 055.02--01 E 12.05 L 58/64 CD 103/ 06

 1 Cylinder head bolt 10 Backing ring 18 O-ring seal
3 Flange 11 Push-rod covering 19 Sleeve
4 O-ring seal 13 Cylinder crankcase 20 Sleeve
5 Cylinder head 14 Piston 21 O-ring seal
6 O-ring seal 16 Parallel pin
7 O-ring seal A Check bore hole
8 Seal B Check bore hole
9 Top land ring C Check bore hole

Figure 3. Removing/fitting the cylinder head

6722 055.02--01 E 12.05 L 58/64 CD 104/ 06

Operating sequence 2 -- Cleaning the cylinder head

Starting condition The cylinder head has been removed.

Steps 1. Remove the inlet and exhaust valves (see Work Card 113.01
113.01).
2. Check the inlet and exhaust ducts and the side facing the combustion
chamber with regard to deposits and, if necessary, remove deposits
adhering to them, but do not damage the surface in the process.
3. Check the cooling spaces for deposits, and remove the deposits if
necessary (see Work Card 000.08).
000.08
4. Clean the top of the cylinder head from oil sludge.
113.01).
5. Install the inlet and exhaust valves (see Work Card 113.01

Operating sequence 3 -- Fitting the cylinder head

Starting condition The cylinder head has been cleaned, and the sealing faces between the
cylinder head and the top land ring as well as the ones between the cylin-
der head and the exhaust pipe segment have been cleaned.

Steps 1. Insert a new sealing ring (8) into the groove.

2. Oil new O-ring seals (18 and 21) with clean lubricating oil and insert
them into the ring grooves, making sure that they are uniformly ten-
sioned over their entire circumferences and are not twisted. See Fig-
ure 3 .
3. Place the support (055.228-1) on the cylinder head (5), and attach it
by means of the hexagon socket bolts (23). See Figure 1 .
4. Screw the pilot rod (034.006) into the support.
5. Attach the suspension link (002.484) to the support by means of the
shackle (002.456) and fasten it to the lifting tackle.
6. Lift the cylinder head (5).
7. Oil new O-ring seals (4, 6 and 7) with clean lubricating oil and insert
them into the ring grooves, making sure that they are uniformly ten-
sioned over their entire circumferences and are not twisted. Refer to
Figure 3 .
8. Move the cylinder head (5) over the centre of the cylinder. See Fig-
ure 3 .
9. Loosen the hexagon socket bolts of the push-rod coverings (11) on
the cylinder crankcase (13).
Important! This permits the push-rod coverings to align themselves
with the cylinder head.
10. Fit the cylinder head (5) carefully, guiding it by means of the pilot rod.
▲ Attention! When positioning the cylinder head, observe the fol-
lowing:
: Do not damage the cylinder head bolts (1),
: pay attention to the parallel pin (16) and the sleeves (19 and 20),
: pay attention to the alignment of flanges (3)/push-rod
coverings (11)!
11. Remove the tools.
12. Screw the nuts (2) onto the cylinder head bolts (1) and tighten them
firmly by hand. Refer to Figure 2 .
055.01.
13. Tighten the cylinder head bolts (1) - see Work Card 055.01
14. Tighten the hexagon socket bolts of the push-rod covering (11) on the
cylinder crankcase (13).
434.01).
15. Fit the fuel injection pipe (see Work Card 434.01
16. Connect the exhaust pipe to the cylinder head (5) - see Work Card
289.01.
289.01
17. Fit the covering of the exhaust pipe.
18. Fit all the pipes and pipe unions on the respective cylinder head.

6722 055.02--01 E 12.05 L 58/64 CD 105/ 06

 19. After installation/fitting of all engine parts (push-rods, rocker arm
casing, etc.), fill cooling water into the engine and vent the cooling
water pipe.
20. After completing assembly work, check at operational cooling water
pressure whether the O-ring seals are in order and no water is leak-
ing from the check bore holes (A, B and C). See Figure 3 .
21. With the engine running, verify that no gas is leaking from the check
bore holes (A, B). See Figure 3 .
▲ Attention! If the cylinder head leaks despite the fact that the cylin-
der head screws have been tightened correctly, it must be detached
again and the sealing ring (8) has to be checked!

6722 055.02--01 E 12.05 L 58/64 CD 106/ 06

Cylinder head
Grinding of seating faces 055.03

Purpose of jobs to be done

Ensure correct execution of work,

assess wear pattern/condition,
restore contact pattern.

Brief description

In case the wear pattern of a valve seat is incorrect, the seat is to be

regenerated (continuous bearing area) by grinding.
The work concerns:
establishment of a correct contact pattern.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems drained
- Operating media systems closed/depressurised

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Milling and grinding tool 055.229 Standard
1 Tool rod 055.229--1 Standard
1 Guide tube 055.229--2 Standard
1 Stop disk 055.229--3 Standard
1 Extension 055.229--4 Standard
1 Guide bush (starting valve seat) 055.229--6 Standard
1 Milling head 055.229--8 Standard
1 Guide piece 055.229--10 Standard
1 Grinding wheel (injection valve seat) 055.229--11 Standard
1 Grinding wheel (starting valve seat) 055.229--14 Standard
1 Tap wrench 055.229--16 Standard
1 Plate 055.229--18 Standard
1 Clamping piece 055.229--20 Standard

6722 055.03--01 E 01.06 L 58/64 CD 101/ 07

 Qty Designation No. Availability
1 Small grinding plates (set) 055.229--34 Standard
1 Pliers for retaining rings 055.229--36 Standard
1 Cleaning device 055.108 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Grease (acid--free) -- Inventory
1 Depth gauge -- Inventory
1 Torch -- Inventory
1 Touching--test ink -- Inventory

Related work cards

Work card Work card Work card

055.02 161.01 221.01

1 Cylinder head
2 Insert
3 Insert
4 Insert
5 Washer
7 Washer
9 Pot sleeve
23 Retaining ring
24 Feather key
25 Hexagon nut
27 Washer
31 Hexagon nut
37 Hexagon nut
38 Stud

A Valve seat
B Permissible minimum
dimension

Figure 1. Cylinder head - Insert for injection valve

Preliminary remark

Important! Every time starting and injection valves are removed, the
respective valve seat in the cylinder head is to be checked by means of an
ink-contact “touching” test. This ink-contact “touching” test should show a
continuous, bearing surface on the valve seat. If this is not the case, the
valve seat has to be reground.

6722 055.03--01 E 01.06 L 58/64 CD 102/ 07

Marking on the tool components In order to facilitate the assignment of the stop disks, guide bushes and
grinding wheels to the individual valves, these have been marked as fol-
lows:

AS . . Starting valve
E . . . Injection valve.

1 Cylinder head
37 Hexagon nut
38 Stud

Figure 2. Valve bore for injection valve - Grinding the valve seat

Operating sequence 1 -- Grinding the injection valve seat

Starting condition The injection valve has been removed.

Steps 1. Check the small grinding plates (055.229-34) on the grinding wheel
(055.229-11).
Important! Pull used-up small grinding plates off the grinding wheel.
Remove adhering remainders of glue by means of quick-acting cleanser
Loctite 7061. Glue new small grinding plates onto the grinding wheel.

Number of small grinding plates:

Grinding wheel for injection valve . . 10 off (see Figure 2 ).

2. Insert the feather key (24) into the groove and slip the grinding wheel
(055.229-11) onto the tool rod (055.229-1). Refer to Figure 1 .
3. Slip the washer (27) on, screw the hexagon nut (25) onto the tool rod
and tighten it.
4. Fit the washer (5) with pot sleeve (9), washer (7) and nut (31) onto
the tool rod (055.229-1). Refer to Figure 1 .

6722 055.03--01 E 01.06 L 58/64 CD 103/ 07

 5. Slip the stop disk (055.229-3) onto the guide tube (055.229-2) until it
contacts the retaining ring (23), and secure it in place by means of
the second retaining ring (23). Refer to Figure 1 .
6. Insert the tool rod with the grinding wheel attached into the insert (2)
and place it on the valve seat (A).
7. Slip the guide tube with the stop disk attached over the tool rod and
introduce it until it contacts the insert (2).
8. Slip the guide piece (055.229-10) over the guide tube and place it on
the insert (4). Refer to Figure 2 .
Important! Make sure to install the guide piece correctly (diameter
of the guide piece/marking “E” on the guide piece).
9. Slip the clamping piece (055.229-20) over the tool rod (055.229-1)
and attach it to the tool rod by means of the hexagon socket bolts.
10. Slip the plate (055.229-18) all the way over the tool rod and studs
(38) and place it on the clamping piece, then secure it in place by
screwing the hexagon nuts (37) on loosely. Refer to Figure 2 .
11. Slip the extension (055.229-4) and the tap wrench (055.229-16) onto
the tool rod.
12. Move the grinding wheel back and forth by rotating the tap wrench.
▲ Attention! Only grind away enough material to ensure that the
valve seat (A) is bright over the entire width and without damage!
Therefore, remove the tool repeatedly and check the valve seat!
13. After completion of the grinding procedure, remove the tool.
14. Clean the valve seat (A) thoroughly using the cleaning device
(055.108). Refer to Figure 3 .

1 Cylinder head

Figure 3. Valve bore for injection valve - Cleaning the valve seat
15. Disassemble the tool, clean it and store it in the wooden box.
16. After repeated grinding of a valve seat (A), remove the cylinder head
(1) - see Work Card 055.02 -, determine the dimension (B) and note it
down. Refer to Figure 1 .
Important! If a measured dimension is smaller than the admissible
dimension, the insert (2) has to be replaced.

6722 055.03--01 E 01.06 L 58/64 CD 104/ 07

 Admissible minimum dimension (B):
Injection valve . . . . 48.3 mm.

Operating sequence 2 -- Grinding the starting valve seat

1 Cylinder head
5 Washer
7 Washer
9 Pot sleeve
23 Retaining ring
24 Feather key
25 Hexagon nut
27 Washer
31 Hexagon nut
39 Hexagon nut
40 Stud

A Valve seat
C Admissible minimum
dimension

Figure 4. Cylinder head - Valve bore for starting valve

Starting condition The starting valve has been removed.

Steps 1. Check the small grinding plates (055.229-34) on the grinding wheel
(055.229-14).
Important! Pull used-up small grinding plates off the grinding wheel.
Remove adhering remainders of glue by means of quick-acting cleanser
Loctite 7061. Glue new small grinding plates onto the grinding wheel.

Number of small grinding plates:

Grinding wheel for starting valve . . . 12 off (see Figure 5 ).

2. Insert the feather key (24) into the groove and slip the grinding wheel
(055.229-14) onto the tool rod (055.229-1). Refer to Figure 4 .
3. Slip the washer (27) on, screw the hexagon nut (25) onto the tool rod
and tighten it.
4. Fit the washer (5) with pot sleeve (9), washer (7) and nut (31) onto
the tool rod (055.229-1). Refer to Figure 4 .
5. Slip the guide bush (055.229-6) onto the guide tube (055.229-2) until
it contacts the retaining ring (23) and secure it in place by means of a
second retaining ring (23). Refer to Figure 4 .
6. Insert the tool rod with the grinding wheel attached into the valve bore
and place it on the valve seat (A).

6722 055.03--01 E 01.06 L 58/64 CD 105/ 07

 1 Cylinder head
39 Hexagon bolt
40 Stud

Figure 5. Valve bore for starting valve - Grinding the valve seat
7. Slip the guide tube with the guide bush attached over the tool rod and
insert it into the valve bore until it is seated.
8. Slip the guide piece (055.229-10) over the guide tube and place it on
the cylinder head (1). Refer to Figure 5 .
Important! Make sure to install the guide piece correctly (diameter
of the guide piece/markings “AS” on the guide piece).
9. Slip the clamping piece (055.229-20) over the tool rod (055.229-1)
and attach it to the tool rod by means of hexagon socket bolts.
10. Slip the plate (055.229-18) all the way over the tool rod and the studs
(40) and place it on the clamping piece and secure it in place by
screwing the hexagon nuts (39) on loosely. Refer to Figure 5 .
11. Slip the extension (055.229-4) and the tap wrench (055.229-16) onto
the tool rod.
12. Move the grinding wheel back and forth by rotating the tap wrench.
▲ Attention! Only grind away enough material to ensure that the
valve seat (A) is bright over the entire width and without damage!
Therefore, remove the tool repeatedly and check the valve seat!
13. After completion of the grinding procedure, remove the tool.
14. Clean the valve seat (A) thoroughly by means of the cleaning device
(055.108). Refer to Figure 6 .
15. Disassemble the tool, clean it and store it in the wooden box.

6722 055.03--01 E 01.06 L 58/64 CD 106/ 07

1 Cylinder head

Figure 6. Valve bore für starting valve - Cleaning the valve seat
16. After grinding a valve seat (A) repeatedly, remove the cylinder head
(1) - see Work Card 055.02 -, determine the dimension (C) and note
it down. Refer to Figure 4 .
Important! If a measured dimension is smaller than the admissible
dimension, the cylinder head has to be replaced.

Admissible minimum dimension (C):

Starting valve . . . . 52.5 mm.

6722 055.03--01 E 01.06 L 58/64 CD 107/ 07

Valve seat rings
Removing and installing 055.04

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Removal and installation of valve seat rings are not part of the work
specified in the maintenance schedule.
The work/steps include:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1
1 Assistant 1

Tools/appliances required

Qty Designation No. Availability

1 Extractor 113.281 Standard
1 Extractor 002.513 Standard
1 Counterbrace 002.525 Standard
1 Mounting device 113.277 Standard
1 Thrust pad 113.280 Standard
1 Thrust pad 114.057 Standard
1 Guide piece 113.277--3 Standard
1 Handle 113.277--4 Standard
1 Clamping piece 113.277--5 Standard
1 High--pressure pump 009.341 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning device (hollow piston) 009.022 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Gloves (neoprene) -- Inventory

6722 055.04--01 E 12.05 L 58/64 CD 101/ 08

 Qty Designation No. Availability
1 Micrometer (inside) -- Inventory
1 Sliding caliper -- Inventory
1 Welding apparatus (autogenous) -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

009.03 009.05 055.02
055.05 113.01

Preliminary remark

Inlet or exhaust valve seat rings must be removed and renewed

- if corrosion and impact damage have occurred that cannot be remedied
by turning on a lathe,
- if material has broken out or if there are burn-through points or stress
cracks and
- if the rework limit has been reached (see Work Card 113.04
113.04).

2 Cylinder head
3 Inlet valve seat ring
4 Exhaust valve seat ring
5 O-ring seal
6 O-ring seal
7 Bush
8 Welding torch

W Heating points
Figure 1. Heating the valve seat rings

6722 055.04--01 E 12.05 L 58/64 CD 102/ 08

Operating sequence 1 -- Removal of an inlet or exhaust valve seat ring

Starting condition The cylinder head has been removed, clamped into the cylinder head turn-
over stand (see Work Card 055.05)
055.05 and cleaned carefully of oil and fuel.
The corresponding valve has been removed. Combustion chamber side
points upwards.

▲▲▲ Danger! Removing an exhaust valve seat ring (4):

If the working instructions are not observed, the impact of severe
heat may cause decomposition of the O-ring seals (5 and 6) which
results in the development of highly toxic and caustic vapours (hy-
000.21!
drofluoric acid) - see Work Card 000.21

2 Cylinder head 10 Shell 13 Hexagon nut

3 Inlet valve seat ring 11 Crown 14 Adjusting nut
9 Expanding unit 12 Bolt 15 Spindle

Figure 2. Removal of the valve seat ring

Steps 1. Using a welding torch (8), heat up the inlet valve seat ring (3) or the
exhaust valve seat ring (4) on the valve seat at four points, offset by
approximately 90ƒ , until the material starts to melt. See Figure 1 .

6722 055.04--01 E 12.05 L 58/64 CD 103/ 08

 ▲ Attention! Removal of the inlet or exhaust valve seat rings with-
out previous heating up and cooling down is not possible!
2. Allow the cylinder head (2) with the valve seat ring to cool down.
Important! The tangential stress decays in the zone of heating be-
cause the yield point is exceeded.
3. Slacken the expanding unit (9) until the extractor (002.513) can be
inserted in the inlet or exhaust valve seat ring (3 or 4). See Fig-
ure 2 /A.
4. Place the complete extractor (113.281, consisting of the counterbrace
and extractor) over the valve seat ring.
5. After opening the hexagon nuts (13), align the bolts (12) so that they
snugly rest on the cylinder head (2). Then tighten the hexagon nuts
again.
6. Lower the shells (10) by turning the spindle (15) until they are in front
of the gap between the inlet or exhaust valve seat ring (3 or 4) and
the cylinder head (2).
7. Hold the crown (11) and expand the extractor as far as possible by
turning the spindle (15). See Figure 2 /B.
▲ Attention! Make sure that the shells engage in the gap between
the valve seat ring and the cylinder head!
8. By uniformly turning the adjusting nut (14), extract the inlet or ex-
haust valve seat ring (3 or 4). See Figure 2 /C.
▲ Attention! Make sure that the valve seat ring is extracted uni-
formly, i.e. that it does not tilt!
9. Remove the valve seat ring including the tool from the cylinder
head (2).
10. Remove the tools.
11. When removing an exhaust valve seat ring (4), remove the O-ring
seals (5 and 6).
▲ Attention! In case decomposition or brown discolouration is de-
tected on the O-ring seals, neoprene gloves must be worn when
handling them!

2 Cylinder head

K Diameter of the locating

bore for inlet valve seat
ring
L Diameter of the locating
bore for exhaust valve
seat ring
M Contact face on the cylin-
der head for inlet valve
seat ring
N Contact face on the cylin-
der head for exhaust valve
seat ring
Figure 3. Inlet and exhaust valve seat ring - locating bores in the cylinder head
12. Check the locating bore in the cylinder head (2) for damage and
check the dimensions (K and L) at several points. See Figure 3

Max. admissible dimension (K): Inlet valve 195.030 mm

Max. admissible dimension (L): Exhaust valve 209.030 mm.

6722 055.04--01 E 12.05 L 58/64 CD 104/ 08

 ▲ Attention! If the dimensions (K and L) are exceeded, oversize
valve seat rings can be obtained from MAN B&W Diesel AG! These
require reworking of the locating bore!

1 Valve guide 3 Inlet valve seat ring 17 Hexagon nut

2 Cylinder head 16 Hexagon nut

Figure 4. Installation of a valve seat ring - mounting device

Operating sequence 2 -- Installation of an inlet valve seat ring

Starting condition The cylinder head has been clamped into the cylinder head turnover stand
(combustion chamber side points upwards). The locating bore in the cylin-
der head has been cleaned and measured.

Steps 1. Slide the guide piece (113.277-3) into the valve guide (1). Slip the
clamping piece (113.277-3) on and screw the hexagon nut (16) on by
hand until it is seated (do not use the open-jaw or ring wrench to do
so).
2. Screw the handle (113.277-4) into the thrust pad (113.280) until it bot-
toms.
3. Place the thrust pad on the new inlet valve seat ring (3), slip them
both over the guide piece and manually centre them in the locating
bore. See Figure 5 /D and E.
4. Unscrew the handle from the thrust pad.
5. Slip the hydraulic hollow-piston tensioning device (009.022) over the
guide piece and screw the hexagon nut (17) on, hand-tight. Refer to
Figure 6 /F.
6. Connect the high-pressure hose (009.306) to the hydraulic hollow-
piston tensioning tool and the high-pressure pump (009.341). Con-
nect the oil pressure gauge (0 - 400 bar) to the high-pressure pump.

6722 055.04--01 E 12.05 L 58/64 CD 105/ 08

 ▲ Attention! While pumping, watch the oil pressure gauge! A
sudden pressure increase during the forcing-in process is an indica-
tion that the inlet valve seat ring has become tilted!

1 Valve guide
2 Cylinder head
3 Inlet valve seat ring
16 Hexagon nut
Figure 5. Installation of an inlet valve seat ring - centring

1 Valve guide
2 Cylinder head
3 Inlet valve seat ring
16 Hexagon nut
17 Hexagon nut
Figure 6. Installation of an inlet valve seat ring - forcing in

7. Start operation of the high-pressure pump (see Work Card 009.03

009.03),
and pump up the hydraulic hollow-piston tensioning device slowly.
8. Pump up the hydraulic hollow-piston tensioning device until the inlet
valve seat ring (3) is seated. Refer to Figure 6 /G.

6722 055.04--01 E 12.05 L 58/64 CD 106/ 08

 ▲ Attention! Carefully observe the oil pressure gauge shortly before
the inlet valve seat ring becomes seated! Seating is indicated by a
vigorous pressure increase!
9. Release the pressure.
10. Disconnect the high-pressure hose from the hydraulic hollow-piston
tensioning device and high-pressure pump.
11. Remove the tools.
12. Verify that the inlet valve seat ring rests snugly, i.e. without gap, on
the contact face (M) of the locating bore.
13. Turn the inlet valve seat ring (3) by means of a valve seat lathe and
carry out an ink contact “touching” test using a new valve cone (see
Work Cards 113.03 and 113.04).
113.04
14. Install the inlet valve using a new or reground valve cone (see Work
113.01).
Card 113.01

Operating sequence 3 -- Installation of an exhaust valve seat ring

Starting condition The cylinder head has been clamped into the cylinder head turnover stand
(combustion chamber side points upwards). The locating bore in the cylin-
der head and the bush have been cleaned. The locating bore has been
measured.

1 Valve guide
2 Cylinder head
4 Exhaust valve seat ring
5 O-ring seal
6 O-ring seal
16 Hexagon nut
Figure 7. Installation of an exhaust valve seat ring - centring

Steps 1. Slide the guide piece (113.277-3) into the valve guide (1). Slip the
clamping piece (113.227-5) on, and screw the hexagon nut (16) on by
hand until it is seated (do not use the open-jaw or ring wrench to do
so).
2. Oil a new O-ring seal (5) with clean lubricating oil and insert it in the
ring groove of the bush (7), making sure that it is not twisted.
3. Oil a new O-ring seal (6) with clean lubricating oil and insert it in the
ring groove of the exhaust valve seat ring, making sure that it is uni-
formly tensioned over its entire circumference and is not twisted.
4. Screw the handle (113.277-4) into the thrust pad (114.057) until it bot-
toms.

6722 055.04--01 E 12.05 L 58/64 CD 107/ 08

 5. Place the thrust pad on the new exhaust valve seat ring (4), slip them
both over the guide piece and manually centre them in the locating
bore. See Figure 7 /H and I.
6. Unscrew the handle from the thrust pad.

1 Valve guide
2 Cylinder head
4 Exhaust valve seat ring
16 Hexagon nut
17 Hexagon nut
Figure 8. Installation of an exhaust valve seat ring - forcing it in
7. Slip the hydraulic hollow-piston tensioning device (009.022) over the
guide piece, and screw the hexagon nut (17) on, hand-tight. Refer to
Figure 8 /O.
8. Connect the high-pressure hose (009.306) to the hydraulic hollow-
piston tensioning device and the high-pressure pump (009.341).
Connect the oil pressure gauge (0 - 400 bar) to the high-pressure
pump.
009.03),
9. Start operation of the high-pressure pump (see Work Card 009.03
and slowly pump up the hydraulic hollow-piston tensioning device.
▲ Attention! While pumping, watch the oil pressure gauge! A
sudden pressure increase during the forcing-in process is an indica-
tion that the exhaust valve seat ring has become tilted!
10. Pump up the hydraulic hollow-piston tensioning device until the ex-
haust valve seat ring (4) is seated. See Figure 8 /P.
▲ Attention! Carefully observe the oil pressure gauge shortly before
the exhaust valve seat ring becomes seated! Seating is indicated by
a vigorous pressure increase!
11. Release the pressure.
12. Disconnect the high-pressure hose from the hydraulic hollow-piston
tensioning device and the high-pressure pump.
13. Remove the tools.
14. Check the gap between the exhaust valve seat ring (4) and the cylin-
der head (2) at several points to ensure that the width is uniform.
15. Turn the exhaust valve seat ring (4) by means of the valve seat lathe
and carry out an ink-contact “touching” test using a new valve cone
(see Work Cards 113.03 and 113.04).
113.04
16. Insert the exhaust valve using a new or reground valve cone (see
114.01).
Work Card 114.01

6722 055.04--01 E 12.05 L 58/64 CD 108/ 08

Cylinder head with turnover stand
Machining 055.05

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

On cylinder heads, various jobs are to be carried out at regular intervals.

For this purpose, the turnover stand is to be used.
The work includes:
clamping components.

Tools/appliances required

Quant Denomination No. Availability

1 Turnover stand 055.131 Standard
1 Open--jaw and ring spanner (set) -- Standard

Preliminary remarks

The turnover stand is suitable for:

- Thorough cleaning and inspection of cylinder heads,

- Grinding valve seat faces in the cylinder head (refer to work
055.03),
card 055.03
- Re-milling valve seat faces in the cylinder head (refer to work
055.04),
card 055.04
- Checking valve seats (refer to work card 113.03
113.03),
- Measuring inlet and outlet valve seat faces (refer to work card 113.08
113.08),
- Machining valve seats with valve cages clamped in cylinder head (refer
to work card 113.04).
113.04

Operating sequence 1 -- Clamping the cylinder head

Starting condition Cylinder head with lifting device connected to lifting tackle.

Steps 1. Set clamping table (3) into horizontal position by turning the
handwheel (4), bolts (6) to the top with free end.
2. Place cylinder head on the clamping table with the gas ducts
across the turning shaft axis (5) (refer to Figure 1 ).

6619 055.05--02 E 05.98 L 58/64 101/ 02

 3. Using washers (7) and hexagon nuts (8), screw down cylinder
head (10) and remove lifting device.
Now, with the arresting lever (12) tilted upwards, the cylinder head
may be turned to any position by turning the handwheel (4).
Fixation of clamping table is possible at positions 45ƒ from each
other by placing arresting lever into groove of notched disk.
▲ Attention! Always make sure that the arresting lever is placed in
a groove of the notched disk when working on the clamped cylinder
head.

Important! Measuring and refacing of valve seat faces is only to be

carried out on valve cages clamped in accordance with instructions (refer
113.01, 114.01
to work cards 113.01 114.01).

1 Collecting pan 8 Hexagon nuts

2 Frame 9 Valves (installed)
3 Clamping table 10 Cylinder head
4 Handwheel for gear 11 Notched disk
5 Axis, turning shaft 12 Arresting lever
6 Fixing bolts 13 Envelope circle (cylinder head with valves)
7 Washers

Figure 1. Turnover stand for cylinder head

6619 055.05--02 E 05.98 L 58/64 102/ 02

Crankcase cover/Saftey valve/
Coverings

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 073--04 E 06.98 101/ 01

Safety valve on the crankcase cover
Checking, overhauling 073.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure/restore operational reliability.

Brief description

Safety valves on the crankcase covers are to be examined for ease of

motion at regular intervals.
The work/steps include:
checking components,
disassembling and assembling components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Torque wrench 20--200 Nm 008.002 Standard
1 Adapter 12.5x10 001.922 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Screw drivers (set) -- Standard
1 Side nippers -- Inventory
1 Locking wire -- Inventory
1 Pliers for locking wire -- Inventory
1 Loctite 270 -- Inventory

Related work cards

Work card Work card Work card

000.19

6641 073.01--02 E 04.05 L 58/64 101/ 03

Technical details

Term Information
Safety valve 24.5 kg

Operating sequence 1 -- Disassembly of the safety valve

Starting condition The crankcase cover with safety valve has been removed.

Steps 1. Unscrew the hexagon bolts (18), and take the safety valve off the
crankcase cover (4).
2. Remove the seal (11).
3. Remove the locking wire (14).
4. Bend the tab washers (16) backward, and unscrew the hexagon nuts
(15).
5. Take the cover (13), compression spring (10), flame shields (21),
banded filter (20), valve plate (9) as well as the spacer pipes (17) off.
6. Remove the O-ring seal (8).
7. Clean all the individual components, check them for damage and
renew them if necessary.

Operating sequence 2 -- Assembly of the safety valve

Starting condition All individual components have been cleaned and damaged parts re-
newed.

Steps For assembly of the safety valve, proceed in the reverse order followed for
disassembly (see operating sequence 1).
Pay attention to the following:
- Stick a new O-ring seal (8) into the ring groove, making sure that it is
000.19).
not twisted (see Work Card 000.19
- Screw the hexagon nuts (15) including tab washers (16) onto the
distance bolts (12), and tighten them applying a torque of max.
44 Nm. Bend the tab washers over in order to lock the hexagon
nuts in place. Refer to Figure 1 .
- Use a new seal (11).
- Pass the hexagon bolts (18) including new lock washers (19) through
the safety valve, screw the bolts into the crankcase cover (4) and
tighten them applying a torque of max. 44 Nm.
- After assembly of all parts, verify that the safety valves moves easily.

6641 073.01--02 E 04.05 L 58/64 102/ 03

 4 Crankcase cover
8 O-ring seal
9 Spring plate
10 Compression spring
11 Seal
12 Distance bolt
13 Cover
14 Locking wire
15 Hexagon nut
16 Lock washer
17 Spacer pipe
18 Hexagon bolt
19 Lock washer
20 Banded filter
21 Flame shields
22 Sealing plate

Figure 1. Safety valve

6641 073.01--02 E 04.05 L 58/64 103/ 03

Camshaft drive

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 100--04 E 06.98 101/ 01

Camshaft drive
Checking 100.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

The camshaft drive is to be inspected for changes at regular intervals, the

wear pattern is to be assessed so that sources of disturbances are
recognized and, if necessary, remedied in time.
The work includes:
checking components.

Tools/appliances required

Quant Denomination No. Availability

1 Feeler gauge (set) 000.451 Standard
1 Open--jaw and ring spanner (set) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.31 020.03

Operating sequence 1 -- Checking camshaft drive

Tip! It is recomended to have repair work/overhaul of the camshaft

drive carried out in a service base.
If circumstances require repair to be carried out by the own crew,
attention should be paid that all mounting bolts of the camshaft drive
are tightened to the torque loadings as specified in work cards 000.30
000.31.
and 000.31

Starting condition Cover removed from camshaft drive casing.

Steps 1. Make visual inspection of all gearwheels.

2. Measure and note down gear backlash and bearing clearances, using
a feeler gauge (000.451), and compare with the values as specified
(refer to Operating Manual/Technical Data).
3. Check functioning of spray nozzles. If foulded, blow out with
compressed air.
4. Check all bolted connections for correct tightening torque.

6619 100.01--02 E 05.98 L 58/64 101/ 02

 ▲ Attention! Do not turn the engine when the gear train from
crankshaft to camshaft have to be interrupted in the course of
repair work, unless push-rods of inlet and exhaust valves have
been removed (otherwise the valves may become damaged by
the upward moving piston).
When reinstalling or replacing gearwheels, see that the match-marks
are in alignment. The marks are to coincide when the piston of cylinder
No. 1 is in ignition TDC.
020.03.
For installing the crankshaft gearwheel (1) refer to work card 020.03

1 Driving gearwheel (two-part) on crankshaft A Reference dimension

2 Pair of intermediate wheels 195 á 1 for non-reversible engines
3 Axle 78 á 1 for reversible engines
4 Spacer B Reference dimension
5 Intermediate wheel 174.4 (for marking)
6 Gearwheel on camshaft M Marking
7 Butting ring

Figure 1. Camshaft drive

Important! The figure shows the gearwheel markings with

cylinder No. 1 in ignition TDC. There is no marking on intermediate
wheel (5)!

6619 100.01--02 E 05.98 L 58/64 102/ 02

Camshaft bearing

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 102--01 E 06.98 101/ 01

Camshaft bearing
Removing and installing 102.01

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Bearing shells are to be checked at regular intervals. From wear

conditions and appearance of the bearing shell running surface,
conclusions can be drawn on the load conditions, lube oil care etc.
The work/steps include:
removal of components,
checking of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

2 Sleeve 030.167 Standard
2 Nut 012.010 Standard
2 Hydraulic tensioning tool 009.346 Standard
1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.330 Standard
1 Torque wrench 140--760 Nm 008.004 Standard
1 Adapter 25x20 001.924 Standard
1 Screw driver insert 22x25 001.861 Standard
1 Feeler gauge (set) 000.451 Standard
2 Tommy bar 6 000.261 Standard

Related work cards

Work card Work card Work card

000.11 000.30 009.03
009.07 027.02

6619 102.01--02 E 05.98 L 58/64 101/ 03

Operating sequence 1 -- Checking bearing studs

Starting condition Camshaft covers have been removed.

Steps 1. Mount complete tandem tensioning tool (009.346) onto the two
009.07), paying attention to the
studs (1) (refer to work card 009.07
centering (refer to Figure 1 and 2 ).
2. Switch on high-pressure pump (009.338), ascertain release
pressures for both nuts (2), note the values down and compare
000.30).
them with the preloading pressure (refer to work card 000.30
3. Raise pressure in high-pressure pump to specified preloading
pressure and retighten both nuts (2).
4. Release pressure and detach the complete tensioning tools.
5. Unscrew cylindrical botls (6) by approximately 60ƒ and retighten
000.30).
to the specified torque (refer to work card 000.30

Operating sequence 2 -- Removing bearing

▲ Attention! Never remove two bearings adjacent to each other at

the same time. I. e. every second bearing remains installed and
tightened (camshaft must remain supported).
When removing a camshaft bearing, first unscrew the cylindrical
bolts (6) and then the nuts (2).

Steps 1. Unscrew cylindrical bolts (6) and remove (refer to Figure 1 ).

2. Detach lube oil supply pipe.
3. Mount complete tandem tensioning tool (009.346) onto the two
009.07).
studs (refer to work card 009.07
4. Raise pressure in tensioning tool until the nuts (2) come loose.
5. Back off the two nuts (2) by the perscribed value (refer to work
000.30).
card 000.30
6. Release pressure and detach the complete tensioning tool.
7. Remove bearing cap.
8. Turn out the bearing shells. If necessary, relieve camshaft locally by
placing hardwood wedges (do not turn the engine in this situation).
9. Carefully clean the bearing shells and check running surface (refer to
000.11). Renew the bearing shells if necessary.
work card 000.11
Important! Bearing shells will be delivered in ready-for-installation
condition. Therefore no mechanical processing/machining must be carried
out on bearing shells, neither on new nor on used ones.

Operating sequence 3 -- Installing bearing

Starting condition Bearing shells cleaned and lightly oiled.

Important! Make sure that tightening is carried out in the correct

order.

Steps 1. Turn (roll) in one bearing shell half (4) between camshaft and casing
by hand. If necessary, place hardwood wedges to relieve the
camshaft locally.
2. Place second bearing shell half, align both bearing shells axially and
turn them until marking (M) coincides with the parting line. This is to
ensure that positioning pin (5) in the bearing cap is seated in the
recesses in the bearing shells (refer to Figure 1 ).

