Piston, Connecting Rod and Cylinder Liner: Section 506

Section 506
Piston, Connecting Rod and Cylinder Liner
Description
Piston, Connecting Rod and Cylinder Liner 506.01
Working card
Disassembly, Assembly of Piston Connecting Rod 506-01.05

and Piston Rings
Piston 506-01.10
Connecting Rod 506-01.15
Criteria for Replacement of Connecting 506-01.16
Big-end and Main Bearing Shells
Criteria for Replacement of Connecting 506-01.16
Big-end and Main Bearing Shells
Removal/Mounting of Marine Head from Engine 506-01.244
Hydraulic Tightening of Connecting Rod Screws 506-01.25
In-situ Inspection of Connecting Rod Big-end Bearing 506-01.30
Inspection of Cylinder Liner 506-01.35
Grinding of Seal Face on Cylinder Liner and Cylinder Head 506-01.45
Dismantling of Piston and Cylinder 506-01.50
Linerat Low Overhaul Heights
Plates
Piston 50602-03
Connecting Rod 50603-02
Connecting Rod Bearing 50604-02
Piston Rings 50605-02
Cylinder Liner 50610-12
Description
Piston, Connecting Rod and Cylinder Liner 506.01
Page 1 (2) Edition 08
L21/31
Piston
The piston, which is oil-cooled and of the composite

type, has a body made of nodular cast iron and a
crown made of forged deformation resistant steel. It
is fitted with 2 compression rings and 1 oil scraper
ring in hardened ring grooves.
Fig 2 Connecting rod.
Connecting Rod
Fig 1 Piston.
The connecting rod is of the marine head type.
By the use of compression rings with different barrel- The joint is above the connecting rod bearing. This
shaped profiles and chrome-plated running surfaces, means that the big-end bearing need not to be opened
the piston ring pack is optimized for maximum sealing when pulling the piston. This is of advantage for the
effect and minimum wear rate. operational safety (no positional changes/no new
adaption), and this solution also reduces the height
The piston has a cooling oil space close to the piston dimension required for piston assembly / removal.
crown and the piston ring zone. The heat transfer,
and thus the cooling effect, is based on the shaker Connecting rod and bearing body consist of die-
effect arising during the piston movement.The cooling forged CrMo steel.
medium is oil from the engine's lubricating oil system.
The material of the bearing shells are identical to
Oil is supplied to the cooling oil space through a bore those of the crankshaft bearing. Thin-walled bearing
in the connecting rod. Oil is drained from the cooling shells having an AISn running layer are used.
oil space through ducts situated diametrically to the
inlet channels. The bearing shells are of the precision type and are
therefore to be fitted without scraping or any other
The piston pin is fully floating and kept in position in kind of adaption.
the axial direction by two circlips.
The small-end bearing is of the trimetal type and is
pressed into the connecting rod.The bush is equipped
with an inner circumferential groove, and a pocket for
distribution of oil in the bush itself and for the supply
of oil to the pin bosses.
12.35 - ES0
506.01 Piston, Connecting Rod and Cylinder Liner Description
Edition 08 Page 2 (2)
L21/31
Cylinder Liner
Cylinder liner/cooling water jacket/fire land ring
The cylinder liners, made of special centrifugal cast

iron, are encased by a nodular cast iron cooling water
jacket in the upper section. This is centered in the
crankcase. The lower section of the cylinder liner is
guided in the crankcase. The so-called fire land ring
fits on the top of the cylinder liner.
Fig 3 Interaction of fire land ring and stepped piston.
Interaction stepped piston/Fire land ring
The fire land ring which projects above the cylinder

liner bore works together with the recessed piston
crown of the stepped piston to ensure that burnt
carbon deposits on the piston crown do not come
into contact with the running surface of the cylinder
liner. This prevents bore polishing where lube oil
would not adhere properly.
Cooling
Fig 2 Cylinder liner with fire land ring. The coolant reaches the cylinder liner via a line that
is connected to the cooling water jacket. The coolant
flows through trimmed ducts in the cooling water
The subdivision into 3 components i.e. the cylinder jacket to the cooling areas in the cylinder liner, and
liner, cooling water jacket and fire land ring provides fire land ring, and through holes on to the cooling
the best possible structure with reference to resist- chambers in the cylinder heads. The cylinder head,
ance to deformation, with regard to cooling and with cooling water jacket and fire land ring can be drained
regard to ensuring the minimum temperatures on together.
certain component assemblies.
The fire land ring and cylinder head can be checked
by using check holes in the cooling water jacket for
gas and coolant leaks.
12.35 - ES0
Working Card Disassembly/Assembly of Piston, 506-01.05
Page 1 (3)
Connecting Rod and Piston Rings Edition 08
L21/31
Safety precautions Special tools
Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water 52000 177
Shut-off fuel oil 52000 190
Stopped lub. oil circul.
Press Blocking - Reset
Description Hand tools
Disassembly of piston and connecting rod for Wooden wedge, 2 pieces.