6619 102.01--02 E 05.98 L 58/64 102/ 03

 3. Fit the bearing cap (remove wooden wedges for camshaft support,
if any), screw on the nuts (2) and mount handtight with tommy bar.
Gap, if any, between bearing cap (3) and engine crankcase to be
equal on both sides.
4. Tighten cylindrical bots (6) in a first step to specified torque (refer to
work card 000.30).
000.30
5. Mount hydraulic tensioning tools (009.346) (refer to work
card 009.07)
009.07 and tighten studs (1) to specified value (refer
000.30).
to work card 000.30
6. Tighten cylindrical bolts (6) in a second step to specified torque
(refer to work card 000.30).
000.30
7. Remove tensioning tools, connect lube oil pipes.
8. Measure bearing clearances and enter in records.
9. Refit camshaft covers.
Important! Check the last camshaft bearing at free end (refer
027.02).
to work card 027.02

1 Stud
3 Bearing cap
4 Bearing shell half
5 Positioning pin
6 Cylindrical bolt
M Marking

Figure 1. Releasing and tightening of the camshaft bearing studs

1 Stud
2 Nut
3 Bearing cap

Figure 2. Attached tandem hydraulic tensioning tool (009.346) with clamping sleeve and nut

6619 102.01--02 E 05.98 L 58/64 103/ 03

Rocker arm/Rocker arm casing

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 111--04 E 06.98 101/ 01

Valve clearance
Checking and adjusting 111.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

permit/support economic operation,
prevent operating problems/damage.

Brief description

The valve clearance is to be determined and, if necessary, corrected at

regular intervals.
The work includes:
checking/adjusting the valve clearance.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5
1 Assistant 0.5

Tools/appliances required

Qty Designation No. Availability

1 Setting gauge 0.5 113.156 Standard
1 Setting gauge 1.3 113.122 Standard
1 Setting tool 111.135 Standard
1 Socket wrench 111.135--1 Standard
1 Socket wrench 111.135--2 Standard
1 Locating screw M12 111.136 Standard
1 Locating screw M16 111.137 Standard
1 Torque wrench 20--200 Nm 008.002 Standard
1 Adapter 12.5x10 001.922 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Feeler gauge (set) 000.451 Standard

6722 111.01--01 E 12.05 L 58/64 CD 101/ 06

Related work cards

Work card Work card Work card

000.30 111.02

1 Exhaust rocker arm

2 Bearing block
3 Inlet rocker arm
4 Rocker arm casing
5 Cylinder head cover
6 Hexagon nut
7 Valve adjuster

Figure 1. Rocker arm casing with rocker arms

Preliminary remarks

The valve clearance must be checked and, if necessary, adjusted when-

ever new parts are installed or the rocker arm casing is fitted again after
maintenance work.

Operating sequence 1 -- Checking the valve clearance

Starting condition Engine is cold (all engine parts have the same temperature).

▲ Attention! If the engine is at operating temperature, at the earliest

six hours after shutting down!

Running gear of the cylinder concerned has been turned to the ignition-
TDC position (inlet and exhaust valves are closed).

Steps 1. Open the cylinder head cover (5).

2. Insert the locating screw (111.136) through the bearing block (2) and
screw it into the inlet rocker arm (3). See Figures 2 and 3 .
Important! It may be necessary to raise the inlet rocker arm slightly
by hand.

6722 111.01--01 E 12.05 L 58/64 CD 102/ 06

1 Exhaust rocker arm
2 Bearing block
3 Inlet rocker arm
8 Inlet valve
9 Exhaust valve
Figure 2. Setting tools
3. Insert the locating screw (111.137) through the bearing block (2) and
screw it into the exhaust rocker arm (1). See Figures 2 and 3 .
Important! It may be necessary to raise the exhaust rocker arm
slightly by hand.
4. Tighten both locating screws to a torque of 40 Nm.

1 Exhaust rocker arm

2 Bearing block
3 Inlet rocker arm

Figure 3. Raising the inlet and exhaust rocker arms

Important! It is necessary to tighten the locating screws to the

specified torque in order to ensure that the inlet and exhaust rocker arms
rest on the push-rods without clearance.

6722 111.01--01 E 12.05 L 58/64 CD 103/ 06

 5. In each case, measure the valve clearance (A) for the inlet and ex-
haust valves (8 and 9) between the valve stem and the ball cup by
means of the thickness gauges (000.451), and note it down.

For the specified values, see Volume B1 / Operating Instruc-

tions.

6. If necessary, readjust the valve clearance (see operating se-

quence 2).
7. Unscrew and remove both locating screws (111.136 and 111.137).
8. Close the cylinder head cover (5).

1 Exhaust rocker arm

9 Exhaust valve

A Valve clearance

Figure 4. Adjusting the valve clearance

Operating sequence 2 -- Adjusting the valve clearance

Starting condition Engine is cold (all engine parts have the same temperature).

▲ Attention! If the engine is at operating temperature, at the earliest

six hours after shutting down!

Running gear of the cylinder concerned has been turned to the ignition-
TDC position (inlet and exhaust valves are closed).

Steps 1. Open the cylinder head cover (5).

2. Insert the locating screw (111.136) through the bearing block (2) and
screw it into the inlet rocker arm (3). See Figures 2 and 3 .
Important! It may be necessary to raise the inlet rocker arm slightly
by hand.
3. Insert the locating screw (111.137) through the bearing block (2) and
screw it into the exhaust rocker arm (1). See Figures 2 and 3 .
Important! It may be necessary to raise the exhaust rocker arm
slightly by hand.
4. Tighten both locating screws to a torque of 40 Nm.

6722 111.01--01 E 12.05 L 58/64 CD 104/ 06

 Important! It is necessary to tighten the locating screws to the
specified torque in order to ensure that the inlet and exhaust rocker arms
rest on the push-rods without clearance.

1 Exhaust rocker arm

3 Inlet rocker arm
6 Hexagon nut
7 Valve adjuster
8 Inlet valve
9 Exhaust valve
Figure 5. Adjusting the valve clearance

5. Adjust the valve clearance on the inlet valves (8) - see Figure 5 :
6. Slip the socket wrench (111.135-2) onto the hexagon nut (6).
7. Insert the socket wrench (111.135-1) through the socket wrench
(111.135-2) and slip it onto the valve adjuster (7).
8. Loosen the hexagon nut (6) using the socket wrench (111.135-2),
holding the valve adjuster (7) by means of the socket wrench
(111.135-1).
9. Turn the valve adjuster (7) back.
10. Slide the setting gauge (113.156) between the valve stem and the
ball cup.
11. Screw the valve adjuster (7) in until the ball cup rests on the setting
gauge (113.156) without clearance.
12. With the setting gauge inserted, tighten the hexagon nut (6), holding
the valve adjuster (7) by means of the socket wrench (111.135-1).
13. Take the setting tool (111.135) off and remove the setting gauge.
14. Adjust the valve clearance on the second inlet valve in the same way.
15. Adjust the valve clearance on the exhaust valves (9) - see Fig-
ure 5 :
16. Slip the socket wrench (111.135-2) onto the hexagon nut (6).
17. Insert the socket wrench (111.135-1) through the socket wrench
(111.135-2) and slip it onto the valve adjuster (7).
18. Loosen the hexagon nut (6) by means of the socket wrench
(111.135-2), holding the valve adjuster (7) by means of the socket
wrench (111.135-1).
19. Turn the valve adjuster (7) back.
20. Slide the setting gauge (113.122) between the valve stem and the
ball cup.
21. Screw the valve adjuster (7) in until the ball cup rests on the setting
gauge (113.122) without clearance.
22. With the setting gauge inserted, tighten the hexagon nut (6), holding
the valve adjuster (7) by means of the socket wrench (111.135-1).
23. Take the setting tool (111.135) off and remove the setting gauge.

6722 111.01--01 E 12.05 L 58/64 CD 105/ 06

 24. Adjust the valve clearance on the second exhaust valve in the same
way.
25. Unscrew both locating screws (111.136 and 111.137) and remove
them.
26. Close the cylinder head cover (5).

6722 111.01--01 E 12.05 L 58/64 CD 106/ 06

Rocker arm casing with rocker arms
Removing and refitting 111.02

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Rocker arm casings are to be disassembled within the scope of

maintenance and repair work.
The work/steps include:
dismounting components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5
1 Assistant 0.5

Tools/appliances required

Qty Designation No. Availability

1 Suspension device 111.134 Standard
1 Pilot rod 034.006 Standard
1 Shackle A2.0 002.455 Standard
1 Suspension link 002.484 Standard
1 Locating screw M12 111.136 Standard
1 Locating screw M16 111.137 Standard
1 Closing cover 055.233 Standard
1 Torque wrench 20--200 Nm 008.002 Standard
1 Torque wrench 140--760 Nm 008.004 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Standard
1 Adapter 20x25 001.928 Standard

6722 111.02--01 E 12.05 L 58/64 CD 101/ 06

 Qty Designation No. Availability
1 Adapter 25x20 001.924 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Screw driver insert 22x25 001.861 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

000.30 111.01
111.01

Technical details

Term Information
Rocker arm casing with rocker arms 1150 kg

1 Hexagon socket bolt

2 Pipe coupling
3 Charge-air pipe section

Figure 1. Charge-air pipe - top view: pipe couplings fitted / bottom view: pipe
couplings shifted

6722 111.02--01 E 12.05 L 58/64 CD 102/ 06

Operating sequence 1 -- Checking

Starting condition The running gear of the cylinder concerned has been turned to the igni-
tion-TDC position (inlet and exhaust valves are closed).
Arbeitsschritte - Check valve clearance, bolted connections and rocker arm lubrication
at the intervals specified in the maintenance schedule.
- During every removal operation and during overhaul work, check indi-
vidual parts for wear.
- Purge oil bores in the rocker arms with compressed air.
- Turn the engine with turning gear, checking whether the inlet and ex-
haust valves always follow the movements of the rocker arms.

2 Pipe coupling
3 Charge-air pipe section

Figure 2. Pipe coupling between the charge-air pipe sections (sectional view)

Operating sequence 2 -- Removing the rocker arm casing

Starting condition The running gear of the cylinder concerned has been turned to the igni-
tion-TDC position (inlet and exhaust valves are closed).

Steps 1. Undo the hexagon socket bolts (1) and shift the pipe coupling (2) to
the side. See Figure 1 .
Important! Depending on the space conditions, shove the pipe
coupling onto the charge-air pipe section of the neighbouring cylinder or
the charge air pipe section of the rocker arm casing to be removed.
2. Detach the lube oil supply pipe from the rocker arm casing (13) and
protect it against dirt ingress.
3. Remove the fastener for the indicator valve from the rocker arm
casing (13).
4. Open the cylinder head cover (14).
5. Insert the locating screw (111.136) through the bearing block (9),
screw it into the inlet rocker arm (12) and tighten it, hand-tight. See
Figures 4 and 5 .
Important! It may be necessary to raise the inlet rocker arm slightly
by hand.
6. Insert the locating screw (111.137) through the bearing block (9),
screw it into the exhaust rocker arm (7) and tighten it, hand-tight.
See Figures 4 and 5 .
Important! It may be necessary to raise the exhaust rocker arm
slightly by hand.
7. Place the suspension device (111.134) onto the rocker arm casing
(13) and attach it by means of the hexagon bolts (15 and 16). See
Figures 4 and 5 .

6722 111.02--01 E 12.05 L 58/64 CD 103/ 06

 6 Hexagon socket bolt
7 Exhaust rocker arm
8 Hexagon socket bolt
9 Bearing block
10 Cylinder head
11 Parallel pin
12 Inlet rocker arm
13 Rocker arm casing
14 Cylinder head bolt
Figure 3. Rocker arm casing with rocker arms and charge-air pipe section
8. Attach the suspension link (002.481) to the support by means of the
shackle (002.455) and fasten the lifting tackle to the suspension link.
9. Screw the pilot rod (034.006) into the support.
10. Loosen and unscrew the hexagon socket bolts (6 and 8). See Fig-
ure 5 .

7 Exhaust rocker arm

12 Inlet rocker arm
13 Rocker arm casing
15 Hexagon bolt M20x300
16 Hexagon bolt M20x180

Figure 4. Rocker arm casing - Tools for removal/fitting

11. Raise the rocker arm casing (13) carefully, guiding it by means of the
pilot rod.
12. Take the pipe couplings (2) off.
13. Place the rocker arm casing (13) on a clean support.

6722 111.02--01 E 12.05 L 58/64 CD 104/ 06

 14. Seal the air inlet in the cylinder head (10) by means of the sealing
cover (055.233) so that foreign matter cannot fall into the inlet duct.
15. Remove the support (111.134).
▲ Attention! The locating screws (111.136 and 111.137) must not be
removed!
16. Clean the rocker arm casing (13) and rocker arms (7 and 12) as well
as the charge-air pipe section (3).
17. Clean the sealing lips on the pipe couplings (2) and check them for
damage; replace the pipe couplings if necessary.

6 Hexagon socket bolt

8 Hexagon socket bolt
10 Cylinder head
13 Rocker arm casing

Figure 5. Rocker arm casing with rocker arms and charge-air pipe section

Operating sequence 3 -- Fitting the rocker arm casing

Starting condition The rocker arm casing and rocker arms as well as the charge-air pipe sec-
tion have been cleaned, and the rocker arms have been fixed in place by
means of locating screws. The sealing lips of the pipe couplings have
been cleaned.
Steps 1. Clean the contact face on the cylinder head (10).
2. Oil new O-ring seals (17, 18 and 19) with clean lubricating oil, and
insert them into the ring grooves, making sure that they are not
twisted. See Figure 6 .
3. Place the support (111.134) on the rocker arm casing (13), and attach
it by means of the hexagon bolts (15 and 16). See Figures 4
and 5 .
4. Attach the suspension link (002.481) to the support by means of the
shackle (002.455), and fasten the lifting tackle to the suspension link.
5. Screw the pilot rod (034.006) into the support.
6. Raise the rocker arm casing (13), and position it above the cylinder
head (10).
7. Fit the pipe couplings (2). See Figure 1 .
Important! Depending on the space conditions, shove the pipe
coupling onto the charge-air pipe section of the neighbouring cylinder or
the charge-air pipe section of the rocker arm casing to be fitted.
8. Remove the sealing cover (055.143).

6722 111.02--01 E 12.05 L 58/64 CD 105/ 06

 9. Carefully lower the rocker arm casing (13) onto the cylinder head,
guiding it by means of the pilot rod.
▲ Attention! When fitting the rocker arm casing, make sure that it is
fixed in place in the cylinder head by two parallel pins (11)! See Fig-
ure 6 .
Also make sure that the thrust pads on the rocker arms engage in
the push-rod pans!
10. Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket bolts (8 and 6), and tighten them to the specified torque (see
000.30).
work card 000.30
11. Remove the support (111.134).
12. Readjust the valve clearance of the inlet and exhaust valves (see
111.01).
work card 111.01
▲ Attention! Make sure that the locating screws (111.136
and 111.137) are tightened to a torque of 40 Nm for adjusting the
valve clearance!
13. After adjusting the valve clearance, unscrew and remove the locating
bolts (111.136 and 111.137).
14. Close the cylinder head cover (14).
15. Fit the lube oil supply pipe to the rocker arm casing (13).
16. Attach the indicator valve to the rocker arm casing (13).
17. Slide the pipe couplings (2) over the joints and centre them. See Fig-
ure 2 .
18. Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket bolts (1), and tighten them to the specified torque (see work
card 000.30).
000.30

10 Cylinder head
11 Parallel pin
13 Rocker arm casing
17 O-ring seal
18 O-ring seal
19 O-ring seal

Figure 6. Removing/fitting the rocker arm casing

6722 111.02--01 E 12.05 L 58/64 CD 106/ 06

Cam follower/Push-- rod

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 112--04 E 06.98 101/ 01

Push-- rods
Removing and installing 112.01

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Push--rods are to be disassembled and assessed within the scope of

maintenance and repair work.
The work/steps include:
removal of components,
checking of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.2

Tools/appliances required

Qty Designation No. Availability

1 Suspension device 112.006 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Lifting tackle with rope -- Inventory

Related work cards

Work card Work card Work card

111.02

6722 112.01--01 E 01.06 L 58/64 CD 101/ 03

1 Push-rod
2 Push-rod covering
3 Rocker arm
4 Cam follower
5 Camshaft
6 Cylinder crankcase
7 Cylinder head

Figure 1. Valve gear

1 Push-rod
8 Rocker-arm casing
Figure 2. Push-rod with suspension device attached

6722 112.01--01 E 01.06 L 58/64 CD 102/ 03

Operating sequence 1 -- Removal of a push-rod

Starting condition Rocker arm with bracket has been completely removed (see Work Card
111.02)
111.02

Steps 1. Slip the suspension device (112.006) over the push-rod (1) and clamp
it into the ring groove at the upper end of the push-rod.
2. Attach the suspension device to the lifting tackle by means of the
rope, and pull the push-rod out in upward direction.
3. Clean the push-rod, and check the push-rod pan.

Operating sequence 2 -- Installation of a push-rod

Steps 1. Oil the pans of the push-rods (1).

2. Insert the push-rod (1) into the push-rod covering (2) and place it on
the thrust pad of the cam follower (4).
3. Remove the suspension device (112.006).
111.02).
4. Fit the rocker arm with bracket (see Work Card 111.02
111.01).
5. Readjust the valve clearance (see Work Card 111.01

6722 112.01--01 E 01.06 L 58/64 CD 103/ 03

Cam follower
Removing and installing/checking 112.02

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Clearance and components of cam followers are to be checked at regular

intervals.
The work/steps include:
removal of components,
checking of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Torque wrench 140--760 Nm 008.004 Standard
1 Pliers for retaining rings 002.124 Standard
1 Adapter 12.5x20 001.927 Standard
1 Screw driver insert 17x12.5 001.859 Standard
1 Screw driver insert 14x12.5 001.858 Standard

Related work cards

Work card Work card Work card

000.30 112.01 201.01

Operating sequence 1 -- Checking

Starting condition Covers of camshaft covering have been removed.

Steps 1. Check that all cylindrical screws (3 und 6) have been tightened
to the specified torque loading (refer to work card 000.30 and
Figure 1 ).
2. Check running surfaces of all rollers (14) for damage.
3. Switch on lube oil pump and check that all lubricating points are
adequately supplied with oil.

6619 112.02--02 E 05.98 L 58/64 101/ 03

Operating sequence 2 -- Removing the cam followers for inlet and exhaust valves

Starting condition Camshaft coverings, lube oil pipes and push rods have been removed,
and the respective fuel oil pump secured in TDC position.

Steps 1. In order to remove a shaft (9) with cam followers (4 and 10), first of
all the adjacent short shafts (12) together with cam followers (13)
must be removed in accordance with work card 201.01.
201.01
2. Remove the cylindrical screws (3) and take off shaft (9) complete
with cam followers and bearing blocks.
3. Pull the bearing blocks (1 und 2), spacer pipe (11) and butting
disk (7) off the shaft. For doing so, remove retaining rings at the
fixed bearing.
4. Check clearances between bearing bushes of cam followers and
shaft (9). (For clearances refer to Operating Manual/Technical Data).
5. Clean and check bearing points, contact surface on thrust pad (16),
and the running surface of the roller. Check O-ring seals at the shaft
bearing points. Clean all oil bores in shaft and cam followers.

1 Bearing block (2-hole)

2 Bearing block (4-hole)
3 Cylindrical screw
4 Cam follower (inlet)
5 Centering bolt
6 Cylindrical screw
7 Butting disk
8 Spacer pipe
9 Shaft
10 Cam follower (exhaust)
11 Spacer pipe
12 Shaft (eccentric)
13 Cam follower for
injection pump
14 Roller
15 Bearing bush
16 Thrust pad
17 Push-rod
18 Cylinder crankcase

Figure 1. Cam follower for valve control

6619 112.02--02 E 05.98 L 58/64 102/ 03

Operating sequence 3 -- Installing cam follower

The installation takes place in reverse order to that of removal. During

installation, the following points must be observed:

Steps 1. Take care not to damage the O-ring seals in the shaft when fitting
the bearing block.
2. The cylindrical screws (3 and 6) are to be tightened to the specified
000.30).
torque (refer to work card 000.30
▲ Attention! When mounting the bearing blocks (1 and 2), it is the
upper cylindrical screws (3) which are to be tightened first.

6619 112.02--02 E 05.98 L 58/64 103/ 03

Inlet and exhaust valves/Valve seat rings/
Valve guide/Valve rotators

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 113--04 E 06.98 101/ 01

Inlet and exhaust valve/valve rotator
Removing and installing 113.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Inlet and exhaust valves as well as valve rotators are to be disassembled

at regular intervals and overhauled if necessary.
The work/steps include:
removal of components,
disassembly and assembly,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Valve spring tensioner 113.278 Standard
1 Feed spindle 113.278--1 Standard
1 Bridge 113.278--5 Standard
1 Deep groove thrust ball bearing 113.278--9 Standard
1 Conical socket 113.278--13 Standard
1 Spherical disk 113.278--14 Standard
1 Tommy bar, 12 mm 000.264 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Special lubricant -- Inventory
(Molykote G Rapid, Molykote G--n)
1 Lubricating oil, clean -- Inventory

6722 113.01--01 E 12.05 L 58/64 CD 101/ 05

Related work cards

Work card Work card Work card

055.02 055.05 113.06

Technical details

Term Information
Valve cone 15 kg

1 Tapered piece, two-part

2 Valve rotator
3 Compression spring
4 Compression spring
5 O-ring seal
7 Cylinder head
8 Valve guide
9 Valve cone
10 Valve seat ring
Figure 1. Exhaust valve (Sectional view)

Operating sequence 1 -- Checking the valve rotator

The performance of the valve rotator can be checked with the cylinder
head cover open and with the engine running (under at least 10% load). If
an inlet or exhaust valve has not turned for an extended period of time, the
condition of the valve cone and valve seat is to be checked.

6722 113.01--01 E 12.05 L 58/64 CD 102/ 05

 2 Valve rotator
7 Cylinder head
9 Valve cone
11 Hexagon nut
Figure 2. Fitting the valve spring tensioner

Operating sequence 2 -- Removal of the inlet or exhaust valve

Starting condition The cylinder head has been removed and clamped into the turnover stand
055.05).
(see Work Card 055.05

Important! If only the valve rotator or the compression springs are

to be removed, the cylinder head remains fitted and the piston is turned to
ignition TDC.

1 Tapered piece, two-part

9 Valve cone
11 Hexagon nut

A-C Steps
Figure 3. Removal of the two-part tapered piece

6722 113.01--01 E 12.05 L 58/64 CD 103/ 05

Steps 1. Screw the feed spindle (113.278-1) all the way onto the valve cone
(9).
2. Slip the bridge (113.278-5) onto the spindle and place it on the valve
rotator (2).
3. Slip the conical socket (113.278-13), spherical disk (113.278-14) and
the deep-groove thrust ball bearing (113.278-9) on. Refer to Fig-
ure 2 .
▲ Attention! Make sure to fit the conical socket, spherical disk and
the deep groove thrust ball bearing correctly!
4. Coat the thread of the spindle with Molykote G-n.
5. Screw the hexagon nut (11) onto the feed spindle (113.278-1).
6. Pretension/press down the compression springs (3 and 4) by means
of the valve spring tensioner (113.278) so as to permit removal of the
two-part tapered piece (1). Hold the bridge in place using the tommy
bar (000.264). Refer to Figure 3 /B.
7. Remove both parts of the tapered piece (1).
8. Slacken the hexagon nut (11), thus relieving the tension on the com-
pression springs (3 and 4). Refer to Figure 3 /C.
9. Remove the valve spring tensioner (113.278), holding the valve cone
(9) by hand.
▲ Attention! If the valve cone is not held, it will fall out of the valve
guide after the hexagon nut (11) has been removed!
10. Slide the valve cone (9) out of the valve guide (8), and place it on a
clean support.
Important! Note down the assignment valve cone/valve guide. In
case the valve cone is not replaced, it has to be refitted into the same
valve guide from which it was removed.
11. Take the valve rotator (2) and the compression springs (3 and 4) off.
Refer to Figure 4 .
12. Remove the O-ring seal (5).
13. Clean all the individual components and check them for wear (for the
maximum clearance, refer to the Operating Instructions, Volume B1);
replace parts if necessary.
If required, remachine the valve cone (9) and/or the valve seat on the
113.05.
valve seat ring (10) - see Work Cards113.04 and 113.05
14. Check the condition of the valve guide (8), remove it if necessary
(see Work Card 113.06).
113.06

Operating sequence 3 -- Installation of the inlet or exhaust valve

Starting condition All individual components have been cleaned, checked and replaced if
necessary. The bore of the valve guide has been cleaned.

Steps 113.03).
1. Carry out an ink-contact “touching” test (see Work Card 113.03
2. Wet a new O-ring seal (5) with clean lubricating oil and insert it into
the ring groove, making sure that it is not twisted.
3. Treat the shaft of the valve cone (9) with Molykote G-Rapid spray.
4. Insert the valve cone (9) into the valve guide (8) and hold it by hand.
5. Screw the feed spindle (113.278-1) all the way onto the valve cone
(9).
6. Install the compression springs (3 and 4), and place the valve rotator
(2) on the compression springs. Refer to Figure 4 .
7. Slip the bridge (113.278-5) onto the spindle, and place it on the valve
rotator (2).
8. Slip on the conical socket (113.278-13), the spherical disk
(113.278-14) and the deep groove thrust ball bearing (113.278-9).
Refer to Figure 2 .

6722 113.01--01 E 12.05 L 58/64 CD 104/ 05

 ▲ Attention! Make sure to fit the conical socket, spherical disk and
the deep groove thrust ball bearing correctly!
9. Coat the thread of the spindle with Molykote G-n.
10. Screw the hexagon nut (11) onto the spindle.
11. Pretension/press down the compression springs (3 and 4) by means
of the valve spring tensioner (113.278) so as to permit the two-part
tapered piece (1) to be fitted. Hold the bridge steady using the
tommy bar (000.264). Refer to Figure 3 /B.
12. Install both parts of the tapered piece (1).
13. Verify that both parts of the tapered piece (1) have been inserted cor-
rectly and that the gap between the two parts is uniform.
14. Slacken the hexagon nut (11) thus relieving the tension on the com-
pression springs (3 and 4). Refer to Figure 3 /A.
15. Remove the tensioning tool (113.278).

2 Valve rotator
3 Compression spring
4 Compression spring
7 Cylinder head
8 Valve guide
9 Valve cone
Figure 4. Cylinder head with valves

6722 113.01--01 E 12.05 L 58/64 CD 105/ 05

Valve rotator
Checking 113.02

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

Valve rotators are to be assessed at regular intervals.

The work/steps include:
checking components,
removing components,
disassembling and assembling,
installing components.

Tools/appliances required

Qty Designation No. Availability

1 Screw drivers (set) -- Standard
1 Felt--tip pen/Marking pen -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

113.01

Design of the valve rotator

The basic body (1) has a number of pockets, arranged in circumferential

direction, with balls (2) that are forced against the upper end of an inclined
raceway by compression springs (6) acting in tangential direction. Refer
to Figure 3 . The disk spring (3) is located between the basic body and
the cover (4), onto which the valve spring forces are acting. Refer to Fig-
ure 1 . In disassembled condition, the various parts of the rotator are
held together by the snap ring (5).

Operating principle

As the valve starts to open, the increasing valve spring force causes the
disk spring (3) in the valve rotator to flatten and, at the same time, to exert
load on the balls (2) in the pockets of the basic body (1), which forces the
balls to roll down their inclined raceways. The disk spring itself rolls on the

6682 113.02--02 E 10.05 L 40/54, 48/60, L 58/64 CD 101/ 04

 balls. As the disk spring is supported by the balls, the pressure of the disk
spring acting onto the inner edge of the basic body (1) is reduced, which
results in a sliding motion. Disk spring, cover (4) and valve springs, how-
ever, are firmly connected with each other due to friction contact, and thus
prevented from turning. The relative rotation between disk spring / cover
and basic body is transmitted onto the valve via the basic body. As the
valve closes, the force acting on the disk spring and thus on the balls is
reduced, with the result that the balls are pushed back to their original
positions by the compression springs (6), without being rolled.

1 Basic body 4 Cover

2 Ball 5 Snap ring
3 Disk spring

Figure 1. Valve rotator of the inlet valve

Operating sequence 1 -- Checking the valve rotator

Under normal operating conditions, Rotocap valve rotators do not require

any maintenance. Abnormal operating conditions cause the malfunctions
described under operating sequence 2. The rotation of the valves ist to be
checked at the intervals specified in the maintenance schedule.

Starting condition Engine stopped, cylinder head cover opened, valve rotator installed.

Steps 1. Mark the valve rotator with a line by means of the felt-tip pen.
2. Start the engine and operate it at low load.
3. Watch the valve rotator of the inlet valves to see if the basic body
including valve cone rotate evenly:

Reference value = 1 valve rotation per minute

4. Stop the engine.

5. In case malfunctions occur, refer to operating sequence 2.

Operating sequence 2 -- Possible malfunctions and remedial measures

1. Contamination, especially of the ball pockets, which is due to resi-

dues in the oil (abrasives, combustion products). The deposits cause
the individual components to become stuck and hinder the movement
of the balls.

The valve rotator has to be removed, thoroughly washed, and oiled

before refitting. Please refer to operating sequence 3.

6682 113.02--02 E 10.05 L 40/54, 48/60, L 58/64 CD 102/ 04

 2. High base torque due to severe friction between rocker arm and end
of valve stem or due to shaft seals. In case the valve spring position
is excessively inclined, the cover (4) itself may cause a considerable
friction torque on the basic body (1) resulting in the standstill of the
rotator.

The parts that cause the friction and/or the valve spring have to be
replaced.
Important! In case the balls have produced indentations in the race-
ways of the basic body as a result of concentrated load because the valve
stopped rotating, the complete valve rotator has to be replaced.

▲ Attention! If the inlet valve has not rotated for an extended period
of time, check the condition of valve cone and valve seat (see work
card 113.03).
113.03

Operating sequence 3 -- Disassembly and assembly of the valve rotator

Starting condition Valve rotator removed (see work card 113.01

113.01) and placed on a support
(snap ring located on top).

Steps 1. Remove the snap ring (5).

2. Take off cover (4) and disk spring (3).
3. Remove all balls (2) and compression springs (6) from the basic body
(1). Refer to Figure 3 .
4. Wash all individual components in suitable cleaning agent and dry
them afterwards.
5. Check all individual components for wear and ball indentations; re-
place them if necessary (regarding set of wear parts, please refer to
the spare parts catalogue for the engine).

1 Basic body 6 Compression spring

2 Ball A max. admissible
3 Disk spring wear = 0.1 mm

Figure 2. Wear limit on the ball-pocket raceways

Important! When parts of the valve rotator are replaced, the basic
body of the rotator has to be marked with the item number of the set of
wear parts used.
6. Insert balls (2) and compression springs (6) into the ball-pocket race-
ways.
▲ Attention! Make sure that the balls are at the highest point of the
slanting ball-pocket raceways, and thus all located in the same
direction. Refer to Figure 3 .
7. Insert the disk spring (3), put on the cover (4) and install the snap
ring (5).

6682 113.02--02 E 10.05 L 40/54, 48/60, L 58/64 CD 103/ 04

 Important! The inner edge of the disk spring has to rest on the basic
body. Refer to Figure 1 .
8. Immerse the valve rotator in clean lubricating oil and take it back out
shortly before installation.
▲ Attention! Never pack the valve rotator with grease!

Operating sequence 4 -- Installation of the valve rotator

Starting condition Valve rotator cleaned and oiled.

Regarding the installation of the valve rotator, please refer to work card
113.01.
113.01

Important! Only use original valve springs, as only original valve

springs ensure faultless operation of the valve rotator.

Storage Parts that became soiled due to an extended storing period or during
transportation have to be washed in a suitable cleaning agent, dried and
afterwards immersed into clean lubricating oil for a few minutes.

Important! Parts kept in stock have to be stored in well-packed

condition and protected against dust, water, humidity and aggressive
media. Dust causes the individual components to become stuck and hind-
ers or prevents the rotation when the parts are taken into operation.

1 Basic body 3 Disk spring

2 Ball 6 Compression spring

Figure 3. Ball raceways in the basic body of the valve rotator

6682 113.02--02 E 10.05 L 40/54, 48/60, L 58/64 CD 104/ 04

Inlet and exhaust valve
Valve cone and seat surface
Checking and assessing 113.03

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check components for condition/wear,
assess the contact pattern/wear.

Brief description

Inlet and exhaust valve cones and seat surfaces are to be checked at
regular intervals, and overhauled and/or replaced if necessary.
The work/steps include:
carrying out an ink contact (”touching”) test,
assessing contact pattern/wear condition.

Tools/appliances required

Qty Designation No. Availability

1 Touching up device 113.224 Standard
for engine 32/40
1 Touching bow 114.032 Standard
for engine 40/54
1 Touching bow 114.033 Standard
for engine 48/60 B
1 Touching bow 113.054 Standard
for engine 58/64
1 Touching--test ink -- Inventory
1 Grinding paste (silicon--free) -- Inventory
1 Hexagon screw drivers (set) -- Inventory
1 Open--jaw and ring wrenches (set) -- Inventory

Preliminary remarks

Exhaust and inlet valves with a poor contact pattern do not have a long life
expectancy. They have to be overhauled or replaced.
The intervals for overhaul as entered in the maintenance schedule (see
Volume B1 / Operating Instructions) are guide values and depend on the
operating mode and the engine condition, as well as the quality of the fuel
used. The most suitable intervals for overhaul have to be chosen, making
due allowance for the specified checks.
Due to the frequent temperature changes, the material of the valve cone is
subject to fatigue. The valve cones are to be replaced when the operating
times stated in the maintenance schedule (see Volume B1 / Operating In-
structions) have been reached, even if the admissible maximum remachin-
ing limits have not yet been reached.

6682 113.03--05 E 05.06 General 101/ 07

 ▲ Attention! Use beyond this limit involves an unpredictable risk
for the engine!

1 Cylinder head
2 Inlet valve cone
3 Valve seat ring
4 Exhaust valve cone
5 Valve seat ring

Figure 1. Inlet and exhaust valve

The valve seat angle (a) of the valve cone is 120ƒ , with a positive toler-
ance. The valve seat angle (b) in the valve seat ring has a negative toler-
ance, which results in a small differential angle (g). This ensures that in
operation the sealing zone for the hot gases is on the outer margin of the
valve seat area. Refer to Figure 2 .
The contact pattern is checked by means of a touching test.

2 Inlet valve cone a Angle on the valve cone g Differential angle

3 Valve seat ring b Angle on the valve seat
ring

Figure 2. Relation of the geometrical angles between valve seat ring and valve cone - Illustration shows inlet valve

▲ Attention! With valve seat grinders or valve seat lathes that have
long been in use, tolerances resulting from wear may change the
valve seat angle so that an incorrect contact pattern is produced! We
recommend checking by means of a touching test using a new, orig-
inal MAN B&W valve cone! If deviations are found, the valve seat
grinder or the valve seat lathe is to be checked!

6682 113.03--05 E 05.06 General 102/ 07

Operating sequence 1 -- Touching test

Starting condition The cylinder head has been mounted in the cylinder head turnover stand;
inlet/exhaust valves have been dismantled.

2 Inlet valve cone

Figure 3. Touching bow and/or touching up device - Illustration shows inlet valve

Steps 1. Carefully clean the valve seat surfaces.