inspection or/and overhaul. Wooden support.
Assembly of piston and connecting rod after Wire.
inspection or/and overhaul.
Starting position
Disassembly of cylinder unit 505-01.01
Related procedure
Inspection or/and overhaul of piston 506-01.10

Inspection or/and overhaul of
connecting rod 506-01.15
Inspection of connection rod big-end
bearing 506-01.16
Assembly of cylinder unit 505-01.50
Manpower Replacement and wearing parts

08028-0D/H5250/94.08.12
Working time : 1 hour Plate no Item no Qty/Cyl.

Capacity : 1 man 50601 093 1
50601 103 2
50601 127 1
Data
Data for pressure and tolerance (Page 500.35)

Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)
04.21 - ES0
506-01.05 Disassembly/Assembly of Piston, Working Card
Page 2 (3)
Edition 08
Connecting Rod and Piston Rings
L21/31
Separation of Piston and Connecting Rod Fittings of Piston Rings
1) Take out the securing ring (Seeger circlips) with The piston rings should only be fitted to the piston
the plier (Plate 52000, Item 177). Push out the by the use of a special tool; the so-called piston ring
piston pin and lift the connecting rod away. opener.
If the rings are opened further than necessary, there

Assembly of Piston and Connecting Rod is a risk of overstressing which means that the rings
will become permanently distorted and will not fit to
2) Lubricate the piston pin before assembling. the cylinder liner's inner running surface.
3) For assembly of piston and connecting rod, The piston rings should be installed with the identi-
see point 1), but in the opposite direction. fication mark which is stamped into the ring close to
the ring joints, facing upwards, see fig 2.
Before fitting the coil spring loaded scraper ring, the

coil spring is dismantled from the ring by removal of
the joint pin. The coil spring is placed and assembled
in the ring groove. The scraper ring then is fitted in
Joint pin for the groove in such a way that the ring joint is ap-
coil spring Joint coil spring to be
placed opposite to ring joint proximately 180° offset to the spring joint.
Ascertain correct assembling by checking the back

clearance. The back clearance is sufficient when the
face of the ring is below the groove edge when the
ring is pressed against the bottom of the groove.
Ring joint
When installed on the piston, the rings should be
pushed back and forth in the grooves to make sure
that they can move freely. It is also advisable to insert
Fig 1 Joint coil spring to be placed opposite to ring joint a feeler gauge of adequate thickness between ring
and groove.
Adequate clearance is present if the feeler gauge

can be moved all the way around.
To prevent gas leakage through coinciding ring joints,

the piston rings should be turned into positions off-
setting the ring joint 180° to each other.
08028-0D/H5250/94.08.12
04.21 - ES0
Working Card Disassembly/Assembly of Piston, 506-01.05
Page 3 (3)
Connecting Rod and Piston Rings Edition 08
L21/31
Piston Ring no 1:
Marked with ident.
no "1598".
Piston Ring no 2:
Marked with ident.
no "1599".
Scraper Ring:
Marked with ident.
no "0282".
Marking of Piston and Scraper Rings

08028-0D/H5250/94.08.12
Marking
Identification marks to face upwards against the piston crown when mounted.
Note! The marking may include other figures than mentioned above, for instance trade mark and
production codes.
Fig 2 Marking of piston and scraper ring
04.21 - ES0
Working Card 506-01.10
Page 1 (2) Piston Edition 09
L21/31

Stopped lub. oil circul. 52000 190
Cleaning and inspection of piston. Replacement Tools for cleaning of piston, scraper etc.
of piston ring, scraper ring and control of ring
grooves.
Starting position
Piston has been dismantled from

Related procedure
Mounting of piston and

connecting rod
Replacement and wearing parts

Manpower
Plate no Item no Qty/
Working time : 1 hour
Capacity : 1 man
Data

Data for torque moment (Page 500.40)
11.03 - ES0
506-01.10 Working Card
Edition 09 Piston Page 2 (2)
L21/31
Inspection of Piston Note: At each piston overhaul:
1) Remove the piston and scraper rings. - The piston and the scraper ring must be replaced.
- The cylinder liner must be honed according to

2) Clean the piston on the outside and control the instructions.
piston pin drilling and trailing shoe.
- For position and fittings of piston rings, please
3) Inspect the piston ring and scraper ring grooves see working card 506-01.05
for wear.
Note: Piston crown and piston skirt shall normally not

Piston and oil
be dismounted. If dismounting is necessary please
scraper ring.
ask for special instruction or MBD-supervisor must Nominal size.
be present. (mm)
The piston crown must be scrapped if: Piston ring 6

1
A) The wear limit on the testing mandrel is ex- Piston ring 5

ceeded, see fig. 1A. 2
or Scraper ring 6
B) The clearance between the new piston/scraper Table 1 Nominal size

ring and the ring groove is exceeded, see fig.
1B.
A) Testing Mandrel for Ring Grooves B) Clearance Ring/Groove
If the wear limit on the testing mandrel is ex-

ceeded, the specified max. wear limits are
exceeded, and the piston must be scrapped.
0.40 mm
Wear limit line.
Maximum vertical clearance

between new piston ring/scraper
ring and ring groove: 0.40 mm.
The handle is marked

with the nominal size.
Fig 1 Wear limits for ring grooves
11.03 - ES0
Working Card
Page 1 (4) Connecting Rod 506-01.15
Edition 09
L21/31
L27/38

Press Blocking - Reset and hydraulic tools according
to working card 520-01.06
Description
Cleaning, inspection and test measurement of

connecting rod.
Starting position Hand tools
Connecting rod has been Inside micrometer (140 mm).

dismantled from piston 506-01.05 Feeler gauge 0.15 - 0.20 mm.
Related procedure
Mounting of piston and

connecting rod
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06
Working time : 3/4 hour Plate no Item no Qty/

Capacity : 1 man
Data

11.03 - ES0
506-01.15 Connecting Rod
Working Card
Page 2 (4)
Edition 09
L21/31
L27/38
Cleaning of Piston Rod and Marine Head If bolts/nuts Then
1) Clean all machined surfaces on the piston rod have seizures in renew the bolts/screws
and marine head. threads or pittings on
contact surface
2) Degrease the joint faces, holes, piston rod and
marine head screws with a volatile solvent and cannot be turned onto renew the bolts/screws
blow dry with working air. bottom position by hand
Visual Inspection of Faces
3) Inspect the joint faces.
Damages, in the form of visible wear marks

and pittings or even cracks, may be in the joint
faces due to relative movements between the
surfaces.
Wear marks and cracks are visible, but not

perceptible with a fingernail. Pittings and impact
marks are both visible and perceptible.
Note: Handle the piston rod and marine head with

care. In case of damaged joint faces caused by
improper handling, the marine head bearing caps
can no longer be tightened without ovalness of the
big-end bore. Fig 1 Point of measurement
4) Register observed damages in the scheme

„Marine Head Inspection“ for historic use only. Measurement of Big-end Bore
Please see page 4.
For check of ovalness, the upper and lower bearing
5) Carefully smooth single raised spots in the joint caps have to be assembled without bearing shells.
faces caused by pitting and impact marks with
a filesmall. Note: The ident. No on the upper and lower bearing
caps and the piston rod must always be the same,
see fig 3.
Inspection of Piston rod and Marine Head
bolts 8) Mount the upper and lower bearing caps by
means of the hydraulic bolts.
6) Inspect the hydraulic nuts for seizures in the
threads and pittings on the contact surfaces 9) Tighten the bolts with the prescribed pressure,
of the screwheads. please see working card 506-01.25.
7) Turn the hydraulic nuts onto bottom position Note: Connecting rod must be installed.
of the bolts.
10) Measure five different diameters in the groove
of the boring, see fig 1.
11) Register the measurements in the scheme

„Marine Head Inspection“. Please see page 4.
11.03 - ES0
Working Card
Page 3 (4) Connecting Rod 506-01.15
Edition 09
L21/31
L27/38
12) Calculate the maximum ovalness as the diffe- cified maximum ovalness is exceeded, contact MAN
rence between largest and smallest diameter Diesel for overhaul.
measured.
For marine head No 1 in the example, the maximum
13) Check if maximum ovalness is exceeded, ovalness is 0.02 mm and thus reuse is acceptable.
please see page 500.35.
For marine head No 2 in the example, the maximum
ovalness is 0.125 mm and therefore the marine head
If Then is rejected.
maximum ovalness is renew the complete

exceeded marine head, piston Inspection of Piston Rod Bush
rod, screws and
bearing shells 14) Inspect the surface of the piston pin and the
piston rod bush.
maximum ovalness is reuse the marine head
not exceeded 15) Measure the clearance between the piston pin
and bush.
Example of Measurement Results 16) Check if max. clearance is exceeded, see page
500.35.
The example, see fig 2, shows measurements and
damage observations for two marine heads in the If the specified clearance is exceeded, contact
scheme „Marine Head Inspection“ (in case the spe- MAN Diesel for replacement.
Inspection of Bearing Shells for Big-end