▲ Attention! Do not damage the valve cone by using a wrong
cleaning tool (such as a slag hammer)!
2. Fasten the touching bow or the touching up device to the valve cone
(2 or 4). Refer to Figure 3 .
3. Apply a uniform film of touching-test ink, as thin as possible, to the
valve seat of the valve cone (2 or 4).
4. Slide the valve cone (2 or 4) into the appertaining valve guide in the
cylinder head (1) and turn it by one half revolution in vertical position
and under pressure, using the touching bow or the touching up de-
vice.
5. Take the valve cone (2 or 4) out.
6. Check the valve seat in the valve seat ring (3 or 5). If the differential
angle is correct and remachining has been carried out properly, there
must be a continuous bearing zone at the outer margin of the valve
seat.
7. Remove the touching bow or the touching up device.

Operating sequence 2 -- Assessing valve seat surfaces

Starting condition The cylinder head has been mounted in the cylinder head turnover stand,
inlet/exhaust valves have been dismantled.

6682 113.03--05 E 05.06 General 103/ 07

Diagnosis 1 The valve seat surfaces of the valve seat rings are clean, showing slight
varnishing or only minor pitting. Uniform contact pattern all around - refer
to Figure 4 .

Figure 4. Illustrating Diagnosis 1

Action Apply silicon-free grinding paste to the valve seat surface of the valve seat
rings (observe instructions of the supplier!) and clean by hand using the
touching bow or the touching up device until varnishing has been removed.
After cleaning, make a touching test (see operating sequence 1).

Important! Use as little grinding paste as possible for cleaning, and

carefully wash the valve cone and valve seat ring afterwards. Residues of
grinding paste promote wear.
Minor pitting left after removal of varnishing can be tolerated, it has but
little effect on the service life.

Diagnosis 2 The valve seat surface of the valve seat ring shows heavy deposits, rather
deep corrosion pitting and/or distinct pounding marks. There is wear on
the valve seat ring - refer to Figure 5 .

Figure 5. Illustrating Diagnosis 2

6682 113.03--05 E 05.06 General 104/ 07

Action Remachine the valve seat rings using the valve seat grinder and/or valve
seat lathe until the valve seat surfaces are clean or the appearance of the
contact faces is as new (see Work Cards 113.04 and 113.05).
113.05 After clean-
ing, make a touching test (refer to operating sequence 1).

Important! Keep grinding and/or turning treatment to a minimum

and subsequently wash the valve cone and valve seat ring carefully.
Grinding residues promote wear.
Minor pitting left after grinding/turning can be tolerated, it has but little ef-
fect on the service life.

Diagnosis 3 Valve seat surfaces of valve cones are clean, showing slight varnishing or
only minor pitting. Uniform contact pattern all around.

Action Apply silicon-free grinding paste to the valve seat surface of valve cone
and valve seat ring (observe instructions of the supplier!) and clean by
hand using the touching bow or the touching up device until varnishing has
been removed. After cleaning, make a touching test (see operating se-
quence 1).

Important! Use as little grinding paste as possible for cleaning, and

carefully wash the valve cone and valve seat ring afterwards. Residues of
grinding paste promote wear.
Minor pitting left after removal of varnishing can be tolerated, it has but
little effect on the service life.

Diagnosis 4 The valve seat surface of the valve cone shows heavy deposits, rather
deep corrosion pitting and/or distinct pounding marks. There is wear on
the valve cone - refer to Figure 6 .

Figure 6. Illustrating Diagnosis 4

Action Remachine the valve cone using the valve cone grinder until the valve
seat surfaces are clean or the appearance of the contact faces is as new
(see Work Cards 113.xx). After cleaning, make a touching test (refer to
operating sequence 1).

Important! Keep grinding treatment to a minimum and subse-

quently wash the valve cone carefully. Grinding residues promote wear.
Minor pitting left after grinding/turning can be tolerated, it has but little ef-
fect on the service life.

6682 113.03--05 E 05.06 General 105/ 07

Diagnosis 5 Valve cone showing incipient blow-by or cracks in the valve seat armour-
ing. Wear on the valve cone - refer to Figure 7 .

Figure 7. Illustrating Diagnosis 5

Action The valve cone is to be replaced.

Operating sequence 3 -- Assessing the valve cone

Starting condition The cylinder head has been mounted in the cylinder head turnover stand,
inlet/exhaust valves have been dismantled.

Diagnosis 6 Valve cone showing incipient shaft corrosion. Wear on the valve cone -
refer to Figure 8 .

A Shaft corrosion
Figure 8. Illustrating Diagnosis 6
Action The valve cone is to be replaced.

6682 113.03--05 E 05.06 General 106/ 07

Diagnosis 7 Valve cone showing burn-up on the valve plate. Wear on the valve cone -
refer to Figure 9 .

B Burn-up on the valve plate

Figure 9. Illustrating Diagnosis 7

Action If the limit values stated in Work Card 113.09 have been exceeded, the
valve cone is to be replaced.

Diagnosis 8 Valve cone showing stress cracking on the valve shaft. Wear on the valve
cone - refer to Figure 10 .

C Stress cracking on the

valve shaft
Figure 10. Illustrating Diagnosis 8

Action DThe valve cone is to be replaced if stress cracking is found on the valve
shaft. In this connection, crack testing according to Work Card 000.34 is
to be carried out.

6682 113.03--05 E 05.06 General 107/ 07

Valve seating surface
Machining 113.04

Purpose of jobs to be done

Carrying out the work in time according to the maintenance schedule,

ensuring correct execution of work,
restoring contact pattern.

Brief description

Valve seats are to be checked at regular intervals and remachined if

necessary. The HUNGER VD4E--type valve seat lathe is to be used for
this purpose.
The work concerns:
establishment of a correct contact pattern.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 VD4E--type valve seat lathe (277V) 113.284 Optional
1 VD4E--type valve seat lathe (120V) 113.283 Optional
1 VD4E--type valve seat lathe (230V) 113.282 Optional
1 Lathe with head 113.282--1 Optional
1 Control device 277V 113.284--2 Optional
1 Control device 120V 113.283--2 Optional
1 Control device 230V 113.282--2 Optional
1 Tool holder 113.282--3 Optional
2 Clamping screw 113.282--4 Optional
10 Insert 113.282--5 Optional
1 Pilot 113.282--6 Optional
1 Supporting spider 113.282--7 Optional
1 Milling cutter 113.282--8 Optional
1 Hexagon screw driver 4 113.282--9 Optional
1 Hexagon screw driver 5 113.282--10 Optional
1 TORX screw driver 113.282--11 Optional
1 Portable case 113.282--12 Optional
1 Pilot nut 113.282--13 Optional

6722 113.04--01 E 01.06 L 58/64 CD 101/ 08

 Qty Designation No. Availability
1 Marking pen -- Inventory
1 Lubricating oil, clean -- Inventory
1 Cutting oil -- Inventory

Related work cards

Work card Work card Work card

055.04 113.01 113.03
055.05

Operating sequence -- Remachining the valve seat

Starting condition The cylinder head has been dismantled and clamped into the turnover
stand. Inlet and/or exhaust valves have been removed.

▲ Attention! Prior to taking the valve seat lathe into operation, read
the operating instructions of the manufacturer attentively!

Steps 1. Clean the valve guide (3) and the valve seat (A) on the valve seat
ring (1 and/or 4).
2. Chamfer the valve guide (3) on both sides. Refer to Figure 3 .
- Insert the milling cutter (113.282-8) into the valve guide (3).
- Turn the milling cutter, simultaneously pressing it slightly against
the valve guide (3).
- Mill until the conical face is free from possibly adhering carbon
residues and a clean supporting surface for the pilot and/or the
pilot nut (113.282-13) has thus been produced.
- Remove the milling cutter.
- Clean the valve guide (3).
3. Insert the pilot (113.282-6) into the valve guide (3) on the combus-
tion-chamber side.
4. Mount the supporting spider (113.282-7). Refer to Figure 4 .
- Slip the supporting spider onto the pilot.
- Push the supporting spider down until the bolts (5) are located
below the valve seat rings (1 and/or 4).
- Mark the position.
- Remove the pilot and the supporting spider.
- Clamp the supporting spider firmly to the pilot at the marked
position.
5. Install the pilot together with the supporting spider. Refer to Fig-
ure 4 .
- Insert the pilot with the supporting spider fitted into the valve
guide (3).
- Screw the pilot nut onto the pilot and tighten it exerting
moderate force until the pilot is firmly seated in the valve guide (3).
6. Oil the shaft and the front surface of the pilot with clean lubricating
oil.
7. Get the lathe (113.282-1) ready.
- Unlock the stop pin (6), slide it into the depth-feed setting
ring (7) as far as possible, and secure it in place again.
- Turn the depth-feed setting ring (7) clockwise until only 1 to 2 mm
of the depth-feed scale (8) are visible.
- Install the insert (113.282-5) and clamping screw (113.282-4)

6722 113.04--01 E 01.06 L 58/64 CD 102/ 08

 into the tool holder (113.282-3).
- Install the tool holder in the tool slide of the turning head (9).

Figure 1. HUNGER VD4E-type valve seat lathe

6722 113.04--01 E 01.06 L 58/64 CD 103/ 08

1 Valve seat ring
(inlet valve)
2 Cylinder head
3 Valve guide
4 Valve seat ring
(exhaust valve)
A Valve seat
B Face
(remachining limit)

Figure 2. Inlet and exhaust valve seat ring in the cylinder head

1 Valve seat ring

(inlet valve)
2 Cylinder head
3 Valve guide
4 Valve seat ring
(exhaust valve)
Figure 3. Cleaning the valve guide

6722 113.04--01 E 01.06 L 58/64 CD 104/ 08

 8. Slip the lathe onto the pilot. Refer to Figure 5 .
▲ Attention! Take care to avoid that the insert bumps against the
valve seat ring!
9. Adjust the insert.
- Swing the lever (12) out.
- Press the lever (12) inward and swivel it until the insert is
positioned above the centre of the valve seat (A).
▲ Attention! Verify that the insert can be moved across the entire
width of the valve seat!
10. Lower the lathe to working height.
- Hold the lathe from below.
- Unlock the stop pin (6).
- Carefully lower the lathe until the insert is approx. 2 to 3 mm
above the valve seat (A).
- Press the stop pin (6) down against the pilot and secure it in place.
11. Connect the control device (113.282-2, 113.283-2 or 113.284-2).
Refer to Figure 5 .
- Connect the control device to the lathe.
- Connect the power supply cable (11) to a suitable electric power.
supply.
▲ Attention! Verify that the mains voltage corresponds with the
input voltage stated on the type plate of the control device!
12. Advance the insert to valve seat level.
- Verify that the lever (12) snaps into place in its resting position.
- Hold the lathe and put it into operation by depressing the push-
button switch (13).
- Turn the depth-feed setting ring (7) counter-clockwise until the
insert contacts the valve seat (A).
- Turn the depth-feed setting ring (7) clockwise back by two scale
marks in order to lift the insert off the valve seat (A).
- Turn the lathe off by releasing the push-button switch (13).
13. Position the insert in front of the inner edge of the valve seat.
- Move the turning head (9) inward by means of lever (12) until
the insert is just clear of the inner edge of the valve seat (A).
- Have the lever (12) snap in place.
- Turn the depth-feed setting ring (7) counter-clockwise by two
scale marks in order to advance the insert to valve seat level.
14. Adjust the depth of cut.
- Turn the depth-feed setting ring (7) counter-clockwise by
6 to 8 scale marks.
15. Machine the valve seat (A).
- Verify that the cross-feed tripping knob (14) has been pressed
down.
- Set the turning knob (10) on the control device to approx.
180 rpm.
- Moisten the valve seat (A) with cutting oil.
- Hold the lathe and put it into operation by depressing the
the push-button switch (13).
- Keep the push-button switch (13) depressed until the valve
seat (A) has been machined completely.
Release the push-button switch (13) as soon as the insert has
moved beyond the outer edge of the valve seat (A).
- Turn the depth-feed setting ring (7) clockwise back by two scale
marks in order to lift the tip of the insert off the valve seat.

6722 113.04--01 E 01.06 L 58/64 CD 105/ 08

1 Valve seat ring
(inlet valve)
2 Cylinder head
3 Valve guide
4 Valve seat ring
(exhaust valve)
5 Bolt
Figure 4. Installation of the pilot
16. Position the insert in front of the inner edge of the valve seat again,
adjust the depth of cut (approx. 2 to 4 scale marks) and machine
the valve seat face (A). Refer to item 13 to 15.
Important! Repeat the process until the valve seat to be machined
is bright all over.
17. Using a marking pin, apply markings at several points of the valve
seat (A).

6722 113.04--01 E 01.06 L 58/64 CD 106/ 08

 Important! The markings serve the purpose of checking whether or
not the chip removal is uniform.

1 Valve seat ring (inlet valve) 9 Turning head

2 Cylinder head 10 Turning knob
4 Valve seat ring (exhaust valve) 11 Power supply cable
6 Stop pin 12 Lever
7 Depth-feed setting ring 13 Push-button switch
8 Depth-feed scale 14 Cross-feed tripping knob

Figure 5. Fitting the lathe

6722 113.04--01 E 01.06 L 58/64 CD 107/ 08

 18. Carry out the last turning pass as follows:
: Depth feed: 1 scale mark,
: Set the turning knob (10) on the control device to
approx. 200 rpm.
19. Remove the valve seat lathe (113.282, 113.283 or 113.284) com-
pletely, clean it and store it in the portable case (113.282-12).
113.03).
20. Carry out an ink-contact “touching” test (see Work Card 113.03
▲ Attention! In case the required contact pattern can no longer be
achieved by means of the valve seat lathe, it has to be sent to an
MAN B&W Diesel service centre for repair!

Maximum admissible re- The maximum admissible remachining has been reached when the valve
machining seat (A) has been remachined up to face (B). Refer to Figure 2 .
In case the remachining limit has been reached, the valve seat ring (1
055.04).
and/or 4) has to be replaced (see Work Card 055.04

6722 113.04--01 E 01.06 L 58/64 CD 108/ 08

Valve cone
Grinding 113.05

Purpose of jobs to be done

Carrying out the work in time according to the maintenance schedule,

ensuring correct execution of work,
restoring contact pattern.

Brief description

Valve seating faces are to be checked at regular intervals and remachined

if necessary.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Qty Designation No. Availability

1 Valve cone grinder VKM 3.1 113.135 Optional
1 Grinding wheel 113.135--1 Optional
1 Dressing diamond 113.135--3 Optional
1 Coolant 113.135--5 Optional
1 Valve cone grinder VKM 3.4 113.136 Optional
1 Grinding wheel 113.136--1 Optional
1 Dressing diamond 113.136--3 Optional
1 Coolant 113.136--5 Optional
1 Dial gauge -- Inventory
1 Sliding caliper -- Inventory
1 Hammer (wood/plastic) -- Inventory

Related work cards

Work card Work card Work card

113.03 113.09

Preliminary remarks

For regrinding the valve cone, the following valve cone grinders of Messrs
Hunger are to be used for the below-mentioned engine types.

6682 113.05--01 E 07.00 General 101/ 08

 Tool number Engine type
Valve cone grinder VKM 3.1 113.135 20/27, 40/45, 40/54, 48/60, 48/60 B, 52/55 A+B
Valve cone grinder VKM 3.4 113.136 58/64
Table 1. Valve cone grinders to be used for the different engine types

Operating sequence 1 -- Checking the concentricity of the used valve cone

1 Valve cone 2 Collet chuck 3 Steady rest

Figure 1. Checking the valve cone concentricity (inlet valve being shown in the illustration)

Steps 1. Clean the valve cone.

2. Clamp the rear shaft diameter of the valve cone into the valve cone
grinder. Refer to Figure 1 .
3. Measure the concentricity at the front shaft diameter and the seating
face of the valve cone.
4. Decide whether the valve cone can be remachined or whether it has
to be replaced.
Important! The maximum admissible concentricity on the shaft and
seating face of the used valve cone is 0.05 mm. In case this value is
exceeded, the valve cone has to be replaced!
For supplementary remarks regarding the assessment of the valve seat,
113.03.
see work card 113.03

Operating sequence 2 -- Grinding the valve cone seating face

▲ Attention! Prior to taking the device into operation, attentively

read the manufacturer’s directions for use. Use the protection
equipment provided.

Starting condition Valve cone has been cleaned.

For setting and grinding the valve cones, see the directions for use. In this
connection, pay attention to the following items:

6682 113.05--01 E 07.00 General 102/ 08

 Figure 2. Chucked-in exhaust valve cone

Steps 1. Before starting to work, check the grinding wheel for firm seat.
2. Dress the grinding wheel using the dressing diamond.
▲ Attention! Because of the cutting speed, the grinding wheel
diameter must not be less than 150 mm.
3. Insert the valve cone in the work-piece headstock. Clamp the valve
cone on the collar provided for this purpose, keeping the distance as
short as possible (valve plate close to the collet chuck). Refer to
Figure 2 .
4. Tighten the collet chuck (hand-tight, using a hook spanner). In order
to center the collet chuck, knock against the valve plate bottom by
means of a plastic hammer (two to three light taps), retighten the
collet chuck once again.
5. Check the concentricity.
▲ Attention! In case the concentricity exceeds the admissible value,
the service department of MAN B&W Diesel AG is to be consulted.
6. The slide has by the manufacturer been fixed to the desired angle by
means of a pin.
7. Prior to the first grinding pass, adjust the grinding wheel and valve
cone so that centre of valve cone seating face = grinding-wheel
centre. Refer to Figure 3 .
8. Advance until grinding of the valve cone seating face is started.
9. Carry out the grinding, applying light coolant and moving the grinding
wheel to and fro by hand. Take care that the grinding wheel remains
on the valve seat all the time.
Choose the grinding feed as small as possible (0.025 mm = 1/2 large
scale mark), so as to avoid chatter marks.
▲ Attention! By all means, supply a sufficient amount of coolant to
the wedge between grinding wheel and valve cone seating face.
During the course of the grinding process, make sure that the
grinding wheel does not interfere with the valve cone radius (R).
Refer to Figures 4 to 8 .
An increasing grinding noise is an indication that the grinding wheel
does no longer remove material. The grinding wheel is then to be
dressed.
When grinding valve cones of NIMONIC 80 A, the grinding wheel is
to be dressed more often, as it becomes loaded more quickly and
exerts pressure (high grinding sound).
10. Prior to the last grinding pass, redress the grinding wheel.

6682 113.05--01 E 07.00 General 103/ 08

 11. For finish-grinding (last grinding pass), use a low amount of advance
( 0.02 mm) and finish-grind properly.
▲ Attention! After finish-grinding, do not push the grinding wheel
off the valve cone seating face, lift the grinding wheel off the valve
cone seating face.
When the maximum value (H) has been reached, the valve cone must
no longer be used (refer to Tables 2 to 7).
12. Remove the burr on the outer diameter of the valve plate using
appropriate tools (file, grinding stones) and/or break the edge on the
inner seat diameter by means of a grinding stone.

1 Valve cone
4 Grinding wheel

Figure 3. Position of the grinding wheel/valve cone seating face prior to grinding

Operating sequence 3 -- Maximum remachining on the exhaust valve

Preliminary remarks Exhaust valves are subject to continuous development. This has
influences on the shape and/or material composition of the valve cone.

Important! For carrying out remachining work on the valve cone

seat, it is important to correctly classify the exhaust valve cone by its
shape and condition and to read the corresponding maximum remachining
size from the respective table (see Tables 2 to 4).
Criterions of the exhaust valve cones:
- Exhaust valve cones are generally designed as one-part propeller
valves (old/previous design with vane sleeve).
- The valve seat may be designed with a connection angle (refer to
Figures 4 or 5 ) or with a recess (refer to Figure 6 ).
- Exhaust valve cones may either be manufactured from steel alloy with
armouring or from NIMONIC 80 A. For the exhaust valve, the same
remachining limits (H) apply.
Generally, the following applies: The admissible remachining limit has been reached on the valve cone
seating face when the valve cone seat width (G, new condition) has
increased to size (H).

Important! For admissible remachining on the outer valve diameter

and for the permissible burn-up and depth of corrosion on the valve plate,
113.09.
refer to work card 113.09

6682 113.05--01 E 07.00 General 104/ 08

 5 Exhaust valve cone H Max. remachining
6 Vane sleeve R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 4. Remachining an exhaust valve cone with vane sleeve (old design with connection angle)

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B 58/64
G new 4.0 7.3 9.8 11.5 9.3 10.4
H maximum 15.5 23.5 25.5 32.0 27.5 36.0
Table 2. Remachining limits [mm] concerning Figure 4

5 Exhaust valve cone H Max. remachining

7 Rotary vane R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 5. Remachining an the exhaust valve cone (design with connection angle)

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B 58/64
G new 16.5 19.2
H maximum 25.8 38.0
Table 3. Remachining limits [mm] concerning Figure 5

6682 113.05--01 E 07.00 General 105/ 08

 5 Exhaust valve cone H Max. remachining
7 Rotary vane R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 6. Remachining an exhaust valve cone with recess

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B 58/64
G new 4.6 11.5 11.5 9.8
H maximum 7.8 18.4 18.4 16.5
Table 4. Remachining limits [mm] concerning Figure 6

Operating sequence 4 -- Maximum remachining on the inlet valve

Preliminary remarks Inlet valves are subject to continuous development. This has influences
on the shape and/or material composition of the valve cone.

Important! For remachining the valve cone seat, it is important to

correctly classify the valve cone by its shape and condition and to read the
maximum remachining size from the respective table.
Criterions of the inlet valve cones:
- The valve seat may be designed with a connection angle (refer to
Figure 7 ) or with a recess (refer to Figure 8 ).
- Inlet valve cones may either be manufactured from a steel alloy with
armouring (valve plate magnetic) or from NIMONIC 80 A (valve plate not
magnetic).
▲ Attention! For inlet valve cones with recess and of armoured
design, other remachining limits apply than for inlet valve cones
with recess made from NIMONIC 80 A!

Important! Carry out the check for magnetism on the valve plate
underside.

Generally, the following applies: The admissible remachining limit has been reached on the valve cone
seating face when the valve cone seat width (G, new condition) has
increased to dimension (H).

6682 113.05--01 E 07.00 General 106/ 08

 Important! For admissible remachining on the outer valve diameter
and for the permissible burn-up and depth of corrosion on the valve plate,
113.09.
refer to work card 113.09

8 Inlet valve cone H Max. remachining

R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 7. Remachining an inlet valve cone (design with connection angle)

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B 58/64
G new 4.0 7.3 9.8 9.3 10.4
H maximum 15.5 23.5 25.5 27.5 36.0
Table 5. Remachining limits [mm] concerning Figure 7

6682 113.05--01 E 07.00 General 107/ 08

 8 Inlet valve cone H Max. remachining
R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 8. Remachining an inlet valve cone with recess

Inlet valve cone with armouring and recess

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B 58/64
G new 4.6 6.7 8.0 11.5 11.5 9.8
H maximum 7.8 11 14.0 16.0 16.0 14.0
Table 6. Remachining limits [mm] concerning Figure 8

Inlet valve cone from NIMONIC 80 A with recess

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B 58/64
G new 4.6 6.7 8.0 11.5 8.7 9.8
H maximum 8.0 11 12.1 18.4 15.5 16.5
Table 7. Remachining limits [mm] concerning Figure 8

6682 113.05--01 E 07.00 General 108/ 08

Valve guide
Checking, removing and installing 113.06

Purpose of jobs to be done

Ensure correct execution of work.

Brief description

Valve guides must be checked and replaced if necessary within the scope
of maintenance and repair work.
The work/steps include:
checking of components,
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5
1 Assistant 0.5

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 113.279 Standard
1 Clamping piece 113.279--1 Standard
1 Guide piece 113.277--3 Standard
1 Thrust pad 113.280 Standard
1 Thrust pad 114.057 Standard
1 Hydraulic tensioning device (hollow piston) 009.022 Standard
1 High--pressure pump 009.341 Standard
1 High--pressure hose 009.306 Standard
1 Open--jaw and ring wrenches (set) -- Inventory

6722 113.06--01 E 06.06 L 58/64 CD 101/ 06

Related work cards

Work card Work card Work card

009.03 009.05 055.05
113.01

Operating sequence 1 -- Checking the valve guide

▲ Attention! The valve guide is to be replaced whenever the wear

limit has been reached. The wear limit has been reached
- when the valve cone (20) butts against the cylindrical recess (C)
of the valve guide (21) on the combustion-chamber side. Refer to
Figure 1 .
- when the circumferential wear edge (A) on the valve guide (21) is
no longer visible or tangible, which may also only be the case on
part of the circumference.

20 Valve cone
21 Valve guide

A Wear edge in new con-

dition
B Wear edge in worn
condition
C Cylindrical recess

Figure 1. Wear edge on the valve guide

6722 113.06--01 E 06.06 L 58/64 CD 102/ 06

Operating sequence 2 -- Removal of the valve guide

7 Cylinder head 8 Valve guide 13 Hexagon nut M30

Figure 2. Attaching the fitting/unfitting tool

Starting condition The cylinder head has been clamped into the turnover stand, the inlet
and/or exhaust valve has been removed.

Steps 1. Insert the guide piece (113.277-3) into the valve guide (8), and screw
the hexagon nut (13) on, hand-tight.
2. Slip the clamping piece (113.279-1) and thrust pad (113.280) over the
guide piece, paying attention to the centring of clamping piece-thrust
pad.
3. Slip the hydraulic hollow-piston tensioning device (009.022) over the
guide piece, and screw the hexagon nut (13) on, hand-tight. Refer to
Figure 3 /A.
4. Connect the high-pressure hose (009.306) to the hydraulic hollow-
piston tensioning device and the high-pressure pump (009.341).
Connect the oil pressure gauge (0-400 bar) to the high-pressure
pump.
009.03),
5. Put the high-pressure pump into operation (see Work Card 009.03
and pump the hydraulic hollow-piston tensioning device up slowly.
Important! Watch the pressure gauge while pumping.
6. Pull the valve guide (8) out in several stages, releasing pressure
every time. Press the piston of the hydraulic hollow-piston tensioning
device in and retighten the hexagon nut (13). Refer to Figure 3 /B.
7. Release the pressure.
8. Disconnect the high-pressure hose from the hydraulic hollow-piston
tensioning device and the high-pressure pump, and remove the tool.
9. Clean the valve guide (8), check it for wear/damage; replace it if
necessary.

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 7 Cylinder head
8 Valve guide
13 Hexagon nut M30
Figure 3. Removal of the valve guide

Operating sequence 3 -- Installation of the valve guide into the inlet valve

Starting condition The valve guide has been cleaned, checked and replaced if necessary.
The bore in the cylinder head has been cleaned.

Steps 1. Slip the valve guide (8) onto the guide piece (113.277-3) and screw
the hexagon nut (13) on, hand-tight. Insert the guide piece through
the cylinder head (7).
2. Slip the thrust pad (113.280) over the guide piece and place it on the
inlet valve seat ring, paying attention to the centring of thrust piece/
valve seat ring. Refer to Figure 4 /C.
3. Slip the hydraulic hollow-piston tensioning device (009.022) over the
guide piece and screw the hexagon nut (13) on, hand-tight.
4. Connect the high-pressure hose (009.306) to the hydraulic hollow-
piston tensioning device and the high-pressure pump (009.341).
Connect the oil pressure gauge (0-400 bar) to the high-pressure
gauge.
5. Put the high-pressure pump into operation (see Work Card 009.03 009.03),
and pump the hydraulic hollow-piston tensioning device up slowly.
▲ Attention! Make sure that the valve guide (8) is drawn into the
bore correctly! Watch the pressure gauge while pumping! A sudden
pressure increase during the installation process is an indication
that the valve guide has been tilted!
6. Draw in the valve guide (8) in several stages, releasing pressure
every time. Press the piston of the hydraulic hollow-piston tensioning
device in, and retighten the hexagon nut (13). Refer to Figure 4 /D.
7. Release the pressure.

6722 113.06--01 E 06.06 L 58/64 CD 104/ 06

 8. Disconnect the high-pressure hose from the hydraulic hollow-piston
tensioning device and high-pressure pump, and remove the tool.

7 Cylinder head
8 Valve guide
13 Hexagon nut M30
Figure 4. Removal of the inlet valve guide

Operating sequence 4 -- Installation of the valve guide into the exhaust valve

Starting condition The valve guide has been cleaned, checked and replaced if necessary.
The bore in the cylinder head has been cleaned.

Steps 1. Slip the valve guide (8) onto the guide piece (113.277-3), and screw
the hexagon nut (13) on, hand-tight. Insert the guide piece through
the cylinder head (7).
2. Slip the thrust pad (114.057) over the guide piece, and place it on the
exhaust valve seat ring, paying attention to the centring of thrust pad-
valve seat ring. Refer to Figure 5 /E.
3. Slip the hydraulic hollow-piston tensioning device (009.022) over the
guide piece, and screw the hexagon nut (13) on, hand-tight.
4. Connect the high-pressure hose (009.306) to the hydraulic hollow-
piston tensioning device and the high-pressure pump (009.341).
Connect the oil pressure gauge (0-400 bar) to the high-pressure
pump.
009.03),
5. Put the high-pressure pump into operation (see Work Card 009.03
and pump the hydraulic hollow-piston tensioning device up slowly.
▲ Attention! Make sure that the valve guide (8) is drawn into the
bore correctly! Watch the pressure gauge while pumping! A sudden
pressure increase during the installation process is an indication
that the valve guide has been tilted!
6. Draw in the valve guide (8) in several stages, releasing pressure
every time. Press the piston of the hydraulic hollow-piston tensioning
device in, and retighten the hexagon nut (13). Refer to Figure 5 /F.
7. Release the pressure.
8. Disconnect the high-pressure hose from the hydraulic hollow-piston
tensioning device and the high-pressure pump, and remove the tool.

6722 113.06--01 E 06.06 L 58/64 CD 105/ 06

 7 Cylinder head
8 Valve guide
13 Hexagon nut M30
Figure 5. Installation of the exhaust valve guide

6722 113.06--01 E 06.06 L 58/64 CD 106/ 06

Valve plate
Depth of burning marks and corrosion
Checking 113.09

Purpose of jobs to be done

Counteracting corrosion attacks,

keeping the state within the permissible range.

Brief description

When regrinding the valve seat surface, the permissible valve plate
thickness is to be determined.
The work /steps include:
Measure components and
assess wear pattern/condition.

Tools/appliances required

Qty Designation No. Availability

1 Feeler gauge (set) 000.451 Standard
1 Sliding caliper -- Inventory
1 Felt--tip pen/Marking pen -- Inventory
1 Ruler (steel) -- Inventory

Related work cards

Work card Work card Work card

113.03 113.05 113.06

Operating sequence 1 -- Checking the valve plate thickness

Steps 1. Clean valve cone and remove any adhering carbon.

2. Check plate thickness in the as-new condition (HN) at measuring
point C on an identical new valve and note the dimension measured.
3. Using a felt-tip pen, mark one or, depending on the condition of the
valve to be checked, several measuring points C distributed over the
circumference.
4. Using a sliding caliper, check plate thickness at point C and note the
dimension measured.
Dimension A = difference between HN and the dimension measured
must not be larger than 10% of HN (as-new condition) at any point.
Important! If the seat surface of a used valve cone must be
reground, the amount of material expected to be removed by regrinding
must be taken into account in the evaluation of the determined wear

6682 113.09--01 E 05.00 General 101/ 03

 rate A. (The plate thickness will be further reduced by removal of material
from the seat surface S).

5. Laying a ruler on the plate bottom, check wear rate (B) by means of a
depth gauge or feeler gauge approximately in the plate centre, and
note the wear rate measured. Dimension B must not exceed 3.0 mm
at the lowest point.
Important! The valve plate thickness may be reduced to
inadmissible values by regrinding of the valve seat surface (S) and
possible hot corrosion on the plate bottom.

1 Valve plate in as-new

condition
2 Valve plate with
maximum admissible
wear

A Wear rate on plate

edge at point C
B Wear rate in plate
centre
C Measuring point at a
distance of 1/6 of the
outer plate diameter
from the plate edge
D Outer diameter of valve
plate
E Contact blades of the
sliding caliper
HN Plate thickness in the
as-new condition at
point C
S Seating

Figure 1. Determination of wear rate A on valve plate

Operating sequence 2 -- Checking outer diameter (D) of valve plate for corrosion marks

Important! Circumferential corrosion marks of minor depth may

occur at the outer diameter (D) of the valve plate in the transition area
from standard material of valve plate to armour-plating. The transition
area is to be checked for incipient cracks. In case of fissures being found,
the rim (outer diameter is to be reground until all fissures are removed.
However, given machining limits have to be observed.

Steps 1. Clean valve cone. When doing so, do not damage surface by
application of unsuitable cleaning tool (e.g. pick hammer).
2. Check transition area standard material/armour-plating by means of
dye penetration test (Met-L-Check) for fissures (see work card
000.34).
000.34
3. In case of fissures found, valve plate rim (outer diameter) must be
reground until all fissures are removed. Grinding is to be done
without any coolant being used. The following machining limits have
to be observed (refer to Table 1).

6682 113.09--01 E 05.00 General 102/ 03

 Permissible remachining with
Valve plate outer diameter reference to diameter compared
with as-new condition
up to 100 mm 0.2 mm
over 100 mm 0.5 mm
Table 1. Limiting values for reconditioning of valve plate outer diameter

6682 113.09--01 E 05.00 General 103/ 03

Operating device

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 125--04 E 06.98 101/ 01

Three-- way valve
Checking, overhauling 125.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Three--way valve 125.98.306
125.98
1 Set of wear parts 125.99.306
125.99

Three-way valve M306

Operating sequence 1 -- Disassembly of the three-way valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.02--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw off the roller lever (11), screw out the valve guide (12) together
with valve tappet (13) and spring.
4. Disassemble the valve further, and thoroughly clean all individual
parts.
5. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the three-way valve M306, a set of wear parts can
be obtained from MAN B&W Diesel AG.
6. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the three-way valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points.

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particules may cause disturbances in
the valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Roller lever
12 Valve guide
13 Valve tappet
14 Valve seat

V Wear parts

Figure 1. Sectional view of the three-way valve M306

Operating principle

Connection 1 2 4
Position I closed connected
Position II connected closed

6682 125.02--01 E 04.98 General 102/ 02

Three-- way valve
Checking, overhauling 125.04

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Hook spanner -- Inventory
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Three--way valve 125.98.317
125.98
1 Set of wear parts 125.99.317
125.99

Three-way valve M317

Operating sequence 1 -- Disassembly of the three-way valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.04--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the hexagon socket bolts (11) and take off the upper part
of the casing (12).
4. Using the hook spanner, turn out the valve guide (15) together with
piston (13) and valve tappet (14).
5. Take out the valve seat (16) and remove the valve (17).
6. Disassemble the valve further, thoroughly clean all individual parts
and discharge the compressed air.
7. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the three-way valve M317, a set of wear parts can
be obtained from MAN B&W Diesel AG.
8. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the three-way valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Hexagon socket bolt

12 Casing -- upper part
13 Piston
14 Valve tappet
15 Valve guide
16 Valve seat
17 Valve
18 Casing -- lower part

V Wear parts

Figure 1. Sectional view of the three-way valve M317

Operating principle

Connection 1 2 4
5 pressurised connected closed
5 pressureless closed connected

6682 125.04--01 E 04.98 General 102/ 02

3/2-- way solenoid valve
Checking, overhauling 125.05

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Screw drivers (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Qty Designation No.