Marine Head Inspection for L21/31 and L27/38
Criteria for replacement of connecting rod big-end
Cylinder No 1 2 3
bearing, see working card 506-01.16.
Marine head ident. No
Running hours for marine head
A - 0.5 - 3.0
0.01 mm
1/100 mm B + 1.0 - 7.0
Nominal C - 1.0 - 5.0
diameter
L21/31 = Ø200 mm D + 5.5
L27/38 = Ø262 mm E + 0.5 + 3.5
Ovalness: Diff. between min./max. 2.0 12.5
Tightening for measurement see

instruction. Wear Wear Wea
Cracks Cracks Cra
Corrosion/ Corrosion/ Cor

Pitting Pitting Pitt
A
B
C Impact mark Impact mark Im
D Remarks: Remarks: Rem

E
To be To be
reused rejected
Marine head
Ident. No
Max ovalness L21/31 = 0.06 mm

Note! The ident. No on the

marine head and on the bearing
cap must always be the same.
Fig 2 "Marine Head Inspection" Fig 3 The ident. No on the marine head must always be
the same
11.03 - ES0
11.03 - ES0
Working Card
Page 4 (4)
Plant/Ship: Engine Type:

Marine Head Inspection for L21/31 and L27/38 Engine No: Running Hours:
Sign.: Insp. Date:
Cylinder No 1 2 3 4 5 6 7 8 9
Marine head ident. No
Running hours for marine head
A
0.01 mm
1/100 mm B
Nominal C
diameter
L21/31 = Ø200 mm D
L27/38 = Ø262 mm
E
Ovalness: Diff. between min./max.
Connecting Rod
Tightening for measurement see

instruction. Wear Wear Wear Wear Wear Wear Wear Wear Wear
Cracks Cracks Cracks Cracks Cracks Cracks Cracks Cracks Cracks
Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/
Pitting Pitting Pitting Pitting Pitting Pitting Pitting Pitting Pitting
A
B
C Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark
D Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks:
E
Marine head
Ident. No
506-01.15
Note! The ident. No on the
L21/31
L27/38
marine head and on the bearing
Edition 09
cap must always be the same.
Working Card Criteria for Replacement of 506-01.16
Page 1 (5)
Connecting Rod Big-end and Main Bearing Shells Edition 02
General
Safety precautions: Special tools:
Stopped engine Plate no. Item no. Note.

Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Description:
Inspection of bearing shells.

Hand tools:
Magnifier (x30).
Starting position:
Bearing shells removed from engine:

Big-end bearing, 506-01.30
or
Main bearing and guide bearing 510-01.05
Related procedure:
Mounting af bearing shells:

Man power: Replacement and wearing parts:
Working time : 1/4 hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

02.26 - ES0
506-01.16 Criteria for Replacement of Working Card
Edition 02
Connecting Rod Big-end and Main Bearing Shells Page 2 (5)
General
This paper gives information about the evaluation of Bearing Surface
the connecting rod big-end and main bearing shells
when wear appears on the running surface under Standard Miba bimetal bearings have no tin flash.
normal operating conditions.
Oil is used for protective coating.
Bearing damages caused by incorrect running con
ditions, like In new condition the bearing has a silvery, bright
color.
- Corrosion
- Overloading, overheating a.s.o. The running surface might become dull silvery after
only a short time of operation.
are not described in this paper.
In these cases, the bearing shells must be exchan- Criteria for bimetal bearing replacement
ged, of course, and in order to avoid further bearing
failures, the cause of the failure must be found and Actual wear can be determined by measuring wall
eliminated. thickness or via clearance measurements in com-
parison to the specification for a bearing in new
condition.
New Condition
A bearing should be replaced if the wear limit, as
The running surface has a silvery, bright color, see specified by the engine manufacturer, is reached
fig 1. or can be expected to be reached during the next
period of operation.
Another method is to specify a certain time limit for

the useful service life of the bearing. The individual
time limit (recommended maximum time in operation)
specified by the engine manufacturer is based on the
calculated bearing load, minimum oil film thickness
and load profile.
The useful service life of a bearing is also determined

by the fatigue strength of the lining material under
the respective load profile.
Usual running pattern

Fig 1 Without flash
Typical running pattern after completion of running-
in:
02.26 - ES0
Page 3 (5)
General
Bearings to be reused 3. Damage due to foreign particles
Following pictures shows the typical running pattern Shallow scoring and / or imprints that are few in
where bearing shells are reusable. number. See fig 4.
1. Normal wear
Slightly polished zones and symmetrical running

pattern in the most loaded zone of the bearing. Minor
scoring. See fig 2.
Fig 4 Reusable
4. Minor cavitation after long time in opera-

tion
Fig 2 Reusable Minor and shallow material removal outside the most
loaded zone. See fig 5.
2. Minor edge loading
and usual running pattern.