1 3/2--way valve 125.98.329
125.98
1 Set of wear parts 125.99.329
125.99

3/2-way solenoid valve M329

Operating sequence 1 -- Disassembly of the 3/2-way solenoid valve

Starting condition Compressed air and control air system resp. in unpressurised condition.
Valve cleaned on the outside.

6682 125.05--01 E 03.05 General 101/ 03

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out hexagon bolts (11) and hexagon socket bolts (12).
4. Remove connecting piece (13) with emergency switch (14) and un-
screw hexagon socket bolt (12).
5. Disassemble the valve further, and thoroughly clean all individual
components.
6. Check the wear parts (V) for signs of wear and/or hardening (in the
case of sealing rings), replace parts as necessary.
Tip! For overhauling the 3/2-way solenoid valve M329, a set of wear
parts can be obtained from MAN B&W Diesel AG.
7. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 3/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and in the compressed air/control air system resp.
1. When installing new sealing rings, make sure that they are not
twisted.
2. Prior to assembly, slightly oil all parts.
▲ Attention! Make sure that the pins in the valve casing are arran-
ged correctly, depending on the desired application of the 3/2- way
solenoid valve M329. Incorrect arangement of the pins may result in
severe personal injury and engine damage.

11 Hexagon bolt
12 Hexagon socket bolt
13 Connecting piece
14 Emergency switch
15 Valve casing

V Wear parts

Figure 1. Sectional view of the 3/2-way solenoid valve M329

6682 125.05--01 E 03.05 General 102/ 03

Mode of operation

Depending on the arrangement of the pins in the valve casing, the

functions illustrated in the Figures 1 and 2 can be achieved.

Figure 2. Valve functions depending on the arrangement of the pins

6682 125.05--01 E 03.05 General 103/ 03

4/2-- way solenoid valve
Checking, overhauling 125.08

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 4/2--way solenoid valve 125.98.392
125.98
1 Set of wear parts 125.99.392
125.99

4/2-way solenoid valve M392

Operating sequence 1 -- Disassembly of the 4/2-way solenoid valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.08--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections and/or connecting cables (mark them if
necessary), remove fixing bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the socket (11).
4. Disassemble the valve further and thoroughly clean all individual
parts.
5. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the 4/2-way solenoid valve M392, a set of wear
parts can be obtained from MAN B&W Diesel AG.
6. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 4/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

10 Solenoid part
11 Socket
12 Lever for manual ope-
ration

V Wear parts

Figure 1. Sectional view of the 4/2-way solenoid valve M392

Operating principle

Connection 4 3 1 2 4
Solenoid energised connected connected
Solenoid de-energised connected connected

6682 125.08--01 E 04.98 General 102/ 02

5/2-- way solenoid valve
Checking, overhauling 125.08

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Qty Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Qty Denomination No.

1 5/2--way solenoid valve 125.98.367
125.98

5/2-way solenoid valve M367

Operating sequence 1 -- Disassembly of the 5/2-way solenoid valve

Starting condition Compressed air and/or control air system without pressure. Governor
cleaned on the outside.

6682 125.08--02 E 03.99 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check the wear parts for signs of wear and/or hardening (in case of
sealing rings), replace parts as necessary.
5. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 5/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and in the compressed air/control air system resp.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

Figure 1. 5/2-way solenoid valve

Mode of operation

Connection 5 4 1 2 3
Solenoid de-energised connected connected closed
Solenoid energised closed connected connected

6682 125.08--02 E 03.99 General 102/ 02

Pressure reducing valve
Checking, overhauling 125.09

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Pressure reducing valve with manometer 125.98.409
125.98
1 Set of wear parts 125.99.409
125.99

Pressure reducing valve M409

Operating sequence 1 -- Disassembly of the pressure reducing valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.09--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the cylindrical screws (11) and knurled screw (14).
4. Separate the upper part of the casing (12) from the lower part (13)
and remove the wear parts (V).
5. Disassemble the valve further and thoroughly clean all individual
parts.
6. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the pressure reducing valve M409, a set of wear
parts can be obtained from MAN B&W Diesel AG.
7. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the pressure reducing valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Cylindrical screw
12 Casing -- upper part
13 Casing -- lower part
14 Knurled screw

V Wear parts

Figure 1. Sectional view of the pressure reducing valve M409

6682 125.09--01 E 04.98 General 102/ 02

Compressed air filter
Checking, overhauling 125.10

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Compressed air filter 125.98.462
125.98
1 Filter insert 125.99.462
125.99

Compressed air filter M462

Operating sequence 1 -- Disassembly of the compressed air filter

Starting condition Compressed air and/or control air system without pressure. Filter cleaned
on the outside.

6682 125.10--01 E 04.98 General 101/ 02

Steps 1. Loosen the pipe connections (mark them, if necessary), remove fixing
bolts and filter.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. First of all, drain the compressed air filter via the hexagon bolt (13).
4. Screw off the hexagon nut (11) and take off the clamp.
5. Disassemble the filter and thoroughly clean all individual parts.
6. Clean the filter insert (12) according to manufacturer’s specification
or, if necessary, replace it by a new one.
Tip! The filter insert for the compressed air filter M462 can be obtained
from MAN B&W Diesel AG.

Operating sequence 2 -- Assembly of the compressed air filter

For assembly, proceed in the reverse order followed for removal, paying
attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.

11 Hexagon nut
12 Filter insert
13 Hexagon bolt

Figure 1. Sectional view of the compressed air filter M462

6682 125.10--01 E 04.98 General 102/ 02

Limit switch
Checking, overhauling 125.12

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Electric/electronic control and/or switch elements are to be checked and, if

necessary, overhauled at regular intervals.
The work/steps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard

Spare parts required

Quant Denomination No.

1 Limit switch 125.98.745
125.98
1 Set of wear parts 125.99.745
125.99

Limit switch M745

Operating sequence 1 -- Disassembly of the limit switch

Starting condition No voltage is applied to the limit switch.

Steps 1. Loosen the connecting cables (mark them, if necessary), remove

fixing bolts and switch.

6682 125.12--01 E 04.98 General 101/ 02

 2. Remove the roller lever(1), screw out the cylindrical screws (2) and
take off the push-button.
3. Screw out the cylindrical screws (3) and take off the cover (4).
4. Disassemble the limit switch further and thoroughly clean all
individual parts.
5. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the limit switch

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work.

1 Roller lever
2 Cylindrical screw
3 Cylindrical screw
4 Cover

Figure 1. Illustration of the limit switch M745

6682 125.12--01 E 04.98 General 102/ 02

2/2-- way solenoid valve
Checking, overhauling 125.14

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Screw drivers (set) -- Standard
1 Grease (acid--free) -- Inventory

2/2-way solenoid valve M314 / M315 / M316

Operating sequence 1 -- Disassembly of the 2/2-way solenoid valve

Starting condition Compressed-air and control-air system unpressurised. Governor cleaned

on the outside.

Steps 1. Loosen the pipe connections (marking them if necessary), remove

the fixing bolts and the valve.
2. Using appropriate means, close open pipe ends in order to prevent
penetration of dirt.
3. Disassemble the valve, and thoroughly clean all the individual parts.
4. Check wear parts for wear and traces of hardening (in the case of
sealing rings). Replace parts if necessary.
5. Prior to assembly, check all movable parts for ease of motion.

6682 125.14--01 E 12.02 General 101/ 02

Operating sequence 2 -- Assembly of the 2/2-way valve

For assembly, proceed in the reverse order followed for disassembly, pay-
ing attention to the following:

Important! During assembly, make sure that the working place is

scrupulously clean. Even minute dirt particles may cause disturbances in
the valve and/or the compressed-air/control-air system.
1. When installing new sealing rings, take care that they are not twisted.
2. Prior to assembly, slightly oil all components.

Figure 1. 2/2-way solenoid valve M314 / M315 / M316

Method of operation

Connection A B
Solenoid de-excited closed closed
Solenoid excited connected

6682 125.14--01 E 12.02 General 102/ 02

Speed control

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 140...--04 E 06.98 101/ 01

Woodward governor
PGG 200/PGG-- EG 200
Maintaining and checking 140.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of components,
ensure/restore operational reliability.

Brief description

The hydraulic oil of the speed governor is to be checked at regular

intervals.
The work/steps include:
venting,
changing the operating media,
removing components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised
- Power supply/generation interrupted

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1
1 Assistant 1

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 140.013 Standard
1 Swivel arm 140.013--1 Standard
1 Suspension gear 140.006 Standard
1 Ratchet hoist 002.552 Optional
1 Set of tools (Woodward governor) 140.110 Standard
1 Hexagon screw drivers (set) -- Inventory
1 Open--jaw and ring wrenches (set) -- Inventory
1 Sealing compound (silicone) -- Inventory

6722 140.01--01 E 09.06 L 58/64 CD 101/ 06

Related work cards

Work card Work card Work card

140.02

1 Manual speed adjustment 9 Connection for the elec- 19 Oil inlet from the booster
2 Manual load limitation tric unit of the governor to the working unit of the
3 Oil inlet from the booster to (PGG-EG speed gover- speed governor (booster
the speed adjustment nor) outlet 1)
system of the speed 10 Manual speed-droop 20 Oil inlet from the booster
governor (booster outlet 2) adjustment to the control unit of the
4 Switch-over device, 11 Connection for cut-off speed governor (booster
pneumatic (PGG-EG speed soolenoid and speed- outlet 3 - on the opposite
governor) setting motor side)
5 Governor output shaft 12 Needle valve 21 Pipe filter for the EG-unit
6 Drive shaft 13 Oil dipstick (PGG-EG speed gover-
8 Oil outlet to the oil cooler 14 Oil filling socket nor)
(if fitted) 15 Admission indication 22 Connection for charge air
17 Oil outlet to the booster (if fitted)
18 Oil outlet to the oil cooler
(if fitted)

Figure 1. Woodward speed governor

Preliminary remarks

Prior to taking the new speed governor into operation, fill it up with oil, pay-
ing attention to the following: With the engine running, the oil level should

6722 140.01--01 E 09.06 L 58/64 CD 102/ 06

 be between the two markings on the oil dipstick (13). With the engine at
standstill, top the speed governor up to approx. the upper marking and,
with the engine running, top up as stated above. Do not top up too
quickly, as the oil only runs down to the speed governor sump slowly.
After taking the speed governor into operation for the first time, longer
downtimes and after refitting the speed governor, deaerate the oil spaces.
PGG-EG 200 = mechanical-hydraulic speed governor / electric actuator
PGG 200 = only mechanical-hydraulic speed governor

Operating sequence 1 -- Deaeration

Starting condition The engine is running.

Steps 1. Close the needle valve (12) by turning clockwise, and note down the
required amount of turning. Then open it by approx. three to five
turns. The governor should now start hunting. If this is not the case,
hunting has to be induced by changing the admission setting rhythmi-
cally.
2. Open the pipe union (20) far enough to permit air to escape. The
governor has to be kept hunting until only bubble-free oil escapes.
3. Tighten the pipe union. If necessary, top up oil.
4. Close the needle valve (12) slowly until the governor stops hunting,
however, not further than noted down under step 1. Never close the
needle valve completely for an extended period of time!

For setting instructions, please refer to the manufacturer’s brochure on the

speed governor (Technical Documentation, Volume D1).

Important! If the electronic control does not work unobjectionably,

check the pipe filter (21) for contamination; wash it if necessary (only
PGG-EG speed governor).

▲ Attention! Opening of the speed governor and thus damaging the

lead seal without permission or instructions of MAN Diesel SE
means loss of the warranty claim.

Operating sequence 2 -- Oil change

Starting condition The engine has been stopped.

Steps 1. Disconnect the pipe for oil outlet (17) to the booster from the speed
governor casing, in order to drain the oil from the speed governor.
2. Drain the oil, refit the pipe for oil outlet to the speed governor casing.
3. Fill Diesel fuel in through the oil filling socket (14), up to the marking
on the dipstick.
4. Close the needle valve (12) by turning clockwise and note down the
amount of turning required. Then open the valve by approx. three to
five turns and let the engine run for 1/2 to 1 minute (the governor has
to hunt).
5. Shut the engine off and drain the Diesel fuel completely (see items 1
and 2).
6. Fill fresh oil into the speed governor and let the engine run for a short
period of time (the speed governor has to hunt).
7. Drain the oil again (see items 1 and 2).
8. Fill in fresh oil, up to the upper marking on the oil dipstick (13).
9. Start the engine and, if necessary, deaerate the governor if
necessary (see operating sequence (see operating sequence 1).

6722 140.01--01 E 09.06 L 58/64 CD 103/ 06

 10. Check the oil level and, if necessary, top up oil (the oil level should be
between the upper and lower marking).
11. Close the needle valve (12) and then open it by the amount of turning
noted down under step 4.
▲ Attention! Service oil for the speed governor: Using a suitable
grade of oil is a precondition for trouble-free performance of the
speed governor. The oil used must not have a tendency to foaming,
for absorbing oil bubbles and to precipitating sludge or deposits. At
the same time, the oil serves as a corrosion inhibitor for the inner
parts. The use of multigrade oil is recommended. A list of suitable
oils can be obtained from MAN Diesel SE Augsburg.

Operating sequence 3 -- Removal and refitting the speed governor

1 Charge-air cooler casing

2 Flange
3 Hexagon bolt
4 Speed governor
5 Cylinder crankcase
6 Connection rod

Figure 2. Speed governor removal and refitting

Starting condition The engine has been stopped.

Steps 1. Remove the pipe for oil outlet (17) to the booster from the speed gov-
ernor casing, drain the oil from the speed governor.
2. Remove all other pipe connections and power connections (if fitted).
3. Unscrew the hexagon bolts (3) and flange (2) with seal from the
charge-air cooler casing (1).
4. Attach the swivel arm (140.013-1) to the charge-air cooler casing (1)
by means of hexagon bolts (3).
5. Loosen the screw connection (7) between lever (12) and connection
rod (6).
6. Unscrew four screws (9) with washers (10) from the speed governor
drive (11), loosen the speed governor from the supporting face on the
speed governor drive by turning it back and forth.
7. Fasten the speed governor to the swivel arm (140.013-1) using the
suspension gear (140.006) and ratchet hoist (002.552).

6722 140.01--01 E 09.06 L 58/64 CD 104/ 06

1 Charge-air cooler casing
3 Hexagon bolt
4 Speed governor
5 Cylinder crankcase
6 Connection rod
Figure 3. Attaching the fitting/unfitting tool

1 Charge-air cooler casing

4 Speed governor
5 Cylinder crankcase
6 Connection rod
7 Hexagon bolt
8 Hexagon nut
9 Hexagon bolt
10 Washer
11 Speed governor drive
12 Lever
Figure 4. Suspending the speed governor

▲ Attention! When removing the speed governor, take care to avoid

that the speed governor gets tilted, as otherwise the driving shaft (6)
may suffer damage.
8. Using the ratchet hoist (002.552), lift the speed governor (4) off, rais-
ing it straight upwards, then swivel it out and carefully place it on a
wooden support.
9. Clean the flange surface on the speed governor (4) and speed gov-
ernor drive casing (11).

6722 140.01--01 E 09.06 L 58/64 CD 105/ 06

 10. For fitting the speed governor, proceed in the reverse order followed
for removal. Seal the contact face towards the speed governor drive
casing using a sealing compound.
11. Fill oil in and deaerate (see Operating Sequence 1).
Important! After refitting the speed governor on the engine, the set-
ting of the governor linkage is always to be checked. With the control rods
in zero position on the injection pumps, the speed governor also has to be
in zero position. If necessary, the lock nuts of the connection rod (see
203.01) may be loosened and readjusted by turning in order to
Work Card 203.01
reach the zero position.

1 Charge-air cooler casing

4 Speed governor
5 Cylinder crankcase
6 Connection rod
11 Speed governor drive
12 Lever
Figure 5. Removal of the speed governor

6722 140.01--01 E 09.06 L 58/64 CD 106/ 06

Booster servomotor (2-- stage)
Maintaining and checking 140.02

Purpose of jobs to be done

Carrying out work in time according to the maintenance schedule,

avoiding operation problems/damage.

Brief description

The booster servomotor is to be maintained within specified intervals.

The work/steps include:
removal of components,
disassembly and assembly,
mounting of components.

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard

Related work cards

Work card Work card Work card

140.01

Preliminary remarks

Always drain oil from booster servomotor when changing the oil charge of
the Woodward governor.

Operating sequence 1 -- Removing and disassembling

Important! Before removing or reassembling, refer to Woodward

Booster Servomotor Manual.

Steps 1. Disconnect delivery and return pipes as well as compressed air pipe
(match-mark pipes and associated connecting fittings, if necessary)
and remove servo-motor.
2. Unscrew four nuts, take off cover and pour out the oil.
3. Take out compression spring and piston.
4. Clean all the component parts in fuel, check seal rings, replace if
necessary and check suction and delivery valves in cover for
tightness and free movement.

6619 140.02--01 E 04.98 General 101/ 02

 1 Oil inlet from governor
2 Oil outlet to speed
control system of
governor
3 Oil outlet to working
section of governor
4 Oil outlet to control
section of governor
5 Throttle valve for 4
6 Lift limiting screw for
auxilary piston
7 Lift limiting screw for
master piston
8 Air inlet
9 Cover

Figure 1. Booster servomotor

Operating sequence 2 -- Reassembling and mounting

Steps 1. To assemble the servo-motor, reverse the sequence of operations

outlined above and check to see that the piston and the valve balls
move freely. Check setting of lift limiting screw.
2. Mount servo-motor on engine and reconnect the two oil pipes to the
governor.
3. Reconnect pressure air pipe.
Important! Make sure that all pipes are reconnected in the same
position as when removed.
4. Fill governor with oil (if it has not already been done).
5. Start engine several times to cause air pocket to flow from the oil
space to the governor, and have servo-motor filled with oil.
6. Fill in oil until level lies at the lower mark on the sight glass an check
all connections for tightness.

6619 140.02--01 E 04.98 General 102/ 02

Governor drive
Checking 140.03

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

At the governor drive backlash of the teeth and bearing clearances are to
be checked according to the maintenance schedule.
The work/steps include:
dismantling,
checking components,
reassembling.

Tools/appliances required

Quant Denomination No. Availability

1 Feeler gauge (set) 000.451 Standard
1 Open--jaw and ring spanner (set) -- Standard

Operating sequence 1 -- Checking

Steps 1. Mark position of the control linkage and uncouple the linkage from the
governor (1).
2. Unscrew the pipes at the governor.
3. Screw out the hexagon socket bolt (2). Carefully lift the governor
upwards and out, and deposit it on a suitable wooden base. Do not
stand it on the drive shaft!
4. Remove the cover (6).
5. Check backlash of the teeth and the bearing clearances through
the openings left by the removed governor (1) and the cover (6).
Also subject the serrations of the coupling to the governor to a
visual check. For clearances/plays refer to Operating Manual/
Technical Data.
Important! A precise check of all bearing points can only take
place after the drive has completely been disassembled so that all
individual parts can be measured. When the drive is finally assembled
again particular care must be taken that the flange bearing (3) is
assembled with the spray nozzle (5) in the position shown.
6. Fit governor, cover and pipes and then connect the linkage again.

6619 140.03--01 E 04.98 L 58/64 101/ 02

 ▲ Attention! Every time the governor is refitted to the engine, the
setting of the control linkage is to be checked. With the control rods
in zero position on the fuel-injection pumps, the governor must also
be at zero.

1 Woodward governor 4 Drive casing

2 Hexagon socket bolt 5 Spray nozzle
3 Flange bearing 6 Cover

Figure 1. Drive for Woodward governor

6619 140.03--01 E 04.98 L 58/64 102/ 02

Starting air pilot valve/
Starting valve/Main starting valve

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 160...--04 E 06.98 101/ 01

Starting air pilot valve
Disassembling and assembling 160.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure/restore operational reliability.

Brief description

Starting air pilot valves are to be disassembled and overhauled at regular

intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard
1 Securing compound -- Inventory
(Loctite 243)

Operating sequence 1 -- Removing and disassembling

Important! A check is to be carried out for faultless operation

at the intervals specified in the maintenance schedule. When opening
the starting-air system, particular care must be given to the fact that no
dirt enters the valves and the pipes. Open pipe and tube ends are to be
closed off with plastic caps or adhesive tape. The pilot valve must only
be disassembled in a workplace which is absolutely clean. For cleaning
purposes, grease solvents and compressed air are to be used.
When reassembling, painstaking care must be exercised that the place of
work is absolutely clean. Dirt can cause trouble in the starting system.

Steps 1. Remove the compressed-air inlet pipe and the control pipe from the
valve casing.
2. Remove the complete pilot valve and disassemble it. Clean all parts
and blow through the control-air bores, check the sliding surfaces and
the seal ring seal (4) for wear. Replace if necessary.

6619 160.01--01 E 04.98 40/54, 58/64 101/ 03

 1 Valve casing
2 Spacer disk
3 Control piston
4 Seal ring set,
comprising: O-ring seal
and PTFE ring
5 Hexagon bolt
6 Pitot tube
7 Starting cam
A Gap dimension
B Dimension when new
2 á 0.6 mm

Figure 1. Assembling of starting air pilot valve

Operating sequence 2 -- Fitting the seal ring set (4) on control piston (3)

Steps 1. Lay the O-ring seal in the groove.

2. Lay the PTFE ring in water or oil and warm it up to 80-100ƒ C
3. Slide the PTFE ring over the edge of the groove and into the groove.
4. The PTFE ring has been enlarged in the process, now slide it
carefully over the oiled guide bevel of the casing and into the oiled
casing bore.

3 Control piston
4 Seal ring set,
comprising: O-ring seal
and PTFE ring

Figure 2. Control piston

6619 160.01--01 E 04.98 40/54, 58/64 102/ 03

Operating sequence 3 -- Assembling and installing

Check all the parts for cleanliness and reassamble and install them in the
reverse order to that given above. When doing so, particular attention is
to be paid to the following.

Steps 1. Check the ease of movement of the control piston (3).

2. Fit the hexagon bolt (5), using Loctite 243.
3. Check gap dimension (A) and, if necessary, correct it by changing
dimension (B) at spacer (2) (for Dimension A refer to Operating
Manual/Technical Data).
4. After having connected the pipes, check for leaks and for correct
functioning.

6619 160.01--01 E 04.98 40/54, 58/64 103/ 03

Starting valve
Checking, removing and installing 161.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure/restore operational reliability.

Brief description

Starting valves are to be checked at regular intervals and overhauled if

necessary.
The work/steps include:
checking for leaks,
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 161.021 Standard
1 Extracting sleeve 221.215--1 Standard
1 Threaded spindle 221.215--2 Standard
1 Deep groove thrust ball bearing 221.215--5 Standard
1 Cap 221.215--6 Standard
1 Extension 161.021--4 Standard
1 Adapter 161.021--5 Standard
1 Torque wrench 008.017 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Socket wrench insert 36x20 001.771 Standard
1 Ring nut M24 000.192 Standard

6722 161.01--01 E 12.05 L 58/64 CD 101/ 06

 Qty Designation No. Availability
1 Lifting eye bolt M12 000.142 Standard
1 Shackle A0.6 002.452 Standard
1 Shackle A1.6 002.454 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory
1 Securing compound Loctite 638 -- Inventory

Related work cards

Work card Work card Work card

000.30 055.03 161.02

Preliminary remark

▲ Attention! In case the starting air pipe becomes hot during oper-
ation, the engine should be shut off and the defective starting valve
replaced immediately, if possible!
Prior to carrying out any work on the starting valve, depressurise all
air pipes! Close the shut-off valve on the compressed air tank!

Operating sequence 1 -- Check for tightness

Steps 1. Close the control air pipe before the distributing pipe to the starting
air pilot valves (after removal of a pipe section) by means of a union
nut and a sealing plug.
Important! That way, admission of starting air to any of the starting
valves is no longer possible.
2. Open the indicator valve on the cylinder head.
3. Turn the running gear until the piston is in ignition TDC position (inlet
and exhaust valves closed).
4. Ventilate the starting air pipe.
Leaking starting valves can be recognised by air escaping at the indi-
cator valve.
Important! Overhaul leaking starting valves immediately, if possible,
as otherwise the valve seat will be destroyed further.

6722 161.01--01 E 12.05 L 58/64 CD 102/ 06

 6 Cylinder head 9 Hexagon nut

Figure 1. Starting valve in the cylinder head

Operating sequence 2 -- Removal of the starting valve

Starting condition The cylinder head cover has been opened.

Steps 1. Loosen two hexagon nuts (1) and screw them off.
2. Take the sleeves (10) off.
3. Screw the lifting eye bolt (000.142) into the thrust flange (2).
4. Attach the rope to the lifting eye bolt by means of the shackle
(002.452), and suspend it from the lifting tackle. Refer to Fig-
ure 2 /A.
5. Dismantle the thrust flange (2) and put it down. Refer to Fig-
ure 2 /B.
6. Remove the tools.

6722 161.01--01 E 12.05 L 58/64 CD 103/ 06

 1 Hexagon nut
2 Thrust flange
3 O-ring seal
6 Cylinder head
7 Stud
10 Sleeve
Figure 2. Removal/installation of the thrust flange
7. Screw the extension (161.021-4) onto the starting valve (5) until it is
seated. Refer to Figure 3 /C.
8. Place the adapter (161.021-5) on the cylinder head.
9. Screw the threaded spindle (221.215-2) onto the extension until it is
seated.
10. Place the extracting sleeve (221.215-1) on the adapter.
Important! Put the extracting sleeve on in such a way that it is
locked in position by a stud (7). Refer to Figure 3 /D.
11. Slip the deep groove thrust ball bearing (221.215-5) over the
threaded spindle and insert it into the extracting sleeve. Place the
cap (221.215-6) on the deep groove thrust ball bearing. Refer to Fig-
ure 3 /D.
Important! Make sure to install the deep groove thrust ball bearing
correctly.
12. Screw the hexagon nut (9) onto the threaded spindle.
13. Loosen the starting valve (5) by turning the hexagon nut (9), and
carefully lift it out. Refer to Figure 3 /D.
14. Screw the ring nut (000.192) onto the threaded spindle.
15. Attach the rope to the ring nut by means of the shackle (002.454),
and suspend it from the lifting tackle.
16. Remove the starting valve (5) and put it down on the work bench.
Refer to Figure 3 /E.
17. Clean the locating bore in the cylinder head (6) - see Work Card
055.03.
055.03
▲ Attention! While cleaning, care is to be taken to prevent foreign
matter from falling into the combustion chamber!
18. Check the valve seat in the cylinder head (6); grind it if necessary
(see Work Card 055.03).
055.03
19. Cover the opening in the cylinder head (6).
20. Remove the fitting/unfitting tool (161.021).
21. Take the O-ring seals (3 and 4) off.
22. Clean the starting valve (5) on the outside; disassemble it if neces-
sary (see Work Card 161.02).

6722 161.01--01 E 12.05 L 58/64 CD 104/ 06

 4 O-ring seal 7 Stud
5 Starting valve 9 Hexagon nut
6 Cylinder head

Figure 3. Removal of the starting valve

Operating sequence 3 -- Installation of the starting valve

Starting condition All individual components have been cleaned, checked and replaced if
necessary.

Steps 1. Oil a new O-ring seal (4) with clean lubricating oil, and insert it into
the ring groove, making sure that it is evenly tensioned over the en-
tire circumference and not twisted.
2. Screw the extension (161.021-4) onto the starting valve (5) until it is
seated.
3. Screw the threaded spindle (221.215-2) onto the extension until it is
seated.
4. Screw the ring nut (000.192) onto the threaded spindle.
5. Attach the rope to the ring nut by means of the shackle (002.454),
and suspend it from the lifting tackle. Lift the starting valve (5).
6. Position the starting valve (5) over the cylinder head (6) and insert it
into the locating bore.
7. Install the starting valve (5) so that it is seated.
8. Remove the tools.
9. Oil new O-ring seals (3) with clean lubricating oil and insert them into
the ring grooves, making sure that they are tensioned over the entire
circumference and not twisted.
10. Screw the lifting eye bolt (000.142) into the thrust flange (2).
11. Attach the rope to the lifting eye bolt by means of the shackle
(002.452), and suspend it from the lifting tackle. Lift the thrust flange
(2).

6722 161.01--01 E 12.05 L 58/64 CD 105/ 06

 12. Position the thrust flange (2) over the cylinder head (6) and insert it
into the locating bore. Refer to Figure 2 /B.
13. Install the thrust flange (2) so that it is seated. Refer to Figure 2 /A.
14. Remove the tools.
15. Slip the sleeves (10) over the studs (7).
16. Coat the thread and contact face of the hexagon nuts (1) with
MoS2-lubricant, screw the nuts on and tighten them alternately to the
000.30).
specified torque (see Work Card 000.30
▲ Attention! In case the starting valve is installed into a cylinder
head with the latter at service temperature, only screw the two hexa-
gon nuts down hand-tight at first, and tighten them to the specified
torque only after temperature compensation!
If blind inserts are installed instead of the starting valves, they are
tightened to the specified torque as well!
17. After installation of the starting valve, carry out a tightness check (see
Operating Sequence 1).

6722 161.01--01 E 12.05 L 58/64 CD 106/ 06

Main starting valve
Disassembling and assembling 162.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure/restore operational reliability.

Brief description

The main starting valve is to be checked, cleaned and, if necessary,

overhauled at regular intervals.
The work/steps include:
removal of components,
disassembly and assembly,
installation of components.

Safety requirements

- Operating media system closed/depressurised

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard
1 Screw driver (set) -- Standard

Preliminary remarks

Check free movement and good condition of individual parts at intervals

specified in the maintenance schedule. Examine seal rings, replace
damaged parts if necessary.
Examine valve cones and valve seats for damage, reface with fine emery
paste if necessary.

Operating sequence 1 -- Removing and dismantling

Starting condition Compressed-air tank closed. Pressure pipe vented between

compressed-air tank and main starting valve.

6619 162.01--01 E 04.98 48/60, 58/64 101/ 03

 1 Valve casing 14 Valve seat (vent valve)
3 Valve seat 15 Vent valve
4 Valve piston 16 Piston
5 Safety valve 17 Seal set, comprising:
7 Hexagon bolt O-ring seal and PTFE ring
8 Compression spring 18 Nut
9 Seal set, comprising: 19 Closing cap
O-ring seal and PTFE ring 20 Setscrew

Figure 1. Main starting valve

Important! When opening the control air or starting air system,

care should be taken to prevent dirt from entering valves and pipes. Open
pipe ends should be sealed with plastic closing closing caps or adhesive
tape. Clean conditions should be maintained at the workbench when
dismantling valves. For cleaning use a degreasant solvent and
compressed air.
Clean conditions must be maintained at the workbench when
reassembling valves as dust and dirt in any form are likely to cause valve
trouble.

Steps 1. Loosen pipe connections, remove hexagon bolts and remove the
valve.
2. Seal open pipe ends to prevent dirt from entering.
3. Loosen and remove hexagon bolts (7), mark position of the casing (1)
with relation to the valve seat (3).
4. Separate casing from valve seat. Remove all component parts, clean
them, dry with an air hose and inspect condition. Replace parts if
necessary.
5. Loosen and remove closing cap (19), take out the vent valve and
dismantle it completely.
6. Clean all component parts, blow them dry with an air hose and
inspect condition, replace them if necessary.

6619 162.01--01 E 04.98 48/60, 58/64 102/ 03

 7. If necessary, reface valve piston (4) or venting cone (15) in their
seats (3 or 14) with fine emery (grinding) paste.
Important! When grinding in valves, remove as little material as
possible and stop grinding when the annular seating surface shows a dull
grey ring without any pittings. The tightness of the valve can be checked
with fuel oil or marking ink. For refacing the valve piston (4), use a
threaded rod M10 which is to be screwed into the valve piston.

Operating sequence 2 -- Assembling

For assembling, reverse the sequence of operations outlined above.

Particular attention should be given to free movement of moving parts and
tightness of split joints. After reassembly, test the valve for proper
functioning. When it is intended to check the tightness of the casing, the
check should be made without the internal moving parts and with a test
pressure of 45 bar.

For installation the seal sets (9 or 17), proceed as follows:

Steps 1. Lay O-ring seal into groove.

2. Lay PTFE ring into water or oil and heat up to 80-100ƒ C.
3. Slide PTFE ring over the groove edge into the groove.
4. Reshape PTFE ring by introducing the valve piston (4) or venting
cone (15) into the oiled casing (1) or the valve seat (14).

6619 162.01--01 E 04.98 48/60, 58/64 103/ 03

Fuel injection pump/Control linkage

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 200...--04 E 06.98 101/ 01

Fuel injection pump
Checking 200.01

Purpose of jobs to be done

Carrying out work in time according to the maintenance schedule,

ensuring correct execution of work,
checking the state/wear condition of components,
enabling emergency operation.

Brief description

Fuel injection pumps are to be checked at regular intervals.

The work/steps include:
checking components,
putting out of operation components.

Tools/appliances required

Quant Denomination No. Availability

1 Clamp 200.051 Standard
1 Open--jaw and ring spanner (set) -- Standard

Related work cards

Work card Work card Work card

200.03 209.01

Preliminary remarks

The fact, that the fuel-injection pump is in perfect working order

and correctly adjusted is of supreme importance for trouble-free
and economical operation of the engine. For this reason, the injection
pumps are to be checked at the intervals specified in the maintenance
schedule. The moving parts in the pump are lubricated with oil by the
forced-feed lubrication system. The pump plunger and the pump cylinder
are lubricated by the fuel which is delivered by the pump. An oil blocking
device separates the oil from the fuel. This means therefore, that the
fuel-injection pumps only require a minimum degree of maintenance.

Operating sequence 1 -- Checking

Steps 1. Remove the cover for camshaft casing at the crankcase and cylinder
block, and check the condition (lubrication) and firm seating of the

6619 200.01--02 E 04.98 L 58/64 101/ 04

 injection cams, drive rollers and tappet guides (refer also to work
209.01).
card 209.01
2. Remove the collar bolt (8) from between the control rod (rack) (26)
and the governor linkage and check the ease of movement of control
rod and regulating sleeve (23) (refer to Figure 1 ).
Tip! Diesel fuel can be used to free those regulating sleeves which are
tight or gummed-up.
3. Refit collar bolt and control rod and tighten the lock nut (11).
4. Refit cover for camshaft casing to crankcase and cylinder block.
5. Check that fuel system is unpressurized, and close the input to the
injection pump.
6. Unscrew both baffle screws (4) from each injection pump and check
for wear. Pay attention to the sealing rings (3). If necessary, replace
the screws and secure them with lockwire.
7. At somewhat longer intervals, check the leakage-fuel return. If
excessive leakage fuel losses occur, the corresponding
plunger-and-barrel assembly (24) is to be replaced. As the plunger is
matched to the barrel, always replace these two items together.

When installing new pump assemblies, we recommend to replace

the O-ring seals (31,32,33), too.
Important! Wear of plunger-and-barrel assembly is mainly due
to dirt an foreign particles in the fuel. Therefore, it is important that fuel
filters and separators are cleaned often enough. If a plunger seizes during
operation, it is to be removed from the barrel by carefully easing it back
and forth while holding it in Diesel fuel. After removal, the plunger is to
be lapped-in again using Diesel fuel (do not use any emery).
Even if a plunger does seize, the engine can still be stopped because the
spring-loaded lever on the control shaft takes up the turn movement.