Slightly polished stripes along the side faces. See
fig 3.
Fig 5 Reusable
Fig 3 Reusable
02.26 - ES0
Edition 02
General
Bearings to be replaced 7. Damage due to foreign particles
Following pictures shows abnormal wear or dama- Many scores or multiple deep grooves and / or im-
ges that require replacement of bearing shells i.e. prints. See fig 8 and fig 9.
investigation of reasons.
5. Localized heavy smearing of lining mate-

rial
due to local disturbance of the oil film. See fig 6.
Fig 8 Replace
– deep scoring, imprints. Lining material locally smeared
Fig 6 Replace
6. More extensive area of damage with seizure

Locally smeared lining material
caused by a severe disturbance of the oil film. See

fig 7.
Fig 9 Replace
– many deep imprints
Fig 7 Replace
02.26 - ES0
Page 5 (5)
General
8. Deep punctual cavitation 10. Fatigue rupture of the lining material
In severe cases the cavitation extends to the steel Mechanism:

shell, spreads along the interface between steel shell - Development of fine cracks in the lining
and lining material, and undermines the AISn20 material
lining. See fig 10. - Network of cracks (crazing)
- Parts of the lining material break out
Fig 10 Replace
Fig 12 Fatigue rupture
9. Deep cavitation
Cavitation at the end of the oil groove.
Fig 11 Replace
– deep cavitation
02.26 - ES0
Page 1 (5)
General
Safety precautions: Special tools:
Stopped engine Plate no. Item no. Note.

Shut-off fuel oil
Shut-off cooling oil
Description:
Inspection of bearing shells.

Hand tools:
Magnifier (x30).
Starting position:
Bearing shells removed from engine:

or
Related procedure:
Mounting af bearing shells:

Man power: Replacement and wearing parts:
Working time : 1/4 hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

11.04 - ES0
Edition 04
General
This Working Card gives information about the
evaluation of the connecting rod big-end and main
bearing shells when wear appears on the running
surface under normal operating conditions.
Bearing damages caused by incorrect running con

ditions, like
- Corrosion
- Overloading, overheating a.s.o.
are not described in this Working Card.
In these cases, the bearing shells must be exchan-

ged, of course, and in order to avoid further bearing
failures, the cause of the failure must be found and
eliminated. Fig 1 Suction cavitation erosion due to high clearance.
Inspection and replacement criteria for alu-

minium tin bi-metal bearings Under normal engine operating conditions, surface
wear of un-plated tin-based aluminium alloy bearing
Compared with overlay plated, or tri-metal, bearing alloys, such as A20 & A104, should be negligible.
construction, aluminium tin bi-metal bearings have The surface hardness is significantly higher than
a homogeneous construction throughout the lining overlay plated (tri-metal) bearings and affords as
layer. Thus surface wear will never change the much reduced wear rate.
operating characteristics of the bearing unless the
lining is completely removed. The lining thickness The bedding-in process will produce a moderate ini-
is typically of the order of 0.4 to 1.0 mm for medium tial wear rate, while geometric inaccuracies in crank
speed diesel engine bearings. This level of thickness journals, housings and the bearings themselves are
would not be lost by conventional wear and would being accomodated. Once bedding-in is completed,
only be removed by virtue of major operating pro- wear rate usually becomes immeasurable.
blems causing high temperature generation at the
bore surface, or by fatigue.
Although conventional wear will never change the

properties of the surface of the lining, the resulting
increase in clearance can have several effects.These
will all limit the acceptable level of wear, regard-
less of the lining material. The oil flow requirement
through the bearing will increase, and ultimately
the capacity of the engine oil pump will be reached.
Hydrodynamic oil film formation is also a function of
clearance, very large values resulting in reduction of
film thickness. Additionally, as clearance increases, Fig 2 A104 bearing after 22,000 hours. Can refit.
all bearing materials become more prone to suction
cavitation erosion.
11.04 - ES0
Page 3 (5)
General
Direct measurement of bearing wall thickness is the
simplest way of assessing the level of wear. The most
common procedure would be to use a ball ended
micrometer. However, at the low levels of wear that
will usually occur, measurement inaccuracy can
mask the true wear rate, but since it is only gross
wear that will become the limitation, this method is
acceptable. It should be noted that some bearings
are deliberately bored eccentric to counter housing
distortion, and this must be taken into account when
assessing wall thickness measurements. Alternati-
vely, Plastigauge, or other soft material, may be used
Fig 4 Multiple scoring due to excessive fine debris.
for direct measurement of diametral clearance. The
Do not refit.
engine manufacturers' advice on maximum diametral
clearance should be sought. If no such advice is
available, a general rule is that the maximum clea-
rance should not increase by more than 50% of the
minimum design clearance.
A significant rate of wear would only be anticipated

under severe adverse conditions, most commonly
where oil entrained hard debris is present. Fine debris
would be evidenced by an abraded appearance of
the bore surface, while coarse debris would produce
deep scoring with raised edges, often polished an
eventually bedded-in. Large debris may not become
completely embedded in the lining material, and would
also score the shaft. Severe scoring of the bearing
could cause overheating, tin melt and eventually Fig 5 Large embedded debris. Do not refit.
seizure. However, aluminium tin bearing materials,
such as A20 and A104, are tolerant of a significant
level of contaminant, and can absorb it without de-
triment, and such bearings can be refitted.
Replacement frequency for un-plated bi-metal
bearings depends upon visual appearance and/or
operating time. If, on removal and examination, the
bore surface appears overheated, significantly sco-
red, debris contaminated or showing other signs of
distress, then the bearings should be renewed. It is
often the case that bearings operate satisfactorily
even though damaged, particularly if the damage
progresses slowly. However, if such parts are refitted
after inspection or overhaul they may be less tolerant
to slight geometric variations introduced during the
rebuild.
If significant debris has been present in the oil, over

a long time interval, differential wear of the crank
surface may have occurred. This is termed cam wear
and is characterised by wear or wiping of the bearing
Fig 3 Acceptable level of contaminant. Can refit. surface between the ends of partial grooves. If this
11.04 - ES0
Edition 04
General
is evident, the bearings should be replaced, and the
differential wear of the crank surface eliminated.
Fig 6 Cam wear. Do not refit.
Fig 8 Lack of support behind bearing back results in

fatigue in the bore. Do not refit.
Any indication of loss of lining is an obvious reason
not to refit the bearings. However, the cause for
such damage should be investigated, and corrected
where possible. The two most likely causes are Aluminium tin bearings are resistant to corrosion in a normal
fatigue and cavitation erosion. Provided the engine engine environment, but can suffer damage due to water
has been running at its design rating, fatigue should if the engine has been shut down for a long time. If all the
not occur unless some introduced defect is present. oil has drained away, the bore surface and bond lines can
Possibilities include oil or debris trapped between oxidise. Such bearings should not be refitted.
the bearing and its housing, mechanical damage to
the housing bore, the bearing back or bearing bore,
or lack of support behind the bearing.
Fig 9 Corrosion due to water (in this case, outside the

engine). Do not refit.
Fig 7 Carbonised oil behind bearing, causing overloa-

ding. Do not refit.
11.04 - ES0
Page 5 (5)
General
As with any bearing material, if the interface between If bearings are in otherwise good condition, they
the bearing back and the housing bore shows signs should be checked for the presence of positive free-
of fretting, the bearing should be renewed, and any spread before re-fitting. Some loss of freespread is
damage to the housing rectified. Even if the bearing normal, but bearings without positive freespread,
bore surface has not been damaged, refitting in such possibly caused by high temperature operation,
a condition may still result in later damage. cannot be refitted correctly and must be discarded.
Such bearings would have continued to operate
successfully had the assembly not been dismantled,
as freespread loss only occurs when the clamping
bolts are released.
Fig 10 Fretting pits on bearing back. Do not refit.
11.04 - ES0
Page 1 (5) Removal / Mounting of Marine Head from Engine Edition 01
L21/31, L27/38

Press Blocking - Reset and hydraulic tools according
Description
Removal of marine head from engine.
Engine out of operation.
Related procedure
Working time : ½ hour Plate no Item no Qty/

Capacity : 2 men
08028-0D/H5250/94.08.12
Data

03.27 - ES0
Edition 01 Removal / Mounting of Marine Head from Engine Page 2 (5)
L21/31, L27/38
Condition : Piston and connecting rod has

been removed and the fixation tool is installed, see
fig. 1.
Fixation tool
Fig. 1 Fixation of connecting rod bearing
1) Turn the crank through to about TDC.
2) Install the brackets in the lower end of the

crankcase opening, see fig. 2.
08028-0D/H5250/94.08.12
Fig. 2 Bracket installed
03.27 - ES0
L21/31, L27/38
3) Place the guide beam on the brackets and

secure it by means of the screws, see fig. 3.
Guide beam
Bracket
Fig. 3 Placing of guide beam