1 Injection pump 21 Sleeve 40 Hexagon bolt

2 Pump casing 22 Snap ring 41 Screw plug
3 Sealing ring 23 Regulating sleeve 42 Snap ring
4 Baffle screw 24 Pump element 43 Distance sleeve
5 Spring washer (plunger and barrel) 44 Compression spring
6 Pointer 25 O-ring seals 45 Valve cone
7 Cylindrical screw 26 Control rod (rack) 46 Sleeve
8 Collar 27 O-ring seals 47 Spring pin
9 Ball and socket joint 38 Spring pin 48 Parallel pin
10 Hexagon nut 29 Flange A Connection,
11 Lock nut 30 Cylindrical screw injection pipe
12 Cylindrical screw 31 O-ring seals B Connection,
13 Cover 32 O-ring seals leakage fuel pipe
14 Shaft seal 33 O-ring seals C Connection,
15 Sealing ring 34 Hexagon bolt fuel inlet pipe
16 Hexagon nut 35 Snap ring D Connection,
17 Adjusting screw 36 Distance sleeve fuel return pipe
18 Supporting plate 37 Spring E Connection,
19 Spring plate 38 Valve cone blocking oil
20 Compression spring 39 Valve support M Marking

Table 1. Legend to Figure 1

Important! Shape of baffle screws and suction holes in pump

barrels may vary.

6619 200.01--02 E 04.98 L 58/64 102/ 04

Figure 1. Injection pump with control rod (rack)

Operating sequence 2 -- Switching off fuel injection pump (zero delivery)

If defects or troubles occur in one of the engine cylinders (piston, valves,

cylinder head), the fuel injection pump can be set to Zero so that it no
longer delivers. In such cases of emergency, the engine can continue to
run for a short period with the respective cylinder out of operation after
the defective parts have been removed. Switching off is effected by
means of a clamp (200.051), which locks the rack of the applicable pump

6619 200.01--02 E 04.98 L 58/64 103/ 04

 in zero-delivery position (refer to Figure 2 ).
Release of fuel charge for remaining injection pumps is possible by
buckling the lever of the zero-delivery pump in the control linkage.

Important! Fuel admission to the injection pump must not be shut

off in this case (plunger lubrication).

1 Fuel injection pump

Figure 2. Fuel injection pump with control rod (rack) and buckling lever

6619 200.01--02 E 04.98 L 58/64 104/ 04

Fuel injection pump
Removing and installing 200.02

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Fuel injection pumps are to be checked at regular intervals.

The work/steps include:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems drained
- Operating media systems closed/depressurised

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Suspension device 200.132 Standard
1 Washer 200.132--1 Standard
1 Attachment swivel 200.132--2 Standard
1 Torque wrench 750--2000 Nm 008.005 Standard
1 Extension piece 25x400 001.916 Standard
1 Socket wrench insert 46x25 001.785 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Lifting tackle with rope -- Inventory

6722 200.02--01 E 01.06 L 58/64 CD 101/ 05

Related work cards

Work card Work card Work card

000.30 111.02 200.01
203.01 434.01

Technical details

Term Information
Fuel injection pump 155 kg

1 Cylinder head
2 Charge air pipe
3 Hexagon nut
4 Stud
5 Fuel injection pump
6 Fuel return pipe
7 Fuel supply pipe
8 Control rod
9 Connection rod
10 Hexagon nut
11 Hexagon bolt
12 Fuel pump drive
13 O-ring seal
15 O-ring seal
16 Hexagon bolt
17 Hexagon bolt
20 Cylinder crankcase
Figure 1. Fuel injection pump

6722 200.02--01 E 01.06 L 58/64 CD 102/ 05

Operating sequence 1 -- Removal of the fuel injection pump

Starting condition Rocker arm casing with charge air pipe section of the respective cylinder
have been removed (see Work Card 111.02).
111.02 the fuel injection pipe has
been dismantled (see Work Card 434.01).
434.01

Steps 1. Turn the engine so that the roller of the fuel-injection-pump cam fol-
lower is positioned on the base circle of the injection cam.
2. Close all required shut-off valves (e.g. fuel pipes, air pip etc.).
3. Dismantle the fuel supply pipe (7) and the fuel return pipe (6) from
the fuel injection pump (5).
4. Remove all pipes (e.g. fuel leakage pipe, air pipe etc.) from the fuel
injection pump (5).
5. By removing the hexagon bolt (11), separate the connection rod (9)
from the fuel control linkage. Refer to Figure 1 .
▲ Attention! The correct length of the connection rod (9) has been
adjusted and secured by MAN B&W Diesel AG! We advise against
disassembling the connection rod or changing its length!

1 Cylinder head
3 Hexagon nut
4 Stud
5 Fuel injection pump
8 Control rod
9 Connection rod
12 Fuel pump drive
13 O-ring seal
18 Rope
19 Hexagon bolt
Figure 2. Fuel injection pump - Fitting the suspension device

6. In order to protect the control rod (8), push it all the way in (full-load
position).
7. Slip the socket wrench insert (001.785) onto the hexagon nut (3).
8. Insert the extension piece (001.916) into the socket wrench insert.
Insert the torque wrench (008.005) into the extension piece, loosen
the hexagon nuts (3) and screw them off.

6722 200.02--01 E 01.06 L 58/64 CD 103/ 05

 9. Fit the washer (200.132-1) of the suspension device (200.132) to the
fuel injection pump (5) by means of two hexagon bolts (19). Refer to
Figure 2 .
10. Fasten the rope (18) to the attachment swivel (200.132-2) and lifting
tackle.
11. Pull the fuel injection pump (5) out carefully. Refer to Figure 3 .
▲ Attention! When pulling out/removing the fuel injection pump,
take care that the studs (4) are not damaged! Pay regard to the
buckling lever on the control linkage!
12. Move the fuel injection pump (5) to the front by means of the lifting
tackle.
13. Lower the fuel injection pump (5) and place it on a wooden support.
▲ Attention! Do not place the fuel injection pump on the control
rod!
14. Remove the O-ring seal (13) from the fuel injection pump drive (12).
15. Cover the resulting opening on the fuel pump drive.
16. Remove the tools from the fuel injection pump (5).
17. Clean the fuel injection pump (5) on the outside.

1 Cylinder head
4 Stud
5 Fuel injection pump
8 Control rod
9 Connection rod
12 Fuel pump drive
13 O-ring seal
18 Rope
Figure 3. Fuel injection pump - Removal

Operating sequence 2 -- Installation of the fuel injection pump

Starting condition The fuel injection pump has been cleaned and checked; the control rod
has been pushed in all the way as a precautionary measure (full-load posi-

6722 200.02--01 E 01.06 L 58/64 CD 104/ 05

 tion). The roller of the fuel-injection-pump cam follower is positioned on
the base circle of the injection cam.

Steps 1. Clean the contact faces on the fuel injection pump (5) and the fuel
injection pump drive (12).
2. Oil a new O-ring seal (13) with clean lubricating oil and insert it into
the ring groove, making sure that it is evenly tensioned over the en-
tire circumference and not twisted.
3. Fit the suspension device (200.132) to the fuel injection pump (5) by
means of two hexagon bolts (19).
4. Fasten the rope (18) to the attachment swivel (200.132-2) and lifting
tackle.
5. Lift the fuel injection pump (5). Refer to Figure 3 .
6. Move the fuel injection pump (5) up to the engine.
▲ Attention! Watch the buckling lever on the control linkage!
7. Remove the cover from the opening on the fuel injection pump drive.
8. Lower the fuel injection pump (5) into the bore slowly and carefully.
Refer to Figure 2 .
▲ Attention! When installing/lowering the fuel injection pump, make
sure that the studs (4) are not damaged!
9. After lowering the fuel injection pump (5) completely, remove the tool.
10. Coat threads and contact faces of the hexagon nuts (3) with MoS2
lubricant, and screw the nuts on until they are seated.
11. Mount the fuel supply pipe (7) and the fuel return pipe (6) to the fuel
injection pump (5). Use new O-ring seals (15), which have been oiled
with clean lubricating oil, in the process.
12. Align the fuel injection pump.
13. Slip the socket wrench insert (001.785) onto the hexagon nut (3).
14. Insert the extension piece (001.916) into the socket wrench insert.
Insert the torque wrench (008.005) into the extension piece.
15. Tighten the hexagon nuts (3) crosswise to the specified torque (see
Work Card 000.30).
000.30
434.01).
16. Fit the fuel injection pipe (see Work Card 434.01
17. Refit all pipes that were removed (e.g. leakage fuel pipe, air pipe etc.)
to the fuel injection pump (5). Open all shut-off cocks that were
closed.
18. Connect the control linkage with the connection rod (9).
▲ Attention! The correct length of the connection rod (9) has been
adjusted and secured by MAN B&W Diesel AG! We advise against
changing the adjusted length (exception: in case a new fuel injection
pump is fitted - readjustment should be carried out by personnel
from MAN B&W Diesel AG)!
111.02).
19. Fit the rocker arm casing (see Work Card 111.02
If a new fuel injection pump is connected to the control linkage, the firing
pressure is to be determined by taking indicator diagrams after start-up.
The firing pressure is then to be compared with that of the neighbouring
cylinders.

6722 200.02--01 E 01.06 L 58/64 CD 105/ 05

Fuel injection pump
Disassembling and assembling 200.03

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

Fuel injection pumps are to be dismantled within the scope of maintenance

and repair work.
The work/steps include:
disassembly of components,
replacement of sealing rings/sealing elements,
assembly of components.

Tools/appliances required

Qty Designation No. Availability

1 Mounting device 200.093 Standard
1 Assembly cone 200.093--1 Standard
1 Expanding sleeve 200.093--2 Standard
1 Assembly cone 200.093--5 Standard
1 Expanding sleeve 200.093--6 Standard
1 Sizing sleeve 200.093--9 Standard
1 Fitting/unfitting tool 200.040 Standard
1 Torque wrench 20--200 Nm 008.002 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Hexagon screw driver 10 000.298 Standard
1 Hexagon screw driver 6 000.295 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory
1 Special lubricant -- Inventory
(Molykote G Rapid, Molykote G--n)

Related work cards

Work card Work card Work card

000.30 000.32 200.02

6641 200.03--03 E 01.01 L 58/64 101/ 06

Operating sequence 1 -- Disassembly of the fuel injection pump

Starting condition Injection pump has been detached from engine and cleaned externally.

Steps 1. Screw out ten hexagon bolts (40) and pull off valve support (39)
(refer to Figure 2 ).
2. Mount fitting/unfitting tool (200.040) (refer to Figure 1 ).
3. Compress compression spring (20) by screwing in the nuts (54)
until support cup (18) can be removed laterally. If necessary, two
screws M6 can be screwed into the support cup for easier removal
(refer to Figures 1 and 2 ).
4. Screw out nuts (54), thus relaxing the spring.
5. Remove fitting/unfitting tool and take off spring plate (19) as well as
compression spring (20).
6. After having removed snap ring (22), sleeve (21) and regulating
sleeve (23) can be removed and the plunger of pump element (24)
can be pulled out.
▲ Attention! Do not touch the pump plunger with the bare hand!
Protect the control edges on the pump plunger from damage!
7. Screw out baffle screws (4) with sealing ring (3).
8. Screw out hexagon bolts (34) and remove the barrel of the pump el-
ement (24). For doing so, use two bolts (34) as forcing-off bolts.
9. Completely remove flange (29), bolts (8) and both of the ball and
socket joints (9).
▲ Attention! The distance of the two ball and socket joints (9) and
the position of the adjusting screw (17) is fixed by the manufacturer.
We recommend not to change the distance as set.
Measure out position of adjusting screw and note results down for
later comparative check.
10. Remove cover (13) and shaft seal (14), and take off control rod
(rack).

50 Sleeve
51 Hexagon bolt
52 Conical socket
53 Spherical disk
54 Nut M24x2

Figure 1. Fitting/unfitting tool (200.040) mounted for removal of the pump plunger

6641 200.03--03 E 01.01 L 58/64 102/ 06

 2 Pump casing
3 Sealing ring
*4 Baffle screw
5 Spring washer
6 Pointer
7 Cylindrical screw
8 Bolt
9 Ball and socket joint
10 Hexagon nut
11 Lock nut
12 Cylindrical screw
13 Cover
14 Shaft seal
15 Sealing ring
16 Hexagon bolt
17 Adjusting screw
18 Support cup
19 Spring plate
20 Compression spring
21 Sleeve
22 Snap ring
23 Regulating sleeve
*24 Pump element
(Pump plunger with
monoblock cylinder)
25 O-ring seal
26 Control rod (rack)
27 O-ring seal
28 Spring pin
29 Flange
30 Cylindrical screw
31 O-ring seal
32 Sealing ring (square)
33 Variseal sealing ring
34 Hexagon bolt
35 Snap ring
36 Distance sleeve
37 Spring
38 Valve cone
39 Valve support
40 Hexagon bolt
42 Snap ring
43 Distance sleeve
44 Compression spring
45 Valve cone
46 Sleeve
47 Spring pin
48 Parallel pin
49 Variseal sealing ring
M Marking

Figure 2. Individual parts of the injection pump

11. If applicable, disassemble constant-pressure relief valve down to
its individual parts (35-38, 42-45), check for tightness and easy
movement.
12. Clean all individual parts with clean diesel oil and check them for
wear and damage.
Important! A pump element (24) consists of the monoblock cylinder
and the pump plunger. Monoblock cylinder and pump plunger may only be
replaced together, as the two parts are fitted together.

6641 200.03--03 E 01.01 L 58/64 103/ 06

Operating sequence 2 -- Fitting the sealing rings on the monoblock cylinder

Starting condition All sealing rings (31, 32, 33 and 49) have been removed. All ring grooves
have been cleaned and checked for damage.

▲ Attention! Make sure that the mounting device (200.093) and the
place of work are clean!
Fitting the sealing rings in the ring grooves (items 3 to 6 and items 9
to 12) should be carried out as quickly as possible in order to ensure
the best possible elasticity of the sealing rings resulting from heat-
ing up!

Steps 1. Slip the long assembly cone (200.093-1) onto the monoblock cylinder
(24). Refer to Figure 4 /A.
2. Heat the Variseal sealing ring (33) in the water bath to approx. 80ƒ C.
▲▲ Caution! Do not put the sealing ring into and remove it from the
water bath respectively with bare hands! Danger of scalding!

Important! Heating the sealing rings should be effected directly at

the place of work, as the sealing rings cool off quickly in the air and their
elasticity is thus lost again.
3. Remove the sealing ring from the water bath, dry it and put it onto the
assembly cone (200.093-1).
4. Using the expanding sleeve (200.093-2), swiftly slide the sealing ring
over the assembly cone and into the ring groove.
▲ Attention! Pay attention to the correct installation position of the
sealing ring!
Refer to Figure 4 / detail “X”.
5. Remove the expanding sleeve and the assembly cone.
6. Immediately place the sizing sleeve (200.093-9) on the monoblock
cylinder (24), using it to press the sealing ring into the ring groove.
Refer to Figure 4 /B.
After approx. 2 minutes, pull the sizing sleeve off again.
7. Slip the short assembly cone (200.093-5) onto the monoblock cylin-
der (24). Refer to Figure 4 /C.
8. Heat the sealing ring (49) in the water bath to approx. 80ƒ C.
▲▲ Caution! Do not put the sealing ring into and remove it from the
water bath respectiveyl with bare hands! Danger of scalding!
9. Remove the sealing ring from the water bath, dry it and put it onto the
assembly cone (200.093-5).
10. Using the expanding sleeve (200.093-6), swiftly slide the sealing ring
over the assembly cone and into the ring groove.
▲ Attention! Pay attention to the correct installation position of the
sealing ring!
Refer to Figure 4 / detail “Y”.
11. Remove the expanding sleeve and the assembly cone.
12. Immediately place the sizing sleeve (200.093-9) on the monoblock
cylinder, using it to press the sealing ring into the ring groove. Refer
to Figure 4 /D.
After approx. 2 minutes, pull the sizing sleeve off again.
13. Insert new sealing rings (31 and 32), which have been coated with
lube oil, into the ring groove, making sure that they are evenly ten-
sioned over the whole circumference and not twisted. Refer to Fig-
ure 4 /E and detail “Y”.

6641 200.03--03 E 01.01 L 58/64 104/ 06

Arbeitsfolge 3 -- Assembly of the fuel injection pump

Starting condition All individual parts have been cleaned and checked for damage, and re-
placed if necessary. The valves in the monoblock cylinder (24) and in the
valve support (39) have been assembled. Refer to Figure 2 .

▲ Attention! The assembly of fuel injection pumps is to be carried

out with the greatest possible care, as faultless operation and good
sealing is only possible with undamaged and clean individual parts!
This especially applies to the monoblock cylinder and the pump
plunger!
Assembly is a reversal of the work as described under disassembly.
Special attention has to be paid to the following:

Steps 1. Before reassembling, oil the thoroughly cleaned parts sparingly (lu-
bricating oil).
Important! Metallic sealing and seating faces have to be absolutely
dry during assembly!
2. Replace old O-ring seals by new ones, and coat them with lubricating
oil prior to installation.
3. Treat the control rod (rack) (26) with special lubricant.
4. When installing the monoblock cylinder (24) and the valve support
(39), special attention must be paid to the positioning pins (48 and
47).
5. Install regulating sleeve (23) in a way that the marking (M) on control
rod (rack) (26) and regulating sleeve (23) coincide. Check once more
through groove in regulating sleeve before fitting sleeve (21) (refer
to Figure 3 ).
6. Check adjusting screw (17) for change in positon. Refer to Fig-
ure 2 .
7. Coat the threads and seating faces of the hexagon bolts (34 and 40)
with MoS2 lubricant. Tighten hexagon bolts crosswise to the speci-
000.30).
fied torque (see work card 000.30
8. Check that the marking (M) on the pump plunger (24) is situated on
the control rod (rack) side (refer to Figure 2 ), that the pump plunger
is sliding smoothly and can simultaneously be turned easily when the
control rod (rack) (26) is pushed back and forth.

23 Regulating sleeve
26 Control rod (rack)
M Marking

Figure 3. Adjusting control rod to regulating sleeve when assembling

6641 200.03--03 E 01.01 L 58/64 105/ 06

 *24 Monoblock cylinder 32 Sealing ring (square) 49 Variseal sealing ring
31 O-ring seal 33 Variseal sealing ring DS Pressure side

Figure 4. Fitting the sealing rings on the monoblock cylinder

* The shape of the baffle screws and the suction holes in the monoblock cylinder may deviate from the ones shown in the illustrations.

6641 200.03--03 E 01.01 L 58/64 106/ 06

Fuel injection pump
Baffle screws
Checking and replacing 200.05

Purpose of jobs to be done

Carrying out the work in time according to the maintenance schedule,

checking state/wear condition of components,
preventing operating problems/damage.

Brief description

Baffle screws latest have to be checked/replaced in time according to the

maintenance schedule.
The work/steps include:
removal of components,
checking of components,
installation of components.

Tools/appliances required

Qty Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Pliers for locking wire -- Inventory

Preliminary remarks

Baffle screws are submitted to heavy stresses due to pressure changes of

the streaming fuel. They have to be considered as wear parts, which help
to avoid problems on higher-value parts. Smaller wear particles are
removed by the fuel stream. Greater particles can cause damages to the
pump element or the seating face of the injection valve.

Operating sequence 1 -- Removing buffle screws

Steps 1. Close fuel admission and return pipe (if possible).

2. Remove wire retentions (3) on baffle screws (refer to Figure 4 ).
3. Screw out front baffle screw (2). In doing so, collect draining off fuel
with suitable receptacle.
4. Screw out rear baffle screw (2).

6619 200.05--01 E 11.98 40/54, 48/60, 58/64 101/ 04

Operating sequence 2 -- Checking buffle screws for wear

Steps 1. Baffle screws have to be replaced if they are damaged on the funnel
external edges (refer to Figure 1 ).

Figure 1. Damaged nose-type baffle screw

2. Baffle screws have to be replaced if the funnel inner contour is
affected to a level that the damage reaches up to the funnel edge
(refer to Figure 2 ).

Figure 2. Damaged nose-type baffle screw

3. Baffle screws which have suffered only a slight material abrasion in
the funnel inner contour can be still used. They have to be rechecked
or replaced, however, at the latest after 500 operating hours or in
case that the operating values have changed (refer to Figure 3 ).
4. Check baffle screws with friction welded MV6 trunk-type construction
for fissures on the friction welded part and renew, if necessary.

6619 200.05--01 E 11.98 40/54, 48/60, 58/64 102/ 04

 Figure 3. Damaged nose-type baffle screw

Important! Engines type L58/64 should be checked after 1500

operating hours, but at the latest after 2000 operating hours.

1 Injection pump 3 Wire retention

2 Baffle screw (with hexagon socket or 4 Wear region
hexagon insert bit)

Figure 1. Details of the injection pump of engine type L58/64 with trunk baffle screws

6619 200.05--01 E 11.98 40/54, 48/60, 58/64 103/ 04

Operating sequence 3 -- Installing buffle screws

Steps 1. Clean sealing faces on injection pump (1).

2. Provide baffle screws with new copper sealing rings and screw in.
Important! When installing baffle screws with trunk-type
construction watch that they are not submitted to impacts or lateral
pressure (e.g. by depositing roughly).
3. Install new wire retention.
4. Open fuel admission and return pipe.

6619 200.05--01 E 11.98 40/54, 48/60, 58/64 104/ 04

Fuel injection pump
Measuring the plunger lift 200.06

Purpose of jobs to be done

Enable/support economic operation.

Brief description

Check the injection time within the scope of the IMO certification.
The work includes:
determining the plunger lift.

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 Measuring device 200.133 Standard
1 Support 200.133--1 Standard
1 Clamping piece 200.133--2 Standard
1 Clamping piece 200.133--3 Standard
1 Dial gauge 200.133--4 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Memo pad -- Inventory

6722 200.06--01 E 01.06 L 58/64 CD 101/ 03

 3 Injection pump drive
4 Camshaft covering
5 Stud
6 Hexagon nut
7 Knurled screw
8 Hexagon bolt
9 Washer
10 Fuel-injection-pump cam
follower
11 Camshaft

Figure 1. Fuel-injection-pump cam follower with measuring device attached

Operating sequence -- Measure the plunger lift

Starting condition The cover of the camshaft covering has been removed.

Steps 1. Check whether the position of the eccentric shaft coincides with the
value stated in the acceptance test record. If necessary, adjust the
eccentric shaft to the corresponding value (only required on engines
with injection timing adjustment).
2. Turn the hexagon bolt (9) back until the clamping piece (200.133-3) is
freely movable.
3. Place the clamping piece (200.133-2) on the fuel-injection-pump cam
follower (5) of a cylinder and clamp it to the fuel-injection-pump cam
follower by tightening the hexagon bolts (9). Refer to Figure 2 .
▲ Attention! Make sure that the clamping piece rests on and against
the fuel-injection-pump cam follower!
4. Fasten the support (200.133-1) to the camshaft covering (4). Refer
to Figure 1 .
5. Insert the dial gauge (200.133-4) into the support and attach it by
means of the knurled screw (8).
6. Turn the running gear in the engine’s sense of rotation until the cam
base circle is reached. Set the dial gauge to “Zero”. Refer to Fig-
ure 1 .
▲ Attention! Only turn in the sense of rotation of the engine in order
to compensate the clearances existing in the camshaft drive!
7. Using the turning gear (electric motor), turn the running gear until the
piston is positioned shortly before ignition TDC.
8. Actuate the turning gear by means of the hand crank until the piston
is in ignition TDC position (marking on the flywheel).
▲ Attention! In case the ignition TDC is exceeded, repeat the turn-
ing process! Turn in the sense of rotation of the engine only!
9. Take a reading on the dial gauge and note down the measured value.

6722 200.06--01 E 01.06 L 58/64 CD 102/ 03

 10. Remove the complete measuring device (200.133).
11. Determine the values for the remaining cylinders in the same way
and note them down.
12. Calculate the average and compare it with the average value of the
parent engine given in the Technical File, Section 3 of the IMO-certifi-
cation.

7 Knurled screw
8 Hexagon bolt
9 Washer
10 Fuel-injection-pump cam
follower
11 Camshaft
12 Receiver for small
covering covers
13 Receiver for large
covering covers
Figure 2. Fuel-injection-pump cam follower with measuring device attached

6722 200.06--01 E 01.06 L 58/64 CD 103/ 03

Drive of injection pump
Removing and installing/checking 201.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

The drive of the fuel injection pump is to be removed within the scope of
maintenance and repair work.
The work/steps include:
removal of components,
checking of components,
installation of components.

Safety requirements

- Engine shut--down
- Operating media system closed/depressurised
- Engine secured against starting

Tools/appliances required

Qty Denomination No. Availability

1 Fitting/unfitting tool 201.011 Standard
1 Thrust pad 201.011--1 Standard
2 Spindle 201.011--5 Standard
1 Pressure plate 201.011--7 Standard
1 Bolt 201.002 Standard
1 Torque wrench 20--200 Nm 008.002 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Screw driver 2x12 000.395 Standard
1 Hexagon screw driver 10 000.298 Standard
1 Ring nut M20x2 000.184 Standard
1 Eye bolt M12 000.142 Standard
1 Depth gauge -- Inventory
1 Securing compound -- Inventory
(Loctite 243)
1 Hylomar SQ/M -- Inventory
1 Grease (acid--free) -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

6641 201.01--01 E 04.99 L 58/64 101/ 06

Related work cards

Work card Work card Work card

000.30 112.02 200.02

Operating sequence 1 -- Removing the cam follower

Starting condition The fuel injection pump is fitted. Respective cover of camshaft casing has
been removed. Prelubricating pump switched on and 4/2-way solenoid
valve/valves (depending on the number of cylinders) adjusted to the stop
(hydraulic brake/brakes for injection timing is/are released). Refer to
Figure 2 .

Steps 1. Switch off the motor circuit breaker of the injection timer.
2. Loosen the spring brake by actuating the lever (31) on the electric
adjusting motor (41) and keep it pulled during the adjusting process
(lever is spring-loaded). See Figure 1 .
3. By turning the manually operated set wheel, adjust the eccentric shaft
(33) in such a way that the eccentric shaft segments (18) can be
dismantled.
4. Remove the hexagon bolts (10) with washers (11) on covering side
(the bolts are secured with Loctite). Hexagon bolts and washers on
engine side remain fitted.
5. Turn the engine in such a way that the injection pump is in TDC
position (maximum cam elevation).
6. Remove screw plug (21) with sealing ring (22) and insert bolt
(201.002) instead, so that the tappet (8) is locked in TDC position.
▲ Attention! Insertion of the bolt is only permitted for assembly
work with the engine at standstill (except turning the engine).
Operating the engine with injection pumps stopped this way would
lead to damage of the pump drive.
7. Turn the engine carefully until the roller is situated on the cam base
circle. While doing so, carefully loosen slide piece (12) from tappet
(8). Hard bouncing of the roller onto the cam, and of slide piece onto
the cam follower must be avoided.
▲ Attention! Do not turn the engine in this condition before items 8
to 10 have been carried out on this cylinder!
8. Loosen cylindrical screws (28) at the juncture of the eccentric shaft
segment (18) and the adjacent shaft segments; however, do not
unscrew them completely.
9. Loosen eccentric shaft segment from fixing bolts (32) in the contact
faces by applying pressure to cam follower (19) or to the upper screw
heads of the slackened cylindrical screws. Do not damage the
contact faces of the shafts.
10. Completely remove cylindrical screws, dismantle cam follower with
shaft segment.

Operating sequence 2 -- Installing the cam follower

Installing is a reversal of the removing procedure. Please pay attention to

the following:

Steps 1. Tighten the cylindrical screws (28) to the specified torque (see work
000.30).
card 000.30

6641 201.01--01 E 04.99 L 58/64 102/ 06

 2. Secure the hexagon bolts (10) by means of Loctite Type 243 (see
000.19).
work card 000.19
3. Pull out the bolt (201.002) using the eye bolt M12 (000.142).
4. Switch on the motor circuit breaker of the injection timer.
5. Turn the 4/2-way solenoid valve/valves back to the stop (hydraulic
brake/brakes for injection timing is/are actuated). Refer to Figure 2 .
Important! On engine start, the injection timer is automatically reset
to its original position.

Operating sequence 3 -- Removing the complete drive

Starting condition Fuel pump has been removed, respective cover of camshaft casing has
been detached.

Steps 1. Turn the engine until the roller stands over the cam base circle.
2. Place thrust pad (201.011-1) onto tappet (8) (refer to Figure 1 ).
3. Screw both of the spindles (201.011-5) into tappet (8) until they
rest on the thrust pad, in the process, ensure that both of the spindles
are tightened evenly.
4. Position pressure plate (201.011-7) and screw on hexagon nut (26).
5. Tighten hexagon nut (26) and press down compression spring (5).
Dismount retaining ring (24).
6. Turn back hexagon nut (26), thus releasing compression spring (5).
7. Screw off hexagon nut (26), take off pressure plate, remove spring
plate (25) and compression spring (5).
8. Screw ring nut (000.184) onto thrust pad.
9. Remove two hexagon bolts (10) with washers (11) (secured with
Loctite 243).
10. Pull tappet (8) and spring plate (7) out together in upward direction by
means of the device. While doing so, hold slide piece (12) to avoid
hard bounding of the slide piece onto the cam follower.
▲ Attention! If the engine is to be turned in this condition, the cam
follower (19) together with the slide piece (12) is to be tied up so that
the cam can rotate freely beneath the roller. Otherwise, the tilted
over slide piece (12) is pressed against the guide bush or casing and
damaged during lifting.
11. If necessary, loosen two cylindrical screws (23), remove taper pin
(20) and detach drive casing (3) with guide bush (4).
12. For removal of cam follower (19) and eccentric part of cam follower
shaft, refer to Operating sequence 1, items 8 to 10.
13. Detach spacer bushes (34 and 35) and butting disks (36) from the
eccentric shaft (18) and push the cam follower off the shaft.
14. Loosen cylindrical screws (27) and remove slide piece (12) with
adapter (13).
15. Loosen hexagon nut (15) and remove bow (16) together with sleeves.
16. Wash all parts in fuel oil, blow out lubricating oil passages using
compressed air, and check the parts for wear.
Important! Replace parts if admissible maximum clearances (refer
to Operating instruction manual/Section 2) are exceeded.
17. Inspect sliding and running surfaces for damage and smooth minor
unevennesses using the oil stone.
18. If necessary, remove two countersunk bolts (1) with washers (2) and
press out guide bush (4). When inserting a new guide bush, pay
attention to the correct position of the recesses for fixation. Coat a
new O-ring seal (6) with acid-free grease and place into cirular
groove. Pay attention that the O-ring seal is not twisted but rather
tensioned uniformly over its whole circumference.

6641 201.01--01 E 04.99 L 58/64 103/ 06

Operating sequence 4 -- Installing the drive

Installing is a reversal of the removing procedure. Please pay attention to

the following:

Steps 1. Oil all parts.

2. Coat threads and seating faces of the hexagon nuts (15) with MoS2
lubricant, screw them on and tighten with specified torque (refer to
work card 000.30).
000.30
3. Coat threads and seating faces of cylindrical screws (27) with MoS2
lubricant, screw them in and tighten them with specified torque (refer
to work card 000.30).
000.30
4. Keep on turning the cylindrical screws (27) by the specified angle of
torsion (refer to work card 000.30).
000.30
5. Install tappet (8) in such a way that the bore for bolt (201.002) is
positioned correctly.
6. When fitting new parts, check control dimension (A). By selecting a
suitable thrust pad (9) (dimensional variations within admissible
manufacturing tolerances), dimension (A) can be adjusted.
7. Insert hexagon bolts (10) again using Loctite Type 243 (refer to work
card 000.19).
000.19
8. Seal seating face of drive casing (3) against the crankcase by means
of Hylomar SQ32/M.

1 Countersunk bolt 17 Camshaft 33 Eccentric shaft

2 Washer 18 Shaft (eccentric) 34 Spacer bush
3 Drive casing 19 Cam follower 35 Spacer bush
4 Guide bush 20 Taper pin 36 Butting disk
5 Compression spring 21 Screw plug 37 Bearing block
6 O-ring seal 22 Sealing ring 38 Bearing block
7 Spring plate 23 Cylindrical screw 39 Fuel cam
8 Tappet 24 Retaining ring 40 Inlet cam
9 Thrust pad 25 Spring plate 41 Electric adjusting motor
10 Hexagon bolt 26 Hexagon bolt
11 Washer 27 Cylindrical screw A Control dimension
12 Slide piece 28 Cylindrical screw 2450.2 in case of “0”
13 Adapter 29 Resilient sleeve setting on the scale of the
14 Hexagon bolt 30 Manually operated set injection timer
15 Hexagon nut wheel M Marking on the adjusting
16 Bow 31 Lever (spring-loaded) device
32 Fixing bolt

Table 1. Legende for Figure 1

6641 201.01--01 E 04.99 L 58/64 104/ 06

Figure 1. Upper illustration half: Drive of the fuel pump
Lower illustration half: Electric injection timer with eccentric shaft

6641 201.01--01 E 04.99 L 58/64 105/ 06

 42 Brake valve
43 Hand lever

S Adjusting path
activated/released

Figure 2. Position of the hand lever on the brake valve in case: hydraulic brake is activated (on the left) / hydraulic brake is
released (on the right)

6641 201.01--01 E 04.99 L 58/64 106/ 06

Cam follower of fuel injection pump
Removing and installing
by means of the dismantling tool 201.02

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

The cam followers of the injection pump drives are to be dismantled within
the scope of maintenance and repair work.
The work/steps consist of:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 Dismantling tool 201.015 Optional
1 Support 201.015--1 Optional
1 Shell 201.015--11 Optional
1 Butt strap 201.015--15 Optional
1 Pipe clip 201.015--18 Optional
1 Bolt 201.002 Standard
1 Shackle A0.6 002.452 Standard
1 Eye bolt M12 000.142 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lifting tackle with rope -- Inventory

Related work cards

Work card Work card Work card

000.30 201.01

6641 201.02--01 E 05.00 L 58/64 101/ 03

Technical details

Term Information
Dismantling tool 20 kg
Cam follower of fuel injection pump 48.5 kg

Operating sequence 1 -- Removal of the cam follower

Starting condition Cover of the camshaft covering removed. The tappet (2) of the injection
pump drive is in TDC position, secured by means of the bolt (201.002).
Cam follower (6) and slide piece (3) of the injection pump drive
dismantled, roller (4) of the cam follower rests on the camshaft base circle
(see work card 201.01).
201.01 Refer to Figure 1 .

▲ Attention! Inserting the bolt (201.002) is only permitted for

mounting work during standstill of the engine (with the exception of
turning the engine). Engine operation with the injection pumps shut
off in this way will lead to a pump drive damage.

Steps 1. Check the pipe clip (201.015-18) of the support (201.015-1) for close
fit, retighten the hexagon bolts (9), if necessary.
2. Attach the support to the lifting tackle by means of shackle (002.452)
and rope.
3. Tighten the rope and lift the support.
4. Carefully insert the support into the engine casing, ensuring that it
touches the underside of the cam follower (6). Refer to Figure 1 .
Important! Make sure that all four contact faces (A) of the support
touch the cam follower!
5. Put the shell (201.015-11) onto the top face of the cam follower and
the support (201.015-1).
Important! Both contact faces (B) of the shell have to touch the cam
follower on the sides.
6. Firmly screw-connect the shell and the support by means of two
hexagon bolts (8).
7. Check the position of the supporting point (P) on the dismantling tool;
if necessary, correct it by shifting the pipe clip on the support. Firmly
retighten the pipe clip again and slightly stretch the rope.
8. Dismantle the cam follower together with the axle section (see work
201.01) and remove it from the engine casing by means of
card 201.01
dismantling tool and lifting tackle.
9. Put the cam follower together with the dismantling tool onto the floor
and remove the dismantling tool.

Operating sequence 2 -- Installation of the cam follower

For the installation of the cam follower, proceed in the reverse order
followed for removal.

6641 201.02--01 E 05.00 L 58/64 102/ 03

 1 Injection pump 7 Cam follower axle A Contact face on the
2 Tappet 8 Hexagon bolt M12 support
3 Slide piece 9 Hexagon bolt with nut B Contact face on the shell
4 Roller M12 P Suspension point of the
5 Camshaft 10 Rope dismantling tool
6 Cam follower

Figure 1. Injection pump drive with cam follower

6641 201.02--01 E 05.00 L 58/64 103/ 03

Injection time adjusting device
Adjusting 202.01

Purpose of jobs to be done

Enable emergency operation in case the automatic injection timing fails.

Brief description

The injection timing enables adjustment of the time of injection as a

function of engine speed and filling.
The work/steps include:
release of the hydraulic brake/brakes,
manual adjustment of the injection timing,
activation of the hydraulic brake/brakes.

Operating sequence 1 -- Manual adjustment of the injection timer

Preliminary remark Manual adjustment of the time of injection during operation may only be
carried out in case there are disturbances in the injection timing (hydraulic
brakes do no longer open, there is no oil pressure for the hydraulic
adjustment, the electric adjusting motor is defective).

Starting condition The motor circuit braker of the injection timer has been switched off.

Steps 1. Turn the hand lever (2) on the brake valve (1) to the stop, the
hydraulic brake (3 and/or 15) will be released. Refer to Figure 1

and/or 2 .
Important! The engine has one hydr. brake including brake valve
each on the injection timer and one at the end of the eccentric shaft.
2. Release the spring brake by actuating the lever (10) on the electric
adjusting motor (13). Refer to Figure 2 .
▲ Attention! Keep the lever pulled until the adjusting process is
completed (lever is spring-loaded).
3. Adjust the eccentric shaft (7) by turning the hand wheel (9) on the
electric adjusting motor, in the process, watch the graduated ring (8)
on the injecting timer.
Important! In order to ensure engine operation under full load, the
injection timer has to be adjusted to 35ƒ early ignition. In part-load
operation, this adjustment may be maintained in emergency operation.
4. Release the lever, the spring brake will be activated.
5. Turn the hand lever on the brake valve back to the stop, the hydraulic
brake will be activated. Refer to Figure 1 .
Important! The engine has one hydr. brake including brake valve
each on the injection timer and one at the end of the eccentric shaft.

6641 202.01--01 E 02.99 L 58/64 101/ 03

 ▲ Attention! Depending on the load condition, the exhaust gas
emission values can only be adhered to with the automatically
acting injection timer. Repair the injection timer immediately.

1 Brake valve
2 Hand lever

A Adjusting path
activated/released

Figure 1. Position of the hand lever on the brake valve with: hydr. brake activated (on the left) / hydr. brake released (on the
right)

6641 202.01--01 E 02.99 L 58/64 102/ 03

 3 Hydr. brake 11 Limit switch B Hydraulic oil connection
4 Camshaft 12 Pointer on the adjusting “Brake released”
5 Exhaust cam device C Hydraulic oil connection
6 Fuel cam 13 electr. adjusting motor “Brake activated”
7 Eccentric shaft 14 Worm gear
8 Graduated ring 15 Injection timing with
9 Hand wheel integrated hydr. brake
10 Lever (spring-loaded)

Figure 2. Injection timing with hydr. brakes

6641 202.01--01 E 02.99 L 58/64 103/ 03

Control linkage
Maintaining and checking 203.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

The control linkage must be checked and lubricated at regular intervals.

The work/steps include:
checking components,
maintaining components.

Tools/appliances required

Quant Denomination No. Availability

1 Grease gun 003.005 Standard
1 Grease gun 003.002 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Grease (multi--purpose) -- Inventory

Related work cards

Work card Work card Work card

200.04

Operating sequence 1 -- Checking

Important! The fuel control linkage has been accurately adjusted

on commissioning of the engine. Checking or changing the setting will be
required only after replacement of individual parts or after a new injection
pump has been fitted (refer to work card 200.04).
200.04 With the control linkage
in zero position, all the control rods (pump racks) of the individual
injection pumps must be also in zero position, otherwise problems might
occur in shutting down the engine due to individual pumps which still
admit fuel.

Starting condition Covering removed.

Steps 1. Check the linkage joints for easy movement.

2. Check bolts and nuts for tight fit.
3. Check buckling levers (24) on the injection pumps for free movement
(free to buckle).

6619 203.01--02 E 04.98 L 58/64 101/ 02

Operating sequence 2 -- Maintaining

Steps 1. At extensive overhauls, check complete fuel control linkage for wear
and correct setting. Check the connections of all injection pumps.
2. Lubricate ball joints and bearing points of control linkage at the
intervals as laid down in the Maintenance Schedule, using
multi-purpose grease.

1 Connecting rod 10 Pointer 18 Connection rod

2 Control rod (pump rack) 11 Lever 19 Scale
3 Pointer 12 Threaded rod 20 Woodward governor
4 Shut-down piston 13 Counter bearing 21 Cam follower
5 Injection pump 14 Guide lever 22 Eccentric shaft
6 Camshaft 15 Connecting rod 23 Control shaft
7 Lever 16 Transmitter 24 Buckling lever
8 Connecting rod 17 Control stand 25 Bearing block
9 Scale

Figure 1. Control linkage with speed governor and injection pump

6619 203.01--02 E 04.98 L 58/64 102/ 02

Camshaft

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 209--01 E 06.98 101/ 01

Camshaft
Checking 209.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

Tracks and bearing points of cams are to be checked at regular intervals.

The work includes:
checking components.

Related work cards

Work card Work card Work card

027.02 102.01

Operating sequence 1 -- Checking

Starting condition Camshaft covers removed, camshafts freely accessible.

Important! In consideration of the Trafulier layer, do not wash

the cams with aggressive cleansers.

1 Exhaust cam
2 Camshaft bearing
3 Fuel cam
4 Inlet cam
5 Camshaft
6 Camshaft gearwheel

Figure 1. Camshaft

6619 209.01--01 E 04.98 L 58/64 101/ 02

Steps 1. Examine cam tracks of exhaust (1), fuel (3) and inlet cams (4) for
damage while turning the engine by means of the turning gear.
Check all sides of the individual cams. Smooth minor unevennesses
with the oil stone (4).
Important! The cam tracks are provided with a Trafulier surface
layer which will be removed on smoothing. In this case it is recommended
to have carried out a Trafulier treatment in one of the service centers.
102.01).
2. Check camshaft bearing bolts for tight fit (refer to work card 102.01
3. Check whether all bearing points are sufficiently supplied with oil.
4. Refit camshaft covers.
▲ Attention! Setting of inlet and exhaust cams has been
established in the factory and must not be changed (clearance
between valves and piston). Also setting of the fuel cams is
factory-established. Change of fuel cam setting is allowed to be
carried out in exceptional cases by educatet and skilled staff only!
Replacement of cams and camshaft parts should be carried out at
a service center using the special tools available there.

6619 209.01--01 E 04.98 L 58/64 102/ 02

Fuel injection valve

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 221--04 E 06.98 101/ 01

Fuel injection valve
Removing and installing 221.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

permit/support economic operation,
prevent operating problems/damage.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work/steps include:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised
- Operating media systems drained

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 221.215 Standard
1 Extracting sleeve 221.215--1 Standard
1 Threaded spindle 221.215--2 Standard
1 Deep groove thrust ball bearing 221.215--5 Standard
1 Cap 221.215--6 Standard
1 Extractor 221.128 Standard
1 Socket wrench insert 434.015 Standard
1 Supporting device 221.214 Standard
1 Base plate 221.214--5 Standard
1 Socket wrench insert 36x20 001.771 Standard
1 Universal joint 20 001.877 Standard

6722 221.01--01 E 12.05 L 58/64 CD 101/ 08

 Qty Designation No. Availability
1 Extension piece 20x200 001.913 Standard
1 Extension piece 20x400 001.914 Standard
1 Torque wrench 008.017 Standard
1 Shackle A1.6 002.454 Standard
1 Ring nut M24 000.192 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Wire brush -- Inventory
1 Lifting tackle with rope -- Inventory
1 Wooden spatula -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

000.30 221.02 434.01

Technical details

Term Information
Thrust flange 10 kg
Fuel injection valve 30 kg

Operating sequence 1 -- Removal of the fuel injection valve

Important! An engine which normally runs on heavy fuel oil is to be

run briefly on diesel oil before removing the fuel injection valve.

Starting condition The cooling water for fuel injection valve cooling has been drained off com-
pletely. The shut-off valves on the fuel pipes have been closed. The cylin-
der head cover and indicator valve have been opened.

▲▲ Caution! Remove the fuel injection valve only when the engine
is at an absolute standstill and the indicator valve is open! The com-
bustion chamber may be under high pressure when the indicator
valve is closed!

Steps 1. Unscrew cooling water supply pipe from cylinder head (6), drain cool-
ing passages of the fuel injection valve (9) by blowing out with com-
pressed air. Then screw pipe back into place.
2. Fasten the base plate (221.214-5) to the rocker arm bracket by
means of hexagon bolts (15). See Figure 1 .
3. Loosen and unscrew hexagon nut (1) on the exhaust side. Take
sleeve (8) off. See Figure 4 /C.
4. Remove tools.
5. Loosen and unscrew hexagon nut (1) on the control side. Take sleeve
(8) off. See Figure 4 /C.
434.01).
6. Remove fuel injection pipe (see Work Card 434.01

6722 221.01--01 E 12.05 L 58/64 CD 102/ 08

 1 Hexagon nut
2 Stud
3 Thrust flange
6 Cylinder head
8 Sleeve
9 Fuel injection valve
15 Hexagon bolt
Figure 1. Loosening/tightening the hexagon nut on the thrust flange, on the ex-
haust side
7. Place the socket wrench insert (434.015) on the threaded piece (7)
and attach it by means of two hexagon socket bolts (M10x50).
8. Loosen the threaded piece (7), unscrew it and remove it from the cyl-
inder head (6). See Figure 3 .
9. Screw extractor (221.128) into thrust flange (3). See Figure 4 /C.
10. Remove thrust flange (3) and put it down. See Figure 4 /D.
Important! During removal, be careful to avoid that the studs (2)
suffer damage.
11. Screw threaded spindle (221.215-2) onto fuel injection valve (9) until
it is seated. See Figure 5 /E.
12. Place extracting sleeve (221.215-1) on bush (5).
Important! Put the extracting sleeve on so as to ensure that it is
fixed in place by the stud (2) on the control side. See Figure 5 /F.
13. Slip the deep-groove thrust ball bearing (221.215-5) over the
threaded spindle and insert it into the extracting sleeve.
Important! Make sure to install the deep-groove thrust ball bearing
correctly.
14. Place the cap (221.215-6) on the extracting sleeve.
15. Screw the hexagon nut (19) onto the threaded spindle.

6722 221.01--01 E 12.05 L 58/64 CD 103/ 08

 3 Thrust flange
6 Cylinder head
9 Fuel injection valve
19 Hexagon nut

Figure 2. Fitting/unfitting tool for injection valve

16. Loosen the fuel injection valve (9) by turning the hexagon nut (19)
and pull it out carefully. See Figure 5 /F.
Important! The fitting/unfitting tool (221.215) must always be used
to remove the fuel injection valve.
17. Screw the ring nut (000.192) onto the threaded spindle. See Fig-
ure 5 /G.
18. Fasten the rope to the ring nut by means of the shackle (002.454)
and attach it to the lifting tackle.
19. Carefully remove the fuel injection valve (9) from the cylinder head
(6) and place it on the work bench.
Important! During removal, be careful to avoid that the studs (2)
suffer damage.
055.03.
20. Clean the locating bore. See Work Card 055.03
▲ Attention! During cleaning, ensure that no foreign matter falls
into the combustion chamber!
21. Check the valve seat (B), grind it if necessary (see Work Card
055.03 See Figure 5 /F.
055.03).
22. Cover the opening on the cylinder head (6).
23. Remove the fitting/unfitting tool (221.215).
24. Remove the O-ring seals (4, 11) from the thrust flange and/or fuel
injection valve.

6722 221.01--01 E 12.05 L 58/64 CD 104/ 08

6 Cylinder head
7 Threaded piece
Figure 3. Removal and installation of the threaded piece
25. Clean the fuel injection valve (9) on the outside, disassemble it if
221.03).
necessary (see Work Card 221.03
Important! Clean the fuel injection valve away from the work bench.
Remove adhering coke deposits with wire brush. Clean the cylindrical
shoulder of the nozzle body with particular care.

▲ Attention! Scrape fuel injection nozzle with wooden spatula only,

to avoid damaging nozzle bores!
26. Clean the threaded piece (7).
27. Check the sealing face on the threaded piece (7) for damage and
221.05).
remachine it if necessary (see Work Card 221.05

6722 221.01--01 E 12.05 L 58/64 CD 105/ 08

 1 Hexagon nut 4 O-ring seal 9 Fuel injection valve
2 Stud 6 Cylinder head
3 Thrust flange 8 Sleeve

Figure 4. Removal of the thrust flange

Operating sequence 2 -- Installation of the fuel injection valve

Starting condition The fuel injection valve, particularly cylindrical shoulder of the nozzle body,
has been cleaned thoroughly. Opening pressure, tightness and nozzle
bores have been checked.

Important! Clean outside of fuel injection valve from reserve stocks

or replacement delivery, and check it.

The locating bore in the cylinder head and the valve seat in the insert have
been cleaned.

Steps 1. Oil new O-ring seals (11) with clean lubricating oil and insert them
into the ring grooves on the fuel injection valve (9), making sure that
they are uniformly tautened over the entire circumference, and not
twisted.
2. Screw the threaded spindle (221.215-2) onto the fuel injection valve
(9) until it is seated.
3. Oil a new O-ring seal (4) with clean lubricating oil and insert it into the
ring groove on the thrust flange (3), making sure that it is uniformly
tautened over the entire circumference, and not twisted.
4. Slip the thrust flange (3) over the threaded spindle (221.215-2) and
place it on the fuel injection valve (9), paying attention to the spring
pin (12).
5. Screw the ring nut (000.192) onto the threaded spindle.
6. Fasten the rope to the ring nut by means of the shackle (002.454)
and attach it to the lifting tackle.
7. Lift the fuel injection valve (9).

6722 221.01--01 E 12.05 L 58/64 CD 106/ 08

 8. In the case of a vertically suspended fuel injection valve (9), fill the
interior (spring chamber) with clean fuel oil through the bore provided
for the threaded piece (7).
Important! This is important for damping the compression spring
when the engine is taken into operation.

2 Stud 11 O-ring seal A Bolt projection

5 Bush 12 Spring pin B Valve seat
9 Fuel injection valve 19 Hexagon nut
10 Insert 20 Bush

Figure 5. Removal of the fuel injection valve

9. Remove the cover for the locating bore in the cylinder head (6).
10. Position the fuel injection valve (9) over the cylinder head (6) and
carefully install it into the locating bore, paying attention to the posi-
tion of the tap hole for the threaded piece (7).
11. Press the fuel injection valve (9) in until it is seated.
Important! During installation, be careful to avoid that the studs (2)
suffer damage.
12. Remove the tools.
13. Coat the thread of the threaded piece (7) with MoS2 lubricant.
14. Insert the threaded piece (7) into the cylinder head (6), screw it into
the fuel injection valve (9) and tighten it to the specified torque (see
Work Card 000.30).
000.30 See Figure 3 .
434.01).
15. Fit the fuel injection valve (see Work Card 434.01
16. Remove the tools.

6722 221.01--01 E 12.05 L 58/64 CD 107/ 08

 17. Slip the sleeves (8) onto the studs (2). Coat the threads and contact
faced of the hexagon nuts (1) with MoS2 lubricant and screw them
onto the studs (2), hand-tight.
▲ Attention! When fitting the fuel injection valve in a cylinder head
which is at operating temperature, first tighten the hexagon nuts
only hand-tight and only tighten them to the specified torque after
temperature equalisation!
18. Tighten the hexagon nut (1) on the control side to the specified torque
000.30).
(see Work Card 000.30
19. Attach the base plate (221.214-5) to the rocker arm bracket by
means of the hexagon bolts (15). See Figure 1 .
20. Tighten the hexagon nut (1) on the exhaust side to the specified
000.30).
torque (see Work Card 000.30
21. Remove the tools.
22. Close the indicator valve.
23. Fill the fuel-injection-valve cooling system with cooling water.
24. Open the shut-off valves on the fuel pipes.
25. Close the cylinder head cover.

6722 221.01--01 E 12.05 L 58/64 CD 108/ 08

Fuel injection valve
Checking 221.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work includes:
checking components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 2

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Connecting piece 221.197--26 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Connecting piece 221.196--26 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Connecting piece 221.195--26 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Connecting piece 221.200--24 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Connecting piece 221.201--23 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Connecting piece 221.202--22 Standard
1 Compressed air max. 15 bar -- Inventory

6629 221.02--03 E 10.02 32/40 upw 101/ 06

 Qty Designation No. Availability
1 Anti--corrosion oil -- Inventory
1 Receptacle for anti--corrosion oil -- Inventory
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard

Related work cards

Work card Work card Work card

221.03 221.04

Remark: The tool numbers of the individual pressure tester components consist of
the tool number of the pressure tester and the item number of the individ-
ual component. Refer to Figures 1 and 2 .
Example: Tool number of the high-pressure hose for engine type
L 58/64: 221.202-6.

Preliminary remarks

The functioning and setting of the injection valve influence the combustion
process, the operating data and the loading of the injection system. In
case the operating data (firing pressure, exhaust gas temperature)
change, the opening pressure and tightness of the valves concerned are
to be checked. The pressure tester permits pressure testing by means of
a hydro-pneumatic high-pressure pump. The device ensures that the work
can be carried out comfortably and under reproducible conditions.

Note

When testing injection valves of modern four-stroke engines, atomisation

no longer is a test criterion, as the nozzle’s behaviour during engine oper-
ation cannot be duplicated by means of the pressure tester.
A poor injection pattern does not permit to draw conclusions on the
nozzle’s performance in the engine. It is fully operational, provided that
the criteria with regard to opening pressure, tightness and unclogged
nozzle bores are fulfilled.

6629 221.02--03 E 10.02 32/40 upw 102/ 06

Structure and diagram of the pressure tester

1 Pressure gauge 0-600 bar 6 High-pressure hose 14 Nozzle-jet collector

2 Air cock 10 Hydraulic pump 15 Collector cover
3 Filter pressure regulator 11 Pressure control valve 16 Fixing head
4 Pneumatic coupling 12 Oil tank
5 Pressure relief valve 13 Oil collecting pan

Figure 1. Pressure tester

Legend: as for Figure 1

9,22,23,24,26
Connecting piece

Figure 2. Pressure tester diagram

6629 221.02--03 E 10.02 32/40 upw 103/ 06

Operating sequence 1 -- Preparation of check

Important! Heavy fuel oil residues in injection valves may adversely

affect the test results and impede cleaning. We therefore recommend op-
erating the engine on Diesel oil for approx. one hour prior to dismantling
injection valves. If this is not possible and the engine has to be shut down
from operation on heavy fuel oil, the injection valve has to be disas-
sembled and cleaned before the checks described here can be carried
out.

Starting condition The injection valve has been removed and cleaned on the outside.

Important! Anti-corrosion oil is to be used for testing the injection

valves because this oil serves as a preservation agent at the same time.
Only absolutely clean anti-corrosion oil may be filled into the pressure
tester; otherwise, disturbances may occur in the pump or in the injection
valve to be tested. The content level in the oil tank (12) is to be checked.

Steps 1. Depending on the engine type, insert the correct reducing jaws into
the fixing head (16) - for the 58/64 engine type, reducing jaws are not
required. Insert the injection valve into the fixing head and clamp it
evenly using the retainer.
2. Depending on the engine type, screw the suitable connecting piece
(9, 22, 23, 24, 26) in at the delivery pipe connection of the injection
nozzle, and screw the high-pressure hose (6) onto the connecting
piece.
3. Place the nozzle-jet collector (13-15) under the injection nozzle and
push it upward so as to ensure that the jets to be expected hit the
outer walls of the nozzle-jet collector.
▲ Attention! Never let the injection nozzle spray into the open, but
always directly into the collector! Fuel jets must not be touched, as
they pierce the skin tissue and cause painful infections! Naked
flames are not allowed in the working area! No smoking at all! If
possible, remove the oil vapour by suction!
Checking and adjusting the injection valves includes the following steps:
- Check the opening pressure,
- check the nozzle bores,
- adjust the specified pressure,
- check for tightness.

Operating sequence 2 -- Check the opening pressure

Steps 1. Turn the knob on the filter pressure regulator (3) all the way to the left
(Minus -), and set the air cock (2) to “Ein” (On).
2. Close the pressure relief valve (5).
3. By turning the knob on the filter pressure regulator (3) to the right
(Plus +), start the hydraulic pump (10) and slowly increase the pres-
sure until the injection valve opens. Note down the opening pressure
and compare it with the specified value (for specified value, refer to
the Operating Instructions, sheet 2.5.2). Keep the pressure tester
running for at least 20 seconds, thus flushing the injection valve.
Important! The hydraulic pressure has to be increased slowly until
the opening pressure is reached, as otherwise faults will occur when read-
ing off the opening pressure. The test pressure must not exceed 400 bar!
When the injection test is carried out for the first time on new nozzle el-
ements, the nozzle needle may be stuck due to preservation and has to be

6629 221.02--03 E 10.02 32/40 upw 104/ 06

 loosened by flushing it thoroughly. In the case of injection nozzles that
have already been used, collect the anti-corrosion oil contaminated with
fuel, and do not fill it back into the pressure tester.

With new nozzles, a drop in opening pressure by 50-90 bar may already
occur after a few operating hours.
This pressure drop does not represent a malfunction and is typical of all
fuel injection valves.

Decision Decrease in opening pressure less than/more than 90 bar?

Decrease in opening pressure less Continue with the next step.

than 90 bar -
Decrease in opening pressure more Disassemble the injection valve
than 90 bar - 221.03).
(according to work card 221.03
Carry out a visual inspection
(spring broken)
If components are in good order,
continue with the next step.

Operating sequence 3 -- Check the nozzle bores

Steps 1. Turn the filter pressure regulator all the way to the left (Minus - ),
open the pressure relief valve (5), and continue as follows (for item-
221.03):
related details, refer to work card 221.03
2. Loosen the hexagon nut (44), and turn back the setting screw (45)
until the tension of the compression spring (49) has been released.
3. Close the pressure relief valve. Start the hydraulic pump by means of
the knob on the filter pressure regulator, and adjust the opening pres-
sure to 30 bar by turning the setting screw (45).
Decision Are all nozzle bores open? Refer to Figure 3 .

Yes - continue with the next step.

No - disassemble the injection valve (according to work card
221.03).
221.03

Figure 3. Judging the nozzle bores. On the left - open, on the right - partly
clogged

Operating sequence 4 -- Adjust the opening pressure to the specified value

Steps 1. Increase the hydraulic pressure by means of the knob on the filter
pressure regulator (3). At the same time, slightly tension the com-
pression spring (49) using the setting screw (45). Repeat the pro-
cess until the specified value (tolerance 20 bar) has been reached
(for specified value, refer to the Operating Instructions, sheet 2.5.2).
Important! Do not adjust a higher pressure than specified as, other-
wise, deformation of the compression spring will result. Only after installa-

6629 221.02--03 E 10.02 32/40 upw 105/ 06

 tion of a new compression spring, adjust the injection pressure to the
specified higher value at first in order to compensate an initial settling of
the compression spring.
2. If the specified value has been adjusted reproducibly, lock the setting
screw (45) by means of the hexagon nut (44), and check the opening
pressure once again.

Operating sequence 5 -- Check the tightness

Steps 1. For checking the tightness, adjust the pressure to 250 bar by means
of the knob on the filter pressure regulator (3), and keep it at this
value. The injection nozzle can be considered tight if no drop falls
within a period of 5 seconds.
Decision Tightness ok? Refer to Figure 4 .

Yes - the injection valve can be used!

No - the injection valve is to be sent to MAN B&W Diesel AG
Augsburg for regeneration.

Figure 4. Judging the tightness. On the left - tight, on the right - dripping

6629 221.02--03 E 10.02 32/40 upw 106/ 06

Fuel injection valve
Disassembling 221.03

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work/steps include:
disassembly of components,
checking of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Socket wrench 221.143 Standard
1 Torque wrench 008.017 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Socket wrench 221.194 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Socket wrench 221.040 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Socket wrench 221.127 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Socket wrench 221.119 Standard

6629 221.03--03 E 10.02 32/40 upw 101/ 06

 Qty Designation No. Availability
1 Torque wrench 008.005 Standard
1 Eye bolt 001.412 Standard
1 Chuck 002.701 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Wire brush -- Inventory
1 Wooden spatula -- Inventory
1 Cleaning wires (set) -- Inventory
1 Depth gauge -- Inventory
1 Tank with fuel -- Inventory
1 Cleaning material (wool) -- Inventory
1 Paper towels -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Securing compound -- Inventory
(Loctite 243)

Related work cards

Work card Work card Work card

000.30 221.02 221.04

Preliminary remarks

Important! Injection valves are to be disassembled if the checks

according to work card 221.02 revealed defects and in case the nozzle
element is to be replaced due to the operating time reached.
Disassembly is carried out in the pressure tester.

Operating sequence 1 -- Disassembly of a fuel injection valve

Steps 1. Rinse the injection valve in fuel, and remove coke deposits sticking to
it by means of a wire brush.
2. Swing the collecting tank (13-15) to the side, and insert suitable re-
ducing jaws into the fixing head (16) of the clamping device (for the
58/64 engine type, reducing jaws are not required).
3. Insert the injection valve into the fixing head, with the injection nozzle
facing downward, and clamp it in place evenly.
4. Loosen the hexagon nut (44), and back off the setting screw (45) until
the tension on the compression spring (49) has been released.
5. Unscrew the hexagon bolts (60) from the fixing head (16). Turn the
fixing head with the injection valve by 180•, and screw the hexagon
bolts back in.
6. Carefully loosen the nozzle tensioning nut (52).

6629 221.03--03 E 10.02 32/40 upw 102/ 06

 Important! If a strong resistance is felt while loosening the nut, it
has to be tried to restore easy movement of the thread by soaking in fuel
oil and by turning the nut back and forth until it can be moved easily. Do
not exert force when loosening the nozzle tensioning nut, as otherwise the
thread may seize and the parts become unusable.

6 High-pressure hose
13-15 Collecting tank
16 Fixing head
60 Hexagon bolt

Figure 1. Pressure tester

7. Unscrew the nozzle tensioning nut and take the nozzle body off.
Take care that the nozzle needle (43) does not fall out.
8. Pull the nozzle needle (43) out of the nozzle body, and immerse it in
fuel for cleaning.
Important! Do not interchange the nozzle needles of the individual
nozzle bodies. They are produced in paires.
9. Unscrew the hexagon bolts (60) from the fixing head (16). Turn the
fixing head with the injection valve back by 180•, and screw the hexa-
gon bolts back in.
10. Remove the injection valve from the fixing head of the pressure
tester, and put it down onto the work bench.
11. Unscrew the setting screw.
12. In case the inner parts are not loose, screw the eye bolt (001.412)
into the thrust pad (48), and pull the thrust pad out. Afterwards, re-
move the compression spring and spring plate (50).
Important! In the case of the 32/40 engine, the set screw (47) has
to be removed for this purpose. On the valves of the larger engines, this
is not required.
13. Immerse all parts in Diesel oil for cleaning, and wash them off, then
blow them by means of compressed air.

6629 221.03--03 E 10.02 32/40 upw 103/ 06

 42 Nozzle body
43 Nozzle needle
44 Hexagon nut
45 Setting screw
46 Holder
47 Set screw
48 Thrust pad
49 Compression spring
50 Spring plate
51 Parallel pin
52 Nozzle tensioning nut

Figure 2. Injection valve (figure shows injection valve of the 32/40 engine type)

Operating sequence 2 -- Check the components

The component check includes the following:

- the nozzle bores,
- the condition of the fitting area,
- the movability of the needle,
- traces of corrosion on the nozzle tensioning nut and on the nozzle
body,
- the nozzle specification.
Tip! Pay particular attention to such sources of error that caused un-
satisfactory results when the injection valve was checked.

6629 221.03--03 E 10.02 32/40 upw 104/ 06

Steps 1. Distinguishing characteristics of nitride-hardened nozzle elements
and seat-insert nozzle elements (refer to Figure 3 ).

Figure 3. Distinguishing characteristic:

On the left - nitride-hardened nozzle element, on the right - seat-insert nozzle el-
ement
2. For nozzle-bore cleaning, clamp a suitable cleaning wire into the
chuck (002.701) and run it through the nozzle bores (refer to Fig-
ure 4 ).

41 Cleaning wire
42 Nozzle body

Figure 4. Cleaning the nozzle bores

3. Inspect all components, especially the sealing faces, for damage/
traces of wear.
Important! The seats and fitting areas must neither be reworked by
hand nor remachined, as the required accuracy cannot be achieved.
4. Check to see if the nozzle needle can be easily moved in the nozzle
body, without noticeable resistance (refer to Figure 5 ).

42 Nozzle body
43 Nozzle needle

Figure 5. Checking the nozzle needle for movability

6629 221.03--03 E 10.02 32/40 upw 105/ 06

 5. Inspect the nozzle body for traces of corrosion. These may be max.
2.5 mm deep. Check the nozzle cooling water outlet temperature; if
necessary, increase it to max. 90ƒ C.
6. Read the nozzle specification off at the collar of the nozzle body, and
compare it with the required specification (refer to Figure 6 ).
For the original specification, please refer to the engine’s acceptance
records.

Figure 6. Nozzle element. On the left - nozzle specification, on the right - regener-
ation marking.
7. Replace damaged parts. Always replace nozzle needle and nozzle
body together. If necessary, have them regenerated by MAN B&W
Diesel AG, Augsburg or Hamburg. Other workshops are not autho-
rised to do this job.
Important! Regenerated nozzle elements are marked by RA or RH
and the date of regeneration. Repeated regeneration is only possible in
the case of seat-insert nozzle elements.

6629 221.03--03 E 10.02 32/40 upw 106/ 06

Fuel injection valve
Assembling 221.04

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work includes:
reassembling components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Socket wrench 221.143 Standard
1 Torque wrench 008.017 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Socket wrench 221.194 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Socket wrench 221.040 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Socket wrench 221.127 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Socket wrench 221.119 Standard
1 Torque wrench 008.005 Standard

6629 221.04--02 E 01.05 32/40 upw 101/ 04

 Qty Designation No. Availability
1 Eye bolt 001.412 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Lubricant (Optimol ”Paste White T”) -- Inventory
1 Securing compound Loctite 243 -- Inventory

Related work cards

Work card Work card Work card

000.30 221.02 221.03

Operating sequence 1 -- Assembly of a fuel injection valve

Important! Prior to assembly, check whether the specification of the

injection nozzle coincides with the required specification. The original
specification can be gathered from the acceptance record (number,
number of nozzle bores, bore diameter, injection angle).

Starting condition The injection valve has been disassembled, all individual components
carefully cleaned and defective parts replaced.

Steps 1. This applies only to the 32/40 engine: Carefully clean the set screw
(47) and the bore hole according to Loctite specification.
2. Screw the eye bolt (001.412) into the thrust pad (48), hold the holder
(46) at an angle (with the sealing face pointing up), and insert the
thrust pad including compression spring (49) and spring plate (50),
paying attention to the position of the groove for the set screw (47) -
refer to Figure 1 .
Verify that the spring plate has been positioned correctly.
3. This applies only to the 32/40 engine: Coat the thread of the set
screw with Loctite 243 securing compound over a length of 5 mm,
and screw the set screw into the holder until it does no longer pro-
trude.
Verify that the thrust pad is still movable in axial direction.
4. Unscrew the eye bolt.
5. Screw the setting screw (45) in, do not yet tension the compression
spring.
6. Depending on the engine type, insert a suitable reducing jaw into the
fixing head (16) of the pressure tester (for the 58/64 engine type, re-
ducing jaws are not required). Refer to Figure 2 .
7. Insert the holder (46) into the fixing head (16) in such a way that the
sealing face for the nozzle body (42) points down, and clamp it
evenly. Turn the fixing head by 180ƒ and fix it in place.
8. Dip the nozzle needle (43) into clean fuel oil, and insert it into the
nozzle body. Verify that it moves easily.
9. Check the nozzle needle lift between the upper edge of the nozzle
body and the step on the nozzle needle.
For the specified value, refer to Volume B1, section “Technical Data”.
10. Wipe the sealing face dry using a paper towel. Slip the nozzle body
and the nozzle needle onto the holder, paying attention to the position
of the two parallel pins (51).
11. Coat the pressure shoulder (D) on the nozzle body (42) with lubricant
“Optimol Paste White T”. Refer to Figure 1 .

6629 221.04--02 E 01.05 32/40 upw 102/ 04

 12. Apply lubricant “Optimol Paste White T” to the thread of the holder
and the nozzle tensioning nut (52) as well as the pressure shoulder
(D) on the nozzle tensioning nut. Refer to Figure 1 .
13. Screw the nozzle tensioning nut onto the holder, hand-tight, and
000.30) in a second
tighten it to the specified torque (see work card 000.30
step. Turn the fixing head by 180ƒ and fix it in place.
14. Screw the hexagon nut (44) loosely onto the setting screw, and
tighten it only after adjusting the injection pressure (see work
card 221.02).
221.02

42 Nozzle body
43 Nozzle needle
44 Hexagon nut
45 Setting screw
46 Holder
47 Set screw
48 Thrust pad
49 Compression spring
50 Spring plate
51 Parallel pin
52 Nozzle tensioning nut

D Pressure shoulder

Figure 1. Injection valve (figure shows injection valve of the 32/40 engine type)

6629 221.04--02 E 01.05 32/40 upw 103/ 04

 6 High-pressure hose
13-15 Receptacle
16 Fixing head
60 Hexagon bolt

Figure 2. Pressure tester

6629 221.04--02 E 01.05 32/40 upw 104/ 04

Fuel injection valve
Sealing faces on the threaded piece
Grinding 221.05

Purpose of jobs to be done

Ensure correct execution of work,

assess wear pattern/condition,
restore contact pattern.