08028-0D/H5250/94.08.12
03.27 - ES0
Edition 01 Removal / Mounting of Marine Head from Engine Page 4 (5)
L21/31, L27/38
4) Turn the crankshaft to the position shown in

fig. 4 and remove the nuts by means of the
hydraulic tool.
Fig. 4 Removal of nuts

08028-0D/H5250/94.08.12
03.27 - ES0
L21/31, L27/38
5) Install the slide piece as shown in fig. 5 and 8) Remove the bearing shells from each marine
remove the bracket. head half.
6) Turn the crankshaft to make the marine head

rest against the beam, see fig. 5. Mounting of Marine Head
7) Pull out the two halves of the marine head. Mounting is carried out in reverse order of the
above.
Slide piece
Fig. 5 Marine head with slide piece

08028-0D/H5250/94.08.12
03.27 - ES0
Working Card Hydraulic Tightening of Connecting Rod 506-01.25
and Marine Head Screws
L21/31

Press Blocking - Reset 52000 334
Tightening procedure for connecting rod bolts.

Check of connecting rod bolts, tightening condi-
tion.
Starting position
Piston, connecting rod, bearing shells and

bearing cap preassembled.
Related procedure

Capacity : 2 men
08028-0D/H5250/94.08.12
Data

04.23 - ES0
506-01.25 Hydraulic Tightening of Connecting Rod Working Card
Edition 08 Page 2 (3)
L21/31
The following sequence is the same for both the Measuring Instruction for Extension of Hy-
connecting rod screws (item 211) and the marine draulic Tightened Bolts
head screws (item 152), see plate 50601.
4) Mount the two dial gauge on the hydraulic tools,
1) Mount the hydraulic tightening bolts and be fig 2.
sure that the studs are screwed home. Tighten
the nuts by hand. Note: For a correct measuring the dial gauge
has to be mounted with the magnetic bracket
2) Mount the hydraulic tools, fig 1, on both con- on the housing of the hydraulic tool.
necting rod bolts.
5) Tension both bolts simultaneously to a pressure
Be aware of the max. lifting height of the tool and of :
adjust the distance between the piston and the cyl-
inder before adding pressure to the tool, please see connecting rod screw : 100 bar
working card 520-01.05. marine head screw : 600 bar
3) Connect the hoses and pressure pump to the by use of the hydraulic tightening tool.
hydraulic tool.
Tightening order
Hydraulic tool
08028-0D/H5250/94.08.12
Fig. 1 Hydraulic tool for tightening of connecting rod screws
04.23 - ES0
Working Card Hydraulic Tightening of Connecting Rod 506-01.25
L21/31
6) Set the dial gauges to "0". 11) Tension the bolts to a pressure of :
7) Check by feeler gauge 0.01 mm. It is not allowed connecting rod screw : 100 bar
that there is clearance between the assembled marine head screw : 600 bar
components.
again.
8) Load the bolts to the specified pressure, see
description 500.40. 12) Read elongation of the screw Δl on the dial
gauge and compare with the value in table.
9) Tension both the nuts hand-tight.
Note: The bolts should be tightened to the
10) Release the pressure. specified tensioning pressure, not according
to the elongation. The elongation only serves
as a means of control. In case of excessive
deviations, repeat the tensioning procedure
and check the measuring instruments and /
or pressure gauges.
13) Release the pressure and remove the hydraulic

tensioning tools.
Note: For general instruction about hydraulic

tighte-ning, please see working card 520-
01.05.
Fig. 2 Hydraulic tool for tightening of connecting rod screws

08028-0D/H5250/94.08.12
04.23 - ES0
Page 1 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 06
L21/31

Shut-off fuel oil
Stopped lub. oil circul. and hydraulic tools according
Press Blocking - Reset to working card 520-01.06
Description
In-situ inspection and/or replacement of connec-

ting rod big-end bearing.
Dismounting and mounting.
Crankcase opened. Open-end spanner, 24 mm.
Related procedure
Inspection of connecting rod

big-end bearing 506-01.16
Tightening and check of connecting
rod screws 506-01.25

08028-0D/H5250/94.08.12
Working time : 1 1/2 hours Plate no Item no Qty/

Capacity : 2 man
Data

03.35 - ES0
Edition 06 In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)
L21/31
Removal of the Connecting Rod Bearing

Cap
1) Turn the crankshaft into the top dead centre.
2) Mount the lifting tool with two screws on each

side of the connecting rod bearing housing.
The upper screw is screwed into the upper
bearing housing and the other into the lower
bearing house, see fig 1.
3) Loosen the two nuts on the marine head, by Step 1

means of the hydraulic tool.
4) Remove the hydraulic tool and then the nuts

and studs.
5) Fit the two pipes for lifting, see fig 2. Step 2
6) Pull upwards in the two lifting pipes to carry

the weight of the lower bearing housing while
removing the upper screws from the lifting
tools.
Support pipes
Fig 2 Mounting of the supporting pipes
7) Lower the bearing cap until the lifting pipes are

resting on the engine frame.
8) The lower bearing shell can now be re-

moved.
9) Mount the inspection bracket, see fig 3.