Brief description

The sealing faces on the threaded piece to the fuel injection valve are to
be checked for damage and, if necessary, remachined every time it is
removed.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Qty Denomination No. Availability

1 Grinding device for delivery pipe 434.045 Standard
1 Locating plate 434.045--1 Standard
1 Threaded ring 434.045--2 Standard
1 Bearing ring 434.045--3 Standard
1 Bearing flange 434.045--4 Standard
1 Spacer ring 434.045--8 Standard
2 Bearing block 434.045--10 Standard
1 Swivel arm 434.045--11 Standard
1 Bracket 434.045--12 Standard
1 Stop 434.045--13 Standard
1 Stop gauge 434.045--14 Standard
1 Grinding wheel 434.045--16 Standard
1 Base plate 434.045--17 Standard
1 Sliding carriage 434.045--18 Standard
1 Shaft 434.045--19 Standard
1 Stop 434.045--20 Standard
1 Counter flange 434.045--21 Standard
1 Adapter flange (threaded piece) 434.045--22 Standard
2 Ball bearing 434.044--24 Standard
2 Ball bearing 434.044--25 Standard
1 Hook spanner 434.045--37 Standard
1 Face spanner 434.045--38 Standard
2 Clamping lever 434.045--41 Standard

6641 221.05--01 E 10.98 L 58/64 101/ 05

 Qty Denomination No. Availability
1 Clamping piece 434.045--42 Standard
5 Emery paper 434.045--44 Standard
1 Hexagon screw driver 5 000.294 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Tommy bar 8 000.262 Standard
1 Electric angle grinder -- Standard
1 Cleaning agent -- Inventory
1 Safety goggles -- Inventory

Related work cards

Work card Work card Work card

221.01 434.01

1 Threaded piece 3 Electric angle grinder

2 Hexagon socket bolt M5x10 4 Support adjusting crank

Figure 1. Grinding device for delivery pipe with attached threaded piece

6641 221.05--01 E 10.98 L 58/64 102/ 05

 2 Hexagon socket bolt
M5x10
5 Stop

Figure 2. Grinding device for delivery pipe

1 Threaded piece
6 Hexangon socket bolt
M6x35

Figure 3. Attaching the threaded piece on the grinding device for delivery pipe

Operating sequence 1 - Attaching the threaded piece to the grinding device for delivery pipe

Important! The grinding device for the delivery pipe must be

installed and operated on a solid support. Vibrations of the grinding device
have an influence on the surface quality of the sealing faces to be ground.
The threaded pieces to be ground must be absolutely free from lube oils
and greases. Any kind of contamination, especially lubricants, reduce the
service time of the emery paper considerably.

6641 221.05--01 E 10.98 L 58/64 103/ 05

Starting condition Threaded piece removed and cleaned.

Steps 1. Loosen both clamping levers (434.045-41) and swivel out the electric
angle grinder (3) together with the bracket (434.045-12) up to the
stop.
2. Screw the adapter flange (434.045-22) onto the threaded ring
(434.045-2) by means of the hexagon socket bolts (2) and tighten
them. See Figure 1 .
3. Attach the stop gauge (434.045-14) to the adapter flange by means
of two hexagon socket bolts (6). See Figure 3 .
Tip! When fastening the stop gauge to the adapter flange by means of
the tommy bar (000.262), hold up at the threaded ring.
4. Screw the counter flange (434.045-21) onto the threaded piece (1).
Tip! The threaded piece has a left-hand thread on the injection valve
side.
5. Screw the threaded piece into the adapter flange by means of the
counter flange, until the cone of the threaded piece contacts the stop
gauge.
6. Screw the counter flange onto the adapter flange and tighten it using
the face spanner (434.045-38) and hook spanner (434.045-37).
7. Attach the clamping piece (434.045-42) to the end of the threaded
piece. See Figure 1 .
8. Remove the stop gauge (434.045-14).
9. Slip the tommy bar (000.262) radially into the threaded ring
(434.045-2), screwing the ring in until it contacts the locating plate
(434.045-1).
▲▲ Caution! It is important that every time a threaded piece is to
be newly ground, the threaded ring is screwed in to such an extent
that it contacts the locating plate.
10. Press the yellow stop knob on the electric angle grinder, put grinding
wheel (434.045-16) together with emery paper (434.045-44) onto the
electric angle grinder and tighten by means of mounting nut.
11. Pull the sliding carriage (434.045-18) back by means of the support
adjusting crank (4).
12. Swivel the bracket (434.045-12) back in again until it contacts the
stop, blocking it on the sliding carriage by means of the two clamping
levers (434.045-41).

Operating sequence 2 - Regrinding of the sealing faces on the threaded piece

Starting condition Threaded piece correctly attached to the grinding device for delivery pipe.
Grinding wheel with new emery paper mounted on the electric angle
grinder.

▲ Attention! The remachining of the sealing face is intricate and

requires particular care. It is recommended to have this work carried
out in a service centre or by personnel from MAN B&W Diesel.

Steps 1. Swing the swivel arm (434.045-11) with the electric angle grinder to
the right-hand stop (5). See Figure 2 .
2. Move the grinding wheel (434.045-16) towards the sealing face of the
threaded piece by means of the support adjusting crank until the
grinding wheel touches the sealing face.
3. Move the swivel arm to the left-hand stop (434.045-13) so that the
front side of the grinding wheel faces the threaded piece. See
Figure 4 .
▲▲ Caution! Wear safety goggles when grinding threaded pieces!

6641 221.05--01 E 10.98 L 58/64 104/ 05

 4. Establish the voltage supply for the electric angle grinder and switch
the grinder on.
5. Turn the threaded piece evenly at the clamping piece (434.045-42),
and, at the same time, move the swivel arm with the electric angle
grinder around the sealing face contour.
▲ Attention! The grinding wheel must not contact the adapter
flange.
6. The feed is effected at the threaded ring (434.045-2) by means of the
tommy bar (000.262). Maximum feed per operation is a scale mark
at the threaded ring.
▲ Attention! The feed is not effected at the support adjusting
crank. The adjusted position remains unchanged during the whole
grinding process.
Sealing faces are to be slightly remachined only, merely to be
smoothed, removing as little of the material as possible.
7. Move the swivel arm to the left-hand stop so that the front face of the
grinding wheel faces the threaded piece. Turn off the electric angle
grinder.
8. Evaluate the result of the grinding process. Repeat the grinding
process until the sealing face has been ground evenly bright.
Important! In case the required contact pattern can no longer be
realised by means of the grinding device for delivery pipe, the grinding
device is to be sent to an MAN service centre for repair.

Tip! Remove used up emery paper immediately and replace by new

emery paper.
9. Remove the threaded piece from the grinding device for delivery pipe
and take off the counter flange.

5 Stop

Figure 4. Right-hand and left-hand stop for the swivel arm

6641 221.05--01 E 10.98 L 58/64 105/ 05

Charge air and exhaust pipe

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 280...--04 E 06.98 101/ 01

Exhaust gas turbocharger/air bypass pipe
Emergency operation
Guaranteeing 280.01

Purpose of jobs to be done

Enabling emergency operation.

Brief description

In case of failure of the turbine rotor or problems with the air bypass,
engine operation can be continued provided certain prerequisites are
observed.
The work/steps include:
behaviour in case of problems,
removing components,
installing components.

Tools/appliances required

Quant Denomination No. Availability

2 Blind flange 280.014 Standard
1 Screen 280.010 Standard
1 Screen 280.008 Standard
1 Open--jaw and ring spanner (set) -- Inventory

Preliminary remarks

For intake of combustion air in case of emergency operation, the cover (7)
on the end section of the charge air pipe (6) must be removed. The
opening must then be protected by the screen (280.008 for engine L 58/64
or 280.010 for engine L 48/60). Take care for cleanliness in the air intake
area. For instructions regarding emergency operation in case of exhaust
gas turbocharger failure, refer to Operating Manual/Section 3.
Dependent on engine version may pipe routings and positions of shut-off
flap and compensator differ from those as shown in the Figure.

Operating sequence 1 -- Installing the screen in case of exhaust gas turbocharger failure

Starting condition Turbine rotor arrested or removed, lube oil admission to turbocharger
interrupted.

Steps 1. On engines with air bypass pipe, remove the complete bypass
pipe (4) with compensator (3) and shut-off flap (5). Seal the
control pipes leading to the shut-off flap.
2. Remove cover (7) from end section of charge air pipe (6).
3. Mount screen (280.008 or 280.010) in place of the cover.

6624 280.01--01 E 04.98 L 48/60, L 58/64 101/ 02

 4. On engines with air bypass pipe, install blind flange (280.014) with
seal to the cover (2) of exhaust piping end section (1).

1 End section of
exhaust piping
2 Cover
3 Compensators (fitted
only in case of engines
equipped with air
bypass pipe)
4 Bypass pipe (fitted
only in case of engines
equipped with air
bypass pipe)
5 Shut-off flap (fitted only
in case of engines
equipped with air
bypass pipe)
6 End section of charge
air pipe
7 Cover

Figure 1. Engine with attached (upper illustration) and removed air bypass pipe (lower illustration)

Operating sequence 2 -- Installation of blind flanges in case of failure of the air bypass device

Steps 1. Detach complete bypass pipe (4) with compensator (3) and shut-off
flap (5). Seal control pipes leading to the shut-off flap.
2. Using blind flanges (280.014) and gaskets, seal off openings for
covers (2 and 7) on the end section of exhaust piping (1) and on
end section of charge air pipe (6).
Important! With the air bypass pipe removed, operation is only
possible at constant nominal speed. When operating on the propeller
curve, turbocharger surging will occur.

6624 280.01--01 E 04.98 L 48/60, L 58/64 102/ 02

Charge air bypass device
Disassembly and assembly,
replacement of sealing elements 280.02

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

Control elements in the charge air/exhaust gas system are to be checked

and, if necessary, replaced within the scope of maintenance and repair
work.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 2

Tools/appliances required

Qty Designation No. Availability

1 Pliers for retaining rings A 10--25 002.121 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Screw drivers (set) -- Standard
1 Grease (acid--free) -- Inventory

6682 280.02--01 E 02.03 General 101/ 04

Operating sequence 1 -- Removal of the bypass flap with drive element

20 Bypass flap
21 Drive element
22 Control pipes
23 Bolted flange joint
24 Seal
25 Adapter flange
Figure 1. Charge air bypass device

Starting condition Control pipes (22) and bypass pipes of the charge air bypass device de-
pressurised.

Steps 1. Separate the control pipes (22) from the drive element (21).
2. Unfasten the bolted flanged joints (23) (refer to Figure 1 ).
3. Dismantle any supports which may be fitted to the adapter flange
(25).
4. Pull the bypass flap (20) with the drive element out of the flange con-
nection, paying attention to the seals (24) in order to prevent that
they are damaged.

Operating sequence 2 -- Replacement of the seal and wear-part sets on the drive element

Steps 1. Remove the bypass flap (20) and the drive element (21) from the
adapter flange (25).
2. Unscrew the hexagon socket bolts (8) of the two covers (7).
3. Take the cover (7) with the cover seal (6) off, paying attention to re-
turn springs (16) which may be fitted. Remove the return springs
(16) - refer to Figure 2 .
4. Move both pistons (5) out of the casing (10) of the drive element by
turning the pinion shaft (11). When removing the two pistons, pay
attention to the guide segments (9).
▲ Attention! Never use compressed air to move the two pistons out
of the casing.
Generally, the following applies: Whenever work is to be done on
the drive element, the connection to the compressed air supply is to
be interrupted.
5. Remove guide rings (4) and O-ring seals (3).
6. Take the retaining ring (1) off by means of the pliers (002.121) pro-
vided for this purpose, and pay attention to the backing ring (2) in the
process.

6682 280.02--01 E 02.03 General 102/ 04

 7. Push the pinion shaft (11) out of the casing (10).

1 Retaining ring 8 Hexagon socket bolt 15 Lower slide ring

2 Backing ring 9 Guide segment 16 Return spring
3 O-ring seal 10 Casing 17 O-ring seal
4 Guide ring 11 Pinion shaft 18 Cap nut
5 Piston 12 O-ring seal 19 Set screw
6 Cover seal 13 O-ring seal
7 Cover 14 Upper slide ring

Figure 2. Drive element

8. Remove the upper and lower slide ring (14 and 15) with O-ring seals
(12 and 13).
9. Clean all components and check them for wear.

10. For assembly, proceed in the reverse order followed for disassembly,
using a new set of seals (consisting of items 3, 6, 12, 13, and 17) as
well as a new set of wear parts (consisting of items 4, 9, 14, and 15).
Important! Do not overstrain the retaining ring (1) when fitting it.
11. When inserting the pistons (5) into the casing (10), make sure that
the gear racks of the pistons engage correctly in the tooth system of
the pinion shaft (11), moving symmetrically.
12. Fit the covers (7) with the cover seals (6) on the casing (10) in correct
position, paying attention to the marking “UP” provided on the cover.

6682 280.02--01 E 02.03 General 103/ 04

Operating sequence 3 -- Fitting the bypass flap with the drive element

Starting condition Bypass flap and drive element checked for tightness. Bypass flap and
drive element fitted to the adapter flange.

Steps 1. Slip the bypass flap (20) with drive elements (21) between the flange
connection of the bypass pipes, making sure that they are positioned
correctly. Furthermore, pay attention to the seals (24) and take care
not to damage them.
2. Refasten the bolted flange joints (23) and tighten them, crosswise.
3. If applicable, remount the supports which were previously attached to
the adapter flange (25).
4. Fit the control pipes (22) to the drive element (21), and check the
system for tightness.
▲ Attention! In case the bypass flap (20) is found to be defective or
untight, it is to be replaced completely!

6682 280.02--01 E 02.03 General 104/ 04

Exhaust pipe
Checking 289.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

The exhaust pipe is to be checked at regular intervals for tightness of the

flanged connections and compensators.
The work includes:
checking components.

Safety requirements

- Engine shut down

Tools/appliances required

Qty Designation No. Availability

1 Extension piece 12.5x125 001.911 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Socket wrench insert 17x12.5 001.754 Standard
1 Ratchet 001.521 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Torch -- Inventory

Operating sequence 1 - Checking the exhaust pipe

Starting condition Engine has cooled down.

Steps 1. Screw out hexagon head bolts (7) and take off cover strips (6) or
cover strip (9) respectively. Refer to Figure 1 .
2. Screw hexagon head bolts (12) out and pull the rear covering (11) off
in upward direction. Refer to Figure 2 .
3. Through the openings in the finger guard (3), screw out hexagon
head bolts (14) and take off the outer covering (16).
4. Check the insulation of the coverings (11 and 16) for black
discoloration.
Important! Untight exhaust pipes show black discoloration in the
respective areas of the insulation.

6641 289.01--01 E 08.01 L 58/64 101/ 04

 1 Finger guard 4 Finger guard 8 Disk
2 Covering cap 6 Cover strip 9 Cover strip
3 Finger guard 7 Hexagon head bolt 10 Turbocharger casing

Figure 1. Covering of the exhaust pipe (figure shows turbocharger mounting on free end of engine)

3 Finger guard
11 Covering
12 Hexagon head bolt
13 Disk
14 Hexagon head bolt
15 Disk
16 Covering
17 Exhaust pipe
18 Covering
19 Quick-acting clutch
20 Covering
21 Adapter to the
cylinder head

Figure 2. Covering of the exhaust pipe (Section A-A)

6641 289.01--01 E 08.01 L 58/64 102/ 04

 5. For mounting the coverings, proceed in the reverse order followed for
removal. As a matter of principle, mount the hexagon head bolts with
the belonging disks.
6. Remove, check and remount the remaining coverings on the
following cylinders the same way. Refer to points 2 to 5.
7. Remove cover plate (25). Refer to figure 4 .
Important! When removing the cover plate, pay attention to the
cable routing for the temperature sensor!
8. Remove the hexagon head bolts (24) from the connection of the
coverings (22 and 28).
9. Disconnect the lever (33) from the covering hood (2) and tilt it
towards the rear.
10. Screw out the hexagon head bolts (31) and remove the covering (30).
Refer to Figure 3 .
11. Screw out the hexagon head bolts (32).
12. Screw out the hexagon head bolts (27) and take off the covering (28).
Figure 4 .
13. Check the insulation of the coverings for black discoloration.
Important! Untight exhaust pipes show black discoloration in the
respective areas of the insulation.
14. For mounting the coverings, proceed in the reverse order followed for
removal.
15. Slip on cover strips (6 and 9) and fasten them by means of hexagon
head bolts (7) including disks (8). Refer to Figure 1 .

1 Finger guard
3 Covering
8 Disk
10 Turbocharger casing
22 Covering
23 Annular lagging
28 Covering
29 Annular lagging
30 Covering
31 Hexagon head bolt
32 Hexagon head bolt

Figure 3. Covering of the exhaust pipe prior to mounting the turbocharger (View C)

6641 289.01--01 E 08.01 L 58/64 103/ 04

 1 Finger guard 24 Hexagon head bolt 29 Annular lagging
2 Covering cap 25 Cover plate 33 Lever
8 Disk 26 Hexagon head bolt 34 Tension spring
22 Covering 27 Hexagon head bolt
23 Annular lagging 28 Covering

Figure 4. Covering of the exhaust pipe prior to mounting the turbocharger (Section B-B)

6641 289.01--01 E 08.01 L 58/64 104/ 04

Exhaust gas blow-- off device
Disassembly and assembly,
replacement of sealing elements 289.02

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

The control elements in the exhaust gas system are to be checked and
replaced if necessary within the scope of maintenance and repair work.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 2

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Screw drivers (set) -- Standard
1 High--temperature grease XOMOX REINM 050 -- Inventory

6707 289.02--01 E 12.02 48/60, 58/64, 48/60 B 101/ 05

Operating sequence 1 -- Removal of the blow-off flap with drive element

1 Blow-off flap
2 Drive element
3 Control pipes
4 Bolted flange joint
5 Seal
6 Adapter flange

Figure 1. Exhaust gas blow-off device

Starting condition Control pipes (3) and blow--off pipes of the exhaust gas blow--off device
unpressurised. For designation of the items, please refer to Figure 1 .

Steps 1. Separate the control pipes (3) from the drive element (2).
2. Unfasten the bolted flange joints (4).
3. Dismantle supports which may be fitted to the adapter flange (6).
4. Pull the blow-off flap together with the drive element out of the flange
connection, paying attention to the seals (5) in order to prevent that
they are damaged.

Operating sequence 2 -- Replacement of the flap shaft packing on the blow-off flap

For designation of the items, please refer to Figure 2 .

Steps 1. Dismantle blow-off flap and drive element from the adapter flange.
2. Remove the clamping sleeve (24) from the flap shaft (3).
3. Unscrew the hexagon nuts (20) together with the spring washers
(21); take off the pressure plate (17) with the thrust ring (16) and the
flap shaft packing (14).
Tip! The packing ring (15) as well as the flap shaft bearing (13) do not
need to be dismantled.
4. Slip a new flap shaft packing (14) over the flap shaft (3) into the bore
hole on the flap body (1).
5. Put on the thrust ring and the pressure plate, and bolt them together
using hexagon nuts (20). Do not forget the spring washers (21).
6. Install the clamping sleeve (24) in the flap shaft (3).
7. Check the flap shaft packing for tightness, and retighten the hexagon
nuts (20) if necessary.

Operating sequence 3 -- Replacement of the bottom seal on the blow-off flap

For designation of items, please refer to Figure 2 .

Steps 1. Loosen the screw plug (25) on the flap body (1) and dismantle it.
2. Remove the sealing ring (26), and replace it by a new one.
3. Screw the screw plug (25) into the flap body (1) and tighten it.

6707 289.02--01 E 12.02 48/60, 58/64, 48/60 B 102/ 05

 1 Flap body 11 Hexagon socket bolt 19 Set screw
2 Flap disk 12 Disk spacer 20 Hexagon nut
3 Flap shaft 13 Flap shaft bearing 21 Spring washer
6 Seat ring 14 Flap shaft packing 24 Clamping sleeve
8 Seat ring gasket 15 Packing ring 25 Screw plug
9 Taper pin 16 Thrust ring 26 Sealing ring
10 Seat ring retainer 17 Pressure plate

Figure 2. Blow-off flap

Operating sequence 4 -- Replacement of the seat ring with the seat ring gasket on the blow-off flap

For designation of items, please refer to Figure 2 .

Steps 1. Unscrew the hexagon socket bolts (11) from the seat ring re-
tainer(10).
2. Move the flap disk (2) into a partly open position (so that it is approxi-
mately located at a 30--degree angle to the flap body).

6707 289.02--01 E 12.02 48/60, 58/64, 48/60 B 103/ 05

 3. Force the seat ring retainer (10) off the flap body. For this purpose,
screw two hexagon bolts into the tap holes on the seat ring retainer
and force the latter off evenly.
4. Check the seat ring gasket (8) and replace it if necessary. Clean the
sealing ring groove before inserting the new seat ring gasket.
5. Move the flap disk (2) to a fully open position (so that it is approxi-
mately located at a 90--degree angle to the flap body).
6. Clean the sealing face of the flap disk (2) and check it.
7. Close the flap disk (2).
8. Insert a new seat ring (6) into the flap body (1).
Important! When inserting the seat ring (6), pay attention to the re-
cess on the flap body.
9. Put the seat ring retainer (10) on, and screw the hexagon socket
bolts (11) evenly in, crosswise. Make sure that the seat ring retainer
abuts to the flap body smoothly, with a maximum projection of
0.2 mm.
10. Carry out a tightness check at nominal pressure, in the preferred flow
direction.

Operating sequence 5 -- Replacement of the shaft packings and the paddle seal on the drive element

1 Housing top 5 Shaft O-ring seal 10 Hexagon socket bolt

2 Bearing bush 6 Paddle seal 11 Stop screw
3 Paddle 7 Housing bottom 12 Seal disk
3a Safety ball bearing 8 Fitting bolt 13 Washer
4 Shaft 9 Hexagon nut 14 Hexagon nut

Figure 3. Drive element

For designation of items, please refer to Figure 3 .

Steps 1. Unscrew the fitting bolts (8) and the hexagon socket bolts (10).

6707 289.02--01 E 12.02 48/60, 58/64, 48/60 B 104/ 05

 2. Separate the housing top (1) from the housing bottom (7), and re-
move shaft (4) with paddle (3).
3. Remove the shaft O-ring seals (5), clean the sealing ring grooves and
insert new shaft O-ring seals.
4. Remove the paddle seal (6), clean the sealing ring groove on the
paddle (3), and insert a new paddle seal.
5. Clean the sealing faces on the housing top and housing bottom;
check the bearing bushes (2) in the housing halves.
6. Insert the shaft (4) with the paddle (3) into the housing bottom. While
doing so, pay attention to the shaft O-ring seal (5) so as to ensure
that it is not damaged.
7. Coat the sealing faces of the housing halves with XOMOX REINM
050 high-temperature grease.
▲ Attention! Use XOMOX REINM 050 high-temperature grease ex-
clusively for joining the two housing halves. Other sealing agents
may cause damage to the drive element.
8. Put the housing top on. While doing so, pay attention to the shaft
O-ring seal (5) so as to ensure that it is not damaged.
9. Screw the fitting bolts (8) in and fasten them in place by means of the
the hexagon nuts (9). Screw the hexagon socket bolts (10) in and
fasten them in place by means of the hexagon nuts (9); tighten them
crosswise.

Operating sequence 6 -- Fitting the blow-off flap with drive element

Starting condition Blow-off flap and drive element checked for tightness. Blow-off flap and
drive element fitted to the adapter flange.
For designation of items, please refer to Figure 1 .
Steps 1. Slip the blow-off flap with the drive element between the flange con-
nection of the blow-off pipe, making sure that the flap is positioned
correctly. Furthermore, pay attention to the seals (5) and take care
not to damage them.
2. Refasten the bolted flange joints (4) and tighten them, crosswise.
3. If applicable, remount the supports which were previously fitted be-
tween the blow-off pipe and the adapter flange (6).
4. Fit the control pipes (3) to the drive element (2), and check the sys-
tem for tightness.

6707 289.02--01 E 12.02 48/60, 58/64, 48/60 B 105/ 05

Lube oil and cooling water pump
(attached to engine)

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 300...--04 E 06.98 101/ 01

Lube oil pump
Disassembling and assembling 300.01

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Lubricating--oil pumps require little or no maintenance. But if operating

problems occur, it is necessary to check the individual components for
damage, and replace them if necessary. If there is damage to the
bearings, replace the entire pump.
The work/steps include:
removal of components,
disassembly and assembly,
mounting of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 3
1 Assistant 3

Tools/appliances required

Qty Designation No. Availability

1 Forcing--off device 009.340 Optional
1 Counterbrace 009.340--11 Optional
1 Forcing--off device 009.331 Optional
1 Forcing--off device 009.331--3 Optional
1 Pipe 009.331--6 Optional
1 Forcing--off disk 009.331--8 Optional
1 Forcing--off bolt 009.331--9 Optional
1 Torque wrench 008.011 Standard
1 Torque wrench 008.017 Standard
1 Power amplifier 008.030 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 25x20 001.924 Optional
1 Adapter 20x12.5 001.923 Standard
1 Cross handle 001.892 Optional
1 Cross handle 001.891 Standard

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 101/ 04

 Qty Designation No. Availability
1 Socket wrench insert 55x25 001.804 Optional
1 Socket wrench insert 14x12.5 001.753 Standard
1 Socket wrench insert 30x12.5 001.759 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Depth gauge -- Inventory
2 Threaded rod -- Standard
1 Lifting tackle with rope -- Inventory
1 Collecting tank -- Inventory
1 Hammer (wood/plastic) -- Inventory
1 Sealing compound -- Inventory

Related work cards

Work card Work card Work card

000.30

3 Drive cover
4 Blank flange
5 Pump casing
6 Ring seal
7 Ring seal
8 Bearing unit (two-part)
9 Hexagon-head bolt
10 Valve casing
11 Valve head
12 Compression spring
13 Ring seal
14 Hexagon-head screw
15 Valve bonnet
16 Screw plug
17 Adapter disk
19 Drive shaft
20 Impeller axle
22 Sleeve
23 Hexagon-head bolt

Figure 1. Lubricating-oil pump (two-stage)

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 102/ 04

 1 Nut 24 Cap screw A Spacing
2 Drive gear-wheel

Figure 2. Forcing-off device for gear-wheel of lubricating-oil pump

Introductory remarks

The lube-oil pump consists of two separate pumps of identical construc-

tion, which are connected by means of the adapter disk (17).

Operating sequence 1 -- Removing and disassembling the lubricating-oil pump

Steps 1. Disconnect the pipes and blank flanges (4) from the lube-oil pump,
allowing the oil to drain into the tank. Be careful not to damage
gaskets and ring seals.
2. Sling the pump from the lifting tackle with a rope, and tauten the
rope.
3. Unscrew the fastening screws on the drive cover (3), remove the
pump carefully, and set it down on a wooden rest.
4. Remove the cap screw (24) that secures nut (1) with the screwdriver
(000.293).
5. Mount the forcing-off device (009.331-3) on the drive gear-wheel (2),
slide the pipe (009.331-6) on, and unscrew nut (1).
6. Force off the drive gear-wheel, using the forcing-off device and the
forcing-off disk (009.331-8).
7. Loosen and unscrew the hexagon-head bolts (23) between the pump
casing (5) and the adapter disk (17).
8. Separate Pump 2 from Pump 1, being careful not to damage the
cylindrical pins. Remove the adapter disk (17).
9. Loosen and unscrew the hexagon-head bolts (23) between the pump
casing (5) and the drive cover (3).
10. Mark the drive shafts (19), impeller axles (20), and bearing units (8)
on both pumps, so that they can be re-installed in the same position.
11. Remove the drive shafts, impeller axles, and bearing units.
12. Remove the taper pins on the drive cover (3) with suitable equipment,
and remove the drive cover with the bolted-on bearing unit.
13. Unscrew the hexagon-head bolts (9) and separate the pressure relief
valve from Pump 2, being careful not to damage the cylindrical pins).
Important! Only disassemble the pressure relief valve if it malfunc-
tions. In that case, proceed as follows:

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 103/ 04

 14. Unscrew two opposite hexagon-head screws (14) on the valve cover
(15), and replace them by two M8-size threaded spindles, about 100
mm long.
15. Screw two M8 hexagon nuts all the way onto the two spindles, until
they rest against the valve cover, and unscrew the other hexagon-
head screws.
16. Relieve the initial tension of the compression springs (12) by backing
off the two M8 hexagon nuts uniformly; steady with the two threaded
spindles.
17. Remove the valve cover (15) and the compression spring (12) with
valve disk (11).
Important! Do not unscrew the screw plug (16). Do not unscrew or
re-adjust the lock screw.
18. Clean all parts, and check them for damage; check the appearance
and wear of the bearing and sliding surfaces. Replace all ring seals,
gaskets, and spring washers.
▲ Attention! If there is damage to the bearings, replace the entire
lube-oil pump.

Operating sequence 2 -- Assembling and mounting the lubricating-oil pump

Starting condition All parts cleaned and checked. All ring seals, gaskets, and spring washers
replaced.
Assembly and mounting are done by analogy to disassembly and removal,
in reverse order. Mind the following points:
1. Lubricate all moving parts with oil.
2. Do not change the setting of the pressure-relief valve (opening pres-
sure set to 7.5 bars).
3. Do not insert paper gaskets between the drive cover, casing, and
pressure-relief valve.
4. Coat the threads of the hexagon-head bolts (9, 23) with oil, screw
them in – not forgetting the spring washers (circlips) – and tighten
000.30).
with the specified tightening torque (see Work Card 000.30
5. If Pump 2 is mounted onto Pump 1, make sure that the teeth of the
drive shafts (19) engage correctly.
6. Check the entire pump for ease of movement.
7. To remount the drive gear-wheel (2), place it on the lightly oiled tap-
ered section of the drive shaft (19), mount the forcing-off device
(009.331-3), and slide the pipe (009.331-6) on.
8. Oil nut (1), screw it onto the drive shaft (19), and tighten it with the
specified initial torque (see Work Card 000.30).
000.30
9. Measure and note down the distance (A) between the end face of the
drive shaft (19) and the nut (1) with a depth gauge.
10. Tighten the nut with the specified tightening torque (see Work Card
000.30).
000.30 Repeat the measurement according to Item 9, and compare
the two values.
The spacing (A) must have increased by 0.6 mm to 1.5 mm.
11. Secure the nut (1) by tightening the cap screw (24) firmly.
12. Before installing, clean the sealing surface between the pump and
engine and coat it with Hylomar SW32M sealant.
13. Fill the pump with oil.
14. Connect the pipes (unpressurized) to the pump, and screw on the
blank flanges (4).
15. When starting the engine, check the pump and piping for leaks and
noises. Loud noises indicate that the lube-oil pump is aspirating air,
so that the pump does not deliver at full capacity and cavitation may
occur.

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 104/ 04

Lube oil pump
Assessing the individual components 300.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Lubricating--oil pumps require little or no maintenance. But if operating

problems occur, it is necessary to check the individual components for
damage, and replace them if necessary. If there is damage to the
bearings, replace the entire pump.
The work /steps include:
Measure components and
assess wear pattern/condition.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Feeler gauge (set) 000.451 Standard
1 Micrometer (outside) -- Inventory
1 Micrometer (inside) -- Inventory
1 Abrasive (emery cloth K400) -- Inventory
1 Oil stone -- Inventory
1 Sealing compound -- Inventory

Related work cards

Work card Work card Work card

300.01

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 101/ 05

Preliminary remarks

These criteria are provided for the evaluation of wear parts on lube oil
pumps. The stated criteria are to render it possible to decide which
components of the gear pump can further be used and which not.
The criteria for the evaluation regarding re-usability are based on the
assumption that the operating conditions of the lube oil pump do not
change during the course of the operating time. This especially applies to
quality and cleanliness of the lubricant used, its treatment and the
occurring maximum temperatures and loading of the pumps.
Components, the re-usability of which is uncertain, are to be replaced in
principle or the time interval to the next pump inspection is to be shortened
in order to rule out the risk of an unexpected pump failure.
Already for the removal of components, proper tools are to be used, in
order to avoid that parts are damaged during dismantling.
The parts to be inspected are to be cleaned thoroughly after removal.
During the assembly of the pump, it is important, beside scrupulous
cleanliness, to make sure that all the re-used components are remounted
as originally positioned within the pump.

Criteria for the evaluation of wear parts on lube oil pumps

1. Seals
On principle, seals are to replaced by new ones every time the lube oil
pump is dismantled.
Grooves, in which O-ring seals are positioned, have to be cleaned
thoroughly and checked for foreign body or damage on the groove edges.
Minor edge damage can manually be smoothed out by means of emery
cloth (grain size 400 according to DIN 69176, part 1 or finer) and a
scraper.
Residues from liquid sealing have to be removed completely before the
pump can be remounted using a new sealing agent.
2. Gear shafts
2.1 Tooth system

1 Tooth flanks
2 Axial butting face
3 Crest of the tooth

Figure 1. Gear shaft

The replacement of gear shafts due to damage in the area of the tooth
system is only necessary if it is determined that material has broken off the
crest of the tooth > 3 mm in longitudinal direction.
Further use of the gear shafts is possible in case of
- scores or scratches on tooth flanks, even if they can be distinctly seen
or felt. Sharp-edged burrs on the tooth system which might exist,

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 102/ 05

 especially on the crests of the teeth, should, as far as possible, be
removed or smoothed by means of a scraper, oil stone or emery cloth
to such an extent that a smooth meshing of theeth with the second
gear shaft is possible, if such a gear shaft is to be re-used.
- individual indentations < 1 cm2 on tooth flanks.
- chip-off of material particles < 1 cm2 in the area of the transition
between axial butting face and tooth flank
2.2 Bearing journal

4 Bearing journal

Figure 2. Bearing journal

Further use of the gear shafts is not possible due to damage in the area of
the bearing journal if
- scores, scratches or chip-offs are found on the bearing journal which
are so deep that they can be made out by touching with the finger nail
or the tip of a pencil.
- material changes due to overheating or distinct blue discolorations are
found on the bearing journals.
2.3 Axial butting faces

2 Axial butting faces

Figure 3. Front surface of the gear shaft

A further use of the gear shaft and/or bearing support due to damage in
the area of the axial butting faces is not possible if
- scores or scratches are found on the axial butting faces which are so
deep that they can be made out by touching with the finger nail or the
tip of the pencil.
Important! Gear shaft and bearing support are adapted to each
other. It is, therefore, not possible here to replace individual components.
It is recommended to replace the lube oil pump and to have the damaged
one repaired by MAN B&W Diesel or by an authorised service center.

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 103/ 05

 3. Bearing bushes
3.1 Structure and wear characteristics
The bearing bushes of the lube oil pumps consist of a steel bush onto
which a bronze layer is sintered. The bronze layer contains a mixture of
PTFE and lead in the pores in way to the shaft which form a grey-green
glimmering slide layer as against the bearing journal of the gear shaft.
During the course of pump operation, the slide layer is gradually worn off
and the bronze layer lying underneath becomes more and more visible.
After a short running-in phase, during the course of which slight deposits
from the slide layer may occur on the bearing journal (harmless), the slide
layer is further worn off approximately analogously to the operating time, if
the stresses acting on the bearing and the operating conditions remain the
same.

3.2 Visual inspection of the bearing bushes

6 Bronze layer
7 Slide layer

Figure 4. Bearing bush in new condition

The bearing bushes are to be replaced when on approx. 70% of the

internal face of the bush the metallic bronze layer is visible.
Further use of the bearing bush is possible if
- the visible bronze portion is less than 35% of the running surface.
- the bearing bushes are otherwise in a good condition, i.e. there are
neither scratches nor scores which penetrate the grey-green slide layer
down to the bronze layer.
- the next maintenance interval corresponds to the operatingt time of the
preceding maintenance interval.

3.3 Bearing bush assessment based on the measurement of the

bearing clearance

A Inner diameter of the

bearing bush
B Outer diameter of the
bearing journal

Figure 5. Diameter for determining the bearing clearance

If there is uncertainty concerning the assessment of the wear condition

based on visible indicators, the measurement of the bearing clearance can

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 104/ 05

 provide more precise information regarding the condition of the bush.
For this purpose, the inner diameter (A) of the bearing bushes and the
outer diameter (B) of the appertaining bearing journals (4) have to be
mesasured.
Further use of the bearing bush is possible if
- in case of a shaft diameter of 60 mm: A -- B < 0.36 mm
- in case of a shaft diameter of 50 mm: A -- B < 0.34 mm

C,D Measuring level

Figure 6. Measuring levels for determining the bearing clearance

Important! Measuring the diameter has to be carried out at both

measuring levels (C, D) of the bearing bush and bearing journal. In case
the limiting value for further use is exceeded, even if this is only the case
on one of the two front surfaces, the bush has to be replaced.

3.4 Evaluation of the bearing bushes regarding scores or scratches

Individual scores and scratches, which are located within the grey-green
slide layer, permit the further use of the bearing bushes, unless the
assessment criterion mentioned under 3.2 is not complied with.
In case, however, there are scores or scratches in the internal face of the
bush which distinctly extend into the bronze layer or into the steel jacket,
the bushes have to be replaced.

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 105/ 05

Charge air cooler

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 322--04 E 06.98 101/ 01

Charge air cooler
Checking and cleaning 322.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

permit/support economic operation,
prevent operating problems/damage.

Brief description

The charge air cooler has a decisive influence on the operating data and
thus the performance of the engine. It is, therefore, necessary to check
and clean the charge air cooler at regular intervals.
The work/steps concern:
checking the operating data,
removal of components,
chemical/mechanical cleaning of components,
installation of components.

Tools/appliances required

Qty Designation No. Availability

1 Digital pressure gauge Digima--Premo 009.090 Optional
2 Shackle A1.6 002.454 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Pipe brush -- Inventory
1 Cleaning agent -- Inventory
1 Sealing compound (silicone) -- Inventory
1 Receptacle -- Inventory

Related work cards

Work card Work card Work card

000.08 000.40 322.02

Technical details

Term Information
Weight per cooler bundle 984 kg
Test pressure cooling element (water side) 6 bar
Total weight of charge air cooler 2573 kg

6641 322.01--02 E 04.03 L 58/64 101/ 04

 1 Flange 9 Cooler bundle 20 Air inlet casing
2 Finger guard on the 10 Seal 21 Double diffuser
charge air cooler casing 11 Lower water chamber 22 Axial compensator
3 Charge air pipe 12 Cover 23 Connecting pipe for
4 Connection for differential 13 Screw plug (draining) differential pressure
pressure measurement 14 Hexagon bolt measurement
5 Connecting housing 15 Charge air cooler stage II 24 Seal
to the charge air pipe 16 Hexagon bolt 25 Cooling element and/or
6 Hexagon bolt 17 Venting screw upper water chamber
7 Hexagon bolt 18 Charge air cooler stage I 26 Cooling water connecting
8 Washer 19 Finger guard pipe
Figure 1. Two-stage charge air cooler (representation shows attachment on the free engine end)

6641 322.01--02 E 04.03 L 58/64 102/ 04

Operating sequence 1 -- Checking

Steps 1. Cleaning of the charge air cooler is dependent on the pollution level.
Therefore, connect the digital pressure gauge (009.090) upstream
and downstream of the charge air cooler at regular intervals and
000.40).
carry out measurements (see work card 000.40
2. Check the cooling water inlet and outlet temperature during
operation, simultaneously measure the charge air temperature
upstream and downstream of the cooler so as to keep the cooler
rating under permanent control.
Important! Cleaning the charge air cooler on the air side is
necessary when the differential pressure in the uper load range has
reached 60 mbar. Instead of the screw plugs for the connections for
differential pressure measurement, quick-acting couplings can be
provided.

Operating sequence 2 -- Removing the cooling element

Steps 1. Lock the supply and drain connections of the cooling water pipes
(26). Refer to Figure 1 .
Important! In case of charge air coolers without permanent venting,
open the venting screws (17) on the cooling element (25).
2. Let the cooling water cool down to at least 50ƒ C, then dismantle the
cooling water connecting pipes (26) and the venting pipes (if fitted).
3. Put the receptacle underneath the charge air cooler.
4. Remove two covers (12) at the bottom of the charge air cooler
casing.
5. Unscrew the screw plug (13) on the drain connections and drain the
cooling water from both cooler bundles.
6. Screw the screw plug back in and remove the receptacle.
7. Unscrew the external hexagon bolts (16) from flange (1).
8. Screw out two hexagon bolts (6) on the bottom side of the charge air
cooler.
9. Using the shackle (002.454), attach the rope to the suspension fins
on the upper water chamber of the charge air cooler and suspend the
rope from the lifting tackle.
▲ Attention! The suspension fins which have been integrally cast to
the upper water chamber (25) are only provided for suspending the
cooling element and must not be used for removing the complete
charge air cooler with casing. For removal of the complete charge
air cooler, separate suspension fixtures are provided on the sides of
the charge air cooler casing.
10. Cautiously pull the cooling element (25) with attached cooler bundles
(9) out in upward direction and put it down into a cleaning trough.

Operating sequence 3 -- Cleaning the charge air cooler (on the air side)

Steps 1. Brush the finned tubes with liquid cleaner, or spray them with
undiluted solvent (see Table 1).
▲▲ Caution! Some of the cleaning agents are skin-irritant in
undiluted concentration, therefore, wear safety goggles and plastic
gloves when using them. Observe the supplier’s instructions!
2. In case the finned tubes are heavily dirty or if there are incrustations,
the deposited dirt has to soak in liquid cleaner for several hours. For
this purpose, put the cooling element into the cleaning basin in
upright position and close the openings for the cooling water
connecting pipes (26) on the cooling element in order to prevent

6641 322.01--02 E 04.03 L 58/64 103/ 04

 penetration of the liquid cleaner into the interior of the cooler bundles.
3. If a water-soluble cleaning agent is used, subsequently flush the
cooling element amply with water; otherwise purge it with
compressed air.
Designation Manufacturing company
Air Cooler Cleaner Unitor Ship Service AS
Mastemyr
N-1410 Kolbotn/Norway
ACC Plus Unitor Ship Service AS
Mastemyr
N-1410 Kolbotn/Norway
Air Cooler Cleaner Vecom B.V.
Maassluis/Holland
Air Cooler Cleaner Drew Chemical Corp.
ACC-9 Boonton
New Jersey/USA
Air Cooler Cleaner Drew Chemical Corp.
ACC/ME Boonton
New Jersey/USA
Atlas D.G. Cleaner Atlas Mc Alpine LTD
Erith
Kent/England
Air Cooler Cleaner Nalfleet Marine Chemicals
“Sea Shield” ACC Northwich, Cheshire
79101 CW8 4DX/U.K.
Norus Degreaser Norus Sales Co.
Stabekk/Norway
Table 1. Cleaning agent/manufacturer

Operating sequence 4 -- Cleaning the charge air cooler (on the water side)

Steps 1. Remove the upper and lower water chamber (11 and 25) from the
dismantled cooling element. Refer to figure 1 .
2. Loosen the deposits in the finned tubes by means of the pipe brush
and flush the tubes with a strong water jet. For the removal of
000.08.
calcareous deposits, refer to work card 000.08

Operating sequence 5 -- Installing the cooling element

For installation, proceed in the reverse order followed for removal, taking
note of the following:
Steps 1. Always mount the upper and lower water chamber (11 and 25) with
new seals (10 and/or 24). Apply copper paste Molykote 1000 or
acid-free grease to the seals prior to inserting them.
2. In case the charge air cooler has been cleaned on the water side
(see operating sequence 4), it is recommended to carry out a
pressure test before installation.
3. Verify that all other seals are in unobjectionable condition.
4. Prior to lowering the cooling element (25) into the charge air cooler
casing, pay attention to the correct position of the reversing water
chamber and apply Silicone which is unaffected by temperature
changes to the top sealing face of the charge air cooler casing.
5. After opening the supply and drain connections of the cooling water
connecting pipes (26), open the venting screws (17).
Important! Keep the venting screw open long enough to permit all
the air to escape from the cooling element (25).
6. After putting into operation, verify that the pipe connections are tight.
7. Check the flange attachment (1) for air tightness.
8. Inspect the charge air cooler for leakages.

6641 322.01--02 E 04.03 L 58/64 104/ 04

Charge air cooler
Checking, cleaning on the air side 322.03

Purpose of jobs to be done

Ensure correct execution of the work,

remove dirt/residues from components.

Brief description

The charge air cooler has a decisive influence on the operating data and
thus the performance of the engine. It is, therefore, necessary to check
and clean the charge air cooler at regular intervals.
The work/steps include:
Checking the operating data,
sealing off and cleaning the charge--air cooler,
draining the sealed--off space, and
restoring the operational state after ultrasonic cleaning.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 4
1 Assistant 4

Tools/appliances required

Qty Designation No. Availability

1 Ultrasonic cleaning equipment 322.109 Optional
1 Ultrasonic generator 322.084 Optional
2 Ultrasonic bar--type oscillator 322.085 Optional
4 Support 322.086 Optional
1 Flange with slide 322.087 Optional
1 Storing box 322.089 Optional
1 Blind flange 322.110 Optional
1 Blind flange (TCA55) 322.079 Optional
1 Blind flange (TCA66) 322.081 Optional
1 Digital pressure gauge Digima--Premo 009.090 Optional
1 Open--jaw and ring wrenches (set) -- Standard

6641 322.03--01 E 11.05 L 58/64 CD 101/ 08

 Qty Designation No. Availability
1 Cleaning agent -- Inventory
1 Hylomar SQ/M -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.40

1 Air inlet casing 5 Intermediate ring 9 Blind flange

2 Exhaust gas turbocharger 6 Hexagon bolt 10 Hexagon bolt
3 Charge air cooler 7 Hexagon bolt 11 Seal
4 Axial compensator 8 Nut

Figure 1. Removal of the axial compensator before the charge air cooler (illustration shows exhaust gas turbocharger on the
coupling end)

Operating sequence 1 -- Checking

Steps 1. Cleaning of the charge air cooler (3) has to be carried out depending
on the degree of fouling. For this reason, the digital pressure gauge
(009.090) is to be connected upstream and downstream of the
charge air cooler at regular intervals in order to measure the differen-
tial pressure (see Work Card 000.40).
000.40

6641 322.03--01 E 11.05 L 58/64 CD 102/ 08

 ▲ Attention! Cleaning on the air side of the charge air cooler is
necessary whenever the differential-pressure increase compared to
the differential pressure in new condition in the upper load range
has reached the values listed in Table 3 !

1 Air inlet casing 12 Seal 15 Diffuser

2 Exhaust gas turbocharger 13 Hexagon bolt
3 Charge air cooler 14 Nut

Figure 2. Fitting the blind flange upstream of the charge air cooler

Operating sequence 2 -- Sealing off the charge air cooler

Steps 1. Remove the sealing air pipe at connection (A) and, in the case of the
design with turbine disc cooling, the connection pipe and close the
tap holes on the charge air cooler (3) by means of sealing plugs (see
Figure 3 ).
▲▲ Caution! If step 1 is omitted, cleansing fluid will pass into the
exhaust gas turbocharger during the cleaning process, which would
necessitate disassembly and cleaning of the exhaust gas turbo-
charger!
2. Dismantle the charge-air-pressure-gauge pipe at connection (B) and
close the tap hole on the charge air cooler (3) by means of a sealing
plug (see Figure 3 ).
3. Remove the hexagon bolts (7) with nuts (8) from the connection axial
compensator (4) to the diffuser (15). Remove the hexagon bolts (6)
from the connection exhaust gas turbocharger (2) to the intermediate
ring (5), and dismantle the axial compensator (4) together with the
intermediate ring (5) - see Figure 1 .

6641 322.03--01 E 11.05 L 58/64 CD 103/ 08

 4. Depending on where the exhaust gas turbocharger is attached, fit
blind flange (322.079 or 322.081) with seal to the diffuser (15).
Tighten the hexagon bolts (13) with nuts (14) crosswise (see Fig-
ure 2 ).
5. Loosen the pipe coupling (16) and shift it axially (away from the con-
nection housing (21) - see Figure 3 .
6. Fit the blind flange (322.110) with seal to the connection housing (21).
Tighten the hexagon bolts (23) crosswise (see Figure 4 ).

1 Air inlet casing 21 Connection housing C Connection for differential

3 Charge air cooler (after charge air cooler) pressure measurement
16 Pipe coupling A Connection for sealing air D Connection for MODIS
18 Hexagon socket bolt pipe E Connection for MODIS
20 Charge air cooler B Connection for pressure- F Connection for differential
gauge pipe pressure measurement

Figure 3. Shifting the pipe coupling towards the charge air pipe

Operating sequence 3 -- Fitting the ultrasonic cleaning equipment

Starting condition The charge air cooler has been sealed off from the exhaust gas turbo-
charger and from the charge air pipe respectively. Connection pipes such
as sealing air and pressure-gauge pipes have been dismantled, and the
connections closed by means of sealing plugs.

Steps 1. Dismantle the blind flanges (9) with seals (11) from the air inlet casing
(1) and the connection housing (21) - see Figure 1 .
2. Fit the flange with slide (322.087) and seal (24) to the connection
housing (21) - see Figure 5 . Flange on the discharge side according
to SOLAS - international connection to shore.

6641 322.03--01 E 11.05 L 58/64 CD 104/ 08

 1 Air inlet casing 20 Charge air pipe 22 Seal
3 Charge air cooler 21 Connection housing 23 Hexagon bolt
16 Pipe coupling (after charge air cooler)

Figure 4. Fitting the blind flange after charge air cooler

Operating sequence 4 -- Execution of the cleaning process

Starting condition The ultrasonic cleaning equipment (322.109) has been fitted correctly.
The charge air cooler has been sealed off towards the turbocharger and
the charge air pipe. The connections for sealing air and the pressure-
gauge pipes have been closed.

Steps 1. Close the flange with slide (322.087) - see Figure 5 .

Tip! If the surface of the charge air cooler bundle has an oily appear-
ance, precleaning can be done at first using a commercially available
washing-up liquid.
Amount of washing-up liquid to be added: approx. 1%, precleaning period
approx. 0.5 - 1 h.
Precleaning is effected in the same way as the actual main cleaning pro-
cess. Deposits on the charge air cooler bundle cannot be removed by
this.
2. Fill the sealed-off charge-air-cooler casing approx. 90-95% with clean
fresh water.
Tip! Use a firehose with spray nozzle to fill the charge-air-cooler
casing. Rapid filling directly influences the flushing and cleaning effect.
When using a firehose, filling takes approx. 10-15 minutes.
3. Fill in the required amount of cleaning agent (see Table 1 ).

6641 322.03--01 E 11.05 L 58/64 CD 105/ 08

 Important! If the cleaning agent is added earlier, it has a tendency
to severe foaming, which makes it more difficult to fill the charge-air-cooler
casing completely (foaming over of the mixture in the charge-air-cooler
casing).
4. Fill the sealed-off charge-air-cooler casing completely with clean
fresh water so as to ensure that a homogenous water/cleaning-agent
mixture is obtained.

1 Air inlet casing 24 Seal 26 Blind flange

3 Charge air cooler 25 Hexagon bolt 27 Seal
21 Connection housing
(after charge air cooler)

Figure 5. Fitting the flange with slide / inserting the bar-type oscillator
5. Fit the supports (322.086) to the bar-type oscillator (322.085).
6. Insert one bar-type oscillator (322.085) each into the opening on the
air inlet casing (1) and the connection housing (21) - see Figure 5 .
7. Check the immersion depth of the bar-type oscillators (322.085) and,
if necessary, correct it by shifting the supports (322.086) on the cable
of the bar-type oscillators (322.085).
▲ Attention! Make sure that the bar-type oscillators (322.085) are
completely immersed into the water/cleaning-agent mixture.
If the bar-type oscillators are exposed, there is the danger of over-
heating!
8. Connect both of the bar-type oscillators (322.085) to the ultrasonic
generator (322.084).
Important! The two bar-type oscillators (322.085) are to be freely
suspended in the water/cleaning-agent mixture and must not contact the
casing and charge air cooler respectively.

6641 322.03--01 E 11.05 L 58/64 CD 106/ 08

 9. Switch the ultrasonic generator (322.084) on, and adjust the power
output to 90%; the power output is indicated by the batten luminaire
of red control lamps. The indicators “HF” and “P-contr” glow during
normal operation. In case the “A-contr” indication glows, the bar-type
oscillators (322.085) are to be checked for correct immersion depth.
10. Observe the necessary duration of ultrasonic cleaning, depending on
the degree of fouling (see Table 3 ).
11. After completion of the cleaning process, drain the water/cleaning-
agent mixture into a suitable container, and fill the charge-air-cooler
casing with clean water for flushing.
Important! Continue flushing until all of the water/cleaning-agent
mixture has been removed from the charge-air-cooler casing (max. two
flushing procedures). Dirty water/cleaning-agent mixture must not be re-
used for cleaning the charge air cooler.

Engine Volume of Required Required amount of

type charge air amount of cleaning agent in [l]
cooler casing in water in [l]
[l]
L 58/64 CD 2500 2400 100
Table 1. Filling quantities to obtain a four-percent solution

Designation Supplier
Aquabreak PX Unitor Ship Service AS
Mastemyr
N--1410 Kolbotn/Norway
Environclean Unitor Ship Service AS
Mastemyr
N--1410 Kolbotn/Norway
Enviromate 2000 Drew Chemical Corp.
Boonton
New Jersey/USA
Eskaphor N6773 Haug Chemie GmbH
Breite Seite 14 - 16
74889 Sinsheim/Germany
Table 2. Recommended cleaning agents

Differential-pressure Degree of Duration of the

increase* compared to the fouling cleaning process in
differential pressure in new [h]
condition in
[mm WC]
< 100 mm WC hardly not necessary
100 -- 200 mm WC slightly approx. 1
**200 -- 300 mm WC severely approx. 1.5
> 300 mm WC extremely approx. 2
Table 3. Differential-pressure increase - recommended duration of cleaning

* Differential-pressure increase = actual differential pressure - differential pressure in new

condition (see acceptance test record)

** Recommendation: Clean the charge air cooler when this differential-pressure increase has
taken place at the latest, as otherwise a dirt core will form in the charge-air-cooler bundle.

6641 322.03--01 E 11.05 L 58/64 CD 107/ 08

Operating sequence 5 -- Restoring the operational state after cleaning the charge air cooler

For restoring the operational state, proceed in the reverse order followed
for cleaning preparations.

Steps 1. Remove all of the cleaning-system connections.

2. Remove the blind flange (322.079 or 322.081), insert the axial com-
pensator (4) with intermediate ring (5). Seal the flange faces using
Hylomar SQ/M.
3. Remove the blind flange (322.110).
4. Slip the pipe coupling (16) axially over the parting line between
charge air pipe (20) and connection housing (21). Align the pipe
coupling so that it is centred. Coat the threads and contact faces of
the hexagon socket bolts (18) on the pipe coupling with MoS2 lubric-
ant and tighten them to the specified torque (see Work Card 000.30000.30).
5. Fit the blind flange (9) including seals (11) to the top face of the air
inlet casing (1) and connection housing (21), and blind flange (26)
with seal (27) to the underside of the connection casing (21).
6. Fit the sealing air pipe (7) or, in the case of the design with turbine
disc cooling, the connection pipe.
7. Connect the charge-air-pressure-gauge pipe to the charge air cooler.
Important! After completion of the cleaning process, the engine
should be started immediately and kept running for approx. 15 - 30 min-
utes. This has a positive impact on the cleaning result, as it causes the
remainder of dirt to be blown out.
8. In order to check the result of the cleaning process, a differential-
pressure measurement is to be carried out during normal operation of
the engine (see Work Card 000.40);
000.40 the results are to be entered into
the engine log book.

6641 322.03--01 E 11.05 L 58/64 CD 108/ 08

Fuel injection pipe

009... Foundation/Bearings/Alignment
012 Crankcase/Tie rod/Bolts
020 Crankshaft/Coupling bolts
021 Main bearing/Thrust bearing/Flange bearing
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings
050 Cylinder liner/Top land ring
055... Cylinder head/Safety valve
073 Crankcase cover/Covering
100 Camshaft drive
102 Camshaft bearing
111 Rocker arm/Rocker arm casing
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140... Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pipe
322 Charge air cooler
434 Fuel injection pipe

6682 434--04 E 06.98 101/ 01

Fuel injection pipe
Dismounting and mounting 434.01

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

Fuel injection pipes are to be dismounted for maintenance and repair work
on injection valves or injection pumps.
The work/steps include:
removal of components,
disassembly and assembly,
mounting of components.

Tools/appliances required

Quant Denomination No. Availability

1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 17x12.5 001.754 Standard
1 Ratchet 001.521 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Grease (acid--free) -- Inventory

Operating sequence 1 -- Removing

Starting condition Shut-off valves on fuel pipes closed.

Steps 1. Loosen and unscrew the hexagon bolts (29) from threaded
piece (10) and injection pump (35) alternately.
2. Loosen and unscrew three hexagon bolts (27) and push back
the flange (25).
3. Remove injection pipe.
4. If more than one injection pipe is to be removed, these should be
identification-marked so that when refitting, every pipe leads to the
same cylinder again.

6619 434.01--01 E 05.98 L 58/64 101/ 03

 10 Threaded piece
24 O-ring seal
25 Flange
26 Washer
27 Hexagon bolt
28 O-ring seal
29 Hexagon bolt
30 Flange
31 Delivery pipe
32 Nut
33 Snap ring
35 Injection pump

Figure 1. Installing injection pipe between injection pump/cylinder head

Operating sequence 2 -- Dismantling

Steps 1. Remove flange (25).

2. Push back the flanges (30), unscrew the nuts (32) and pull off the
flange.
3. Remove the O-ring seals (24 and 28).
4. Clean the parts removed, check them for damage and replace, if
necessary.

Operating sequence 3 -- Assembling

Steps 1. Insert O-ring seals (24 and 28) into flanges (30) and slide flanges
onto delivery pipe (31).
2. Screw the nuts (32) onto the delivery pipe (31) until the snap ring (33)
contacts the delivery pipe.
3. Slip on flange (25).

Operating sequence 4 -- Installing

Steps 1. Clean sealing surfaces on delivery pipe (31), threaded piece (10) and
injection pump (35) and check for damage.
2. Place the injection pipes and slide forward the flanges (30) to contact
the nuts (32).

6619 434.01--01 E 05.98 L 58/64 102/ 03

 3. Coat threads and contact faces of hexagon bolts (29) with MoS2
lubricant, screw in hexagon bolts and tighten uniformly in diagonally
opposite sequence.
4. Mount flange (25) with three hexagon bolts (27) and washers (26).
5. Open shut-off valves on fuel pipes.
6. After starting the engine check the injection pipes for leakages (visual
control).

6619 434.01--01 E 05.98 L 58/64 103/ 03

Fuel injection pipe
Sealing faces on the delivery pipe
Grinding 434.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

The sealing faces on the delivery pipe of the fuel injection pipe are to be
checked for damage and, if necessary, remachined every time it is
removed.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Qty Denomination No. Availability

1 Grinding device for delivery pipe 434.045 Standard
1 Locating plate 434.045--1 Standard
1 Threaded ring 434.045--2 Standard
1 Bearing ring 434.045--3 Standard
1 Bearing flange 434.045--4 Standard
1 Adapter flange (delivery pipe) 434.045--5 Standard
1 Spacer ring 434.045--8 Standard
2 Bearing block 434.045--10 Standard
1 Swivel arm 434.045--11 Standard
1 Bracket 434.045--12 Standard
1 Stop 434.045--13 Standard
1 Stop gauge 434.045--14 Standard
1 Grinding wheel 434.045--16 Standard
1 Base plate 434.045--17 Standard
1 Sliding carriage 434.045--18 Standard
1 Shaft 434.045--19 Standard
1 Stop 434.045--20 Standard
1 Counter flange 434.045--21 Standard
2 Ball bearing 434.045--24 Standard
2 Ball bearing 434.045--25 Standard
1 Hook spanner 434.045--37 Standard
1 Face spanner 434.045--38 Standard
2 Clamping lever 434.045--41 Standard
5 Emery paper 434.045--44 Standard

6641 434.02--02 E 10.98 L 58/64 101/ 05

 Qty Denomination No. Availability
1 Hexagon screw driver 5 000.294 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Tommy bar 8 000.262 Standard
1 Electric angle grinder -- Standard
1 Cleaning agent -- Inventory
1 Safety goggles -- Inventory

Related work cards

Work card Work card Work card

434.01

1 Delivery pipe 3 Electric angle grinder

2 Hexagon socket bolt M5x10 4 Support adjusting crank

Figure 1. Grinding device for delivery pipe with attached delivery pipe

6641 434.02--02 E 10.98 L 58/64 102/ 05

 2 Hexagon socket bolt
M5x10
5 Stop

Figure 2. Grinding device for delivery pipe

1 Delivery pipe
6 Hexagon socket bolt
M6x35

Figure 3. Attaching the delivery pipe to the grinding device for delivery pipe

Operating sequence 1 - Attaching the delivery pipe to the grinding device for delivery pipe

Starting condition Fuel injection pipe removed, disassembled and cleaned (see work card
434.01).
434.01

Important! The grinding device for the delivery pipe must be

installed and operated on a solid support. Vibrations of the grinding device
have an influence on the surface quality of the sealing faces to be ground.
The delivery pipes to be ground must be absolutely free from lube oils and

6641 434.02--02 E 10.98 L 58/64 103/ 05

 greases. Any kind of contamination, especially lubricants, reduce the
service time of the emery paper considerably.

Steps 1. Loosen both clamping levers (434.045-41) and swivel out the electric
angle grinder (3) together with the bracket (434.045-12) up to the
stop.
2. Screw the adapter flange (434.045-5) onto the threaded ring
(434.045-2) by means of the hexagon socket bolts (2) and tighten
them. See Figure 1 .
3. Attach the stop gauge (434.045-14) to the adapter flange by means
of two hexagon socket bolts (6). See Figure 3 .
Tip! When fastening the stop gauge to the adapter flange by means of
the tommy bar (000.262), hold up at the threaded ring.
4. Screw the counter flange (434.045-21) onto the delivery pipe (1).
Important! The delivery pipe has left-hand threads.
5. Screw the delivery pipe into the adapter flange by means of the
counter flange, until the cone of the delivery pipe contacts the stop
gauge.
6. Screw the counter flange onto the adapter flange and tighten it using
the face spanner (434.045-38) and hook spanner (434.045-37).
7. Remove the stop gauge (434.045-14).
8. Slip the tommy bar (000.262) radially into the threaded ring
(434.045-2), screwing the ring in until it contacts the locating plate
(434.045-1).
▲▲ Caution! It is important that every time a delivery pipe is to be
newly ground, the threaded ring is screwed in to such an extent that
it contacts the locating plate.
9. Press the yellow stop knob on the electric angle grinder, put grinding
wheel (434.045-16) together with emery paper (434.045-44) onto the
electric angle grinder and tighten by means of mounting nut.
10. Pull the sliding carriage (434.045-18) back by means of the support
adjusting crank (4).
11. Swivel the bracket (434.045-12) back in again until it contacts the
stop, blocking it on the sliding carriage by means of the two clamping
levers (434.045-41).

Operating sequence 2 - Regrinding of the sealing faces on the delivery pipe

Starting condition Delivery pipe correctly attached to the grinding device for delivery pipe.
Grinding wheel with new emery paper mounted on the electric angle
grinder.

▲ Attention! The remachining of the sealing faces is intricate and

requires particular care. It is recommended to have this work carried
out in a service centre of by personnel from MAN B&W Diesel.

Steps 1. Swing the swivel arm (434.045-11) with the electric angle grinder to
the right-hand stop (5). See Figure 2 .
2. Move the grinding wheel (434.045-16) towards the sealing face of the
delivery pipe by means of the support adjusting crank until the
grinding wheel touches the sealing face.
3. Move the swivel arm to the left-hand stop (434.045-13) so that the
front side of the grinding wheel faces the delivery pipe. See
Figure 4 .
▲▲ Caution! Wear safety goggles when grinding delivery pipes!
4. Establish the voltage supply for the electric angle grinder and switch
the grinder on.

6641 434.02--02 E 10.98 L 58/64 104/ 05

 5. Turn the delivery pipe evenly and, at the same time, move the swivel
arm with the electric angle grinder around the sealing face contour.
▲ Attention! The grinding wheel must not contact the adapter
flange.
6. The feed is effected at the threaded ring (434.045-2) by means of the
tommy bar (000.262). Maximum feed per operation is a scale mark
at the threaded ring.
▲ Attention! The feed is not effected at the support adjusting
crank. The adjusted position remains unchanged during the whole
grinding process.
Sealing faces are to be slightly remachined only, merely to be
smoothed, removing as little of the material as possible.
7. Move the swivel arm to the left-hand stop so that the front face of the
grinding wheel faces the delivery pipe. Turn off the electric angle
grinder.
8. Evaluate the result of the grinding process. Repeat the grinding
process until the sealing face has been ground evenly bright.
Important! In case the required contact pattern can no longer be
realised by means of the grinding device for delivery pipe, the grinding
device is to be sent to an MAN service centre for repair.

Tip! Remove used up emery paper immediately and replace by new

emery paper.
9. Remove the delivery pipe from the grinding device for the delivery
pipe and take off the counter flange.

5 Stop

Figure 4. Right-hand and left-hand stop for the swivel arm

6641 434.02--02 E 10.98 L 58/64 105/ 05

Buffer piston
Checking 434.04

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Buffer pistons are to be dismantled at regular intervals. In this connection,

the set of piston sealing rings is to be renewed.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Tools/appliances required

Qty Denomination No. Availability

1 Thickness gauges 0.05--1 000.451 Standard
1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Hexagon bolt M10x200 -- Inventory
1 Lubricant (copa slip) -- Inventory
1 Locking wire -- Inventory
1 Pliers for locking wire -- Inventory
2 Flat strip (nylon) -- Inventory

Spare parts required

Qty Denomination No.

1 Set of piston sealing rings 434.20.018
434.20

Preliminary remarks

Knocking noises of the buffer piston during operation are an indication of

compression spring fracture. Undamped relief pressure waves of the fuel
injection pumps in the fuel admission and discharge system may also
result from a seized piston. An increased leakage fuel amount may be
caused by a damaged set of OMEGAT piston sealing rings (2) or by wear
on piston (1) and bush (3). Disassembly of the buffer pistons is to be
carried out immediately upon such findings.

6629 434.04--01 E 11.99 General 101/ 03

 1 Piston
2 Set of OMEGAT piston
sealing rings
3 Bush
4 Cover
5 Stop screw
6 Inner spring
7 Outer spring
8 Hexagon nut
10 Locking wire
11 Seal
12 Connection for leakage
fuel pipe

Figure 1. Sectional drawing of the buffer piston

Operating sequence 1 -- Checking of the buffer piston (during operation)

Starting condition Engine is running at operating temperature.

Steps 1. For the operational check of the piston (1), remove the locking wire
(10) and cautiously screw out the stop screw (5).
2. Insert the test pin (e.g. a long screw driver) into the cover (4) and
ascertain whether the piston carries out pulsating motions.
3. Screw the stop screw back in and secure it by means of the locking
wire (refer to Figure 1).
4. For checking the set of OMEGAT piston sealing rings (2), cautiously
remove the leakage fuel pipe from connection (12).
5. In case of leakage fuel, the set of piston sealing rings is to be
replaced as described under operating sequence 3.

Operating sequence 2 -- Disassembly and checking of the buffer piston components

Starting condition Engine stopped, fuel pipe shut off.

Steps 1. Loosen the hexagon nuts (8) evenly and screw them off.
Take off the cover (4), paying attention to the seal (11).
▲ Attention! Normally, the springs (6 and 7) have been released
before the hexagon nuts (8) are removed. In case the piston (1)
seized in its end position, however, there are still spring forces
acting on the cover when unscrewing the hexagon nuts. Avoid
staying in the axial direction of the buffer piston on opening, danger
of injury!

Dimension Process tolerance Maximum

when new clearance
Piston 90 f7 0.036 ... 0.106 mm 0.250 mm
Bush 90 H7
Table 1. Dimensions and clearances of the buffer piston components
2. Take out the springs (6 and 7), checking them for incipient cracks
and/or fractures.

6629 434.04--01 E 11.99 General 102/ 03

 3. Screw hexagon head bolt M10x200 into the thread on the piston
crown and pull the piston out.
4. Take off the set of OMEGAT piston sealing rings (2), check piston
and bush for free movement, measure wear by means of the feeler
gauge (000.451).
Important! In case the maximum piston clearance is exceeded,
use new parts. Scored bushes should be replaced, since they cause an
increase in leakage fuel. The set of OMEGAT piston sealing rings is to be
renewed every time the buffer piston is checked.

Operating sequence 3 -- Renewal of the OMEGAT piston sealing ring set

Starting condition Old sealing ring set removed. Ring groove of the piston cleaned.

Steps 1. Screw the hexagon head bolt M10x200 into the piston crown and
chuck the hexagon head bolt into the vise, paying attention to the
piston (1) and ensuring that the piston is not damaged.
2. Insert the set of OMEGAT piston sealing rings (2) into the ring groove
as far as possible.
Lay two nylon tapes around the set of OMEGAT piston sealing rings
at a distance of approx. 120ƒ (refer to Figure 2). Using the tapes,
pull the set of OMEGAT piston rings cautiously over the piston edge
into the groove. Afterwards remove the tapes carefully, paying
attention that the set of seals is not twisted.

1 Piston
2 Set of OMEGAT piston
sealing rings
9 Nylon tape

Figure 2. Installation of a new set of OMEGAT piston sealing rings

Operating sequence 4 -- Assembly of the buffer piston

For assembly, proceed in the reverse order followed for removal,

observing the following points:
1. Treat the running face of piston and bush with copa slip prior to
assembly.
2. When introducing the piston, do not damage the set of OMEGAT
piston sealing rings.
3. Secure the stop screw (5) by means of the locking wire (refer to
Figure 1).
4. Attach the leakage fuel pipe to the connection (12).

6629 434.04--01 E 11.99 General 103/ 03