Holder Holder
10) Slowly turn the crankshaft until the upper part

08028-0D/H5250/94.08.12
of the bearing housing is resting on the bracket

and secure it with a screw, see fig 3.
11) Turn the crankshaft until it is possible to remove

the upper bearing shell, see fig 4.
Inspection of Bearing Shells

Hydraulic device
12) Inspect the bearing shells, see working card

506-01.16.
Fig 1 Mounting of holders on the marine head
03.35 - ES0
Page 3 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 06
L21/31
18) Turn the crankshaft into top dead centre.
19) Install the lower bearing shell. Make sure the

ends of the bearing shell are flushed with the
ends of the lower bearing cap.
20) Add some clean engine oil to the bearing

shell.
21) Lift the lower bearing cap up against the up-

per and fit the two screws to interlock the two
Inspection
bearing houses.
bracket
22) Mount the studs and fit the nuts.
23) Mount the hydraulic tool and tighten, see de-

scription 500.40.
Screw for fitting

marine head and
inspection bracket
Fig 3 Mounting of the inspection bracket
Installation of bearing shells
13) Carefully clean the joint faces, the bore and

the bearing shells.
08028-0D/H5250/94.08.12
14) Install the upper bearing shell. Make sure the

ends of the bearing shell are flushed with the
ends of the bearing cap.
15) Add some clean engine oil to the crank jour-

Fig 4 Removal and mounting of the upper marine head bear-
nal.
ing shell
16) Turn the crankshaft until the journal has contact

with the bearing, see fig 4.
17) Remove the inspection bracket.
03.35 - ES0
Page 1 (3) Inspection of Cylinder Liner Edition 10
L21/31

Shut-off fuel oil
Inspection of cylinder liner.
Starting position
Piston and connecting rod

removed
Related procedure
Grinding of seal face on cylinder

head and cylinder liner 506-01.45
Manpower
Replacement and wearing parts
Working time : ½ hour
Capacity : 1 man Plate no Item no Qty/

Data

11.03 - ES0
Edition 10 Inspection of Cylinder Liner Page 2 (3)
L21/31
Measurement of Cylinder Diameter
While the piston is removed from the cylinder, the The measurements normally should be taken in
latter is measured to record the wear. The measure both transverse and in longitudinal direction.
ments are taken by means of an inside micrometer,
with measuring points at TDC-position for the up When measuring, take care that the measuring tool
permost piston ring, halfway down, and at the BDC has approximately the same temperature as the
in the cylinder liner, see fig 1 and page 3. liner. When the wear of a cylinder liner exceeds the
value indicated on page 500.35, i.e. when it be-
comes too troublesome to maintain adequate serv-
ice conditions, the cylinder liner in question should
be replaced.
Fig 1 Measuring points
11.03 -ES0
11.03 - ES0
Engine type Report No.
Measurement of Cylinder Liner Engine No. Encl. No. Page 3 (3)
Working Card
Running hours Insp. date

Plant Fuel Sign.
Cyl. No. 1 2 3 4 5 6 7 8 9
Cyl.liner ident.No.
Running hours
A
B
C
12
86
B A
B
C
322
Liner
C temp.
°C
Remarks...
Inspection of Cylinder Liner
Edition 10
L21/31
506-01.35
Working Card Grinding of Seal Face on 506-01.45
Cylinder Liner and Cylinder Head
L21/31

Shut-off fuel oil
Grinding of seal face on cylinder liner, cylinder Grinding paste.

head and engine frame by hand with grinding tool
and grinding paste.
Starting position
Disassembly of cylinder unit 505-01.01
Related procedure
Assembling of cylinder unit 505-01.50

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

03.46 - ES0
506-01.45 Grinding of Seal Face on Working Card
Page 2 (2)
Edition 05
Cylinder Liner and Cylinder Head
L21/31
Note: The grinding tool, see fig 1, is used for

both grinding the groove in the sealing surface on
the cylinder head (1), the cylinder liner flange (2)
and the surface of the engine frame (3).
If severe damage or corrosion is observed, a ma-

chining of the sealing faces may be required.
2. Cylinder liner
1. Cylinder head 3. Engine frame

Fig 3 Grinding tool at engine frame
Fig 1 Grinding tool
1) Loosen the sealing ring in liner flange and take

it out.
2) Face-grind the sealing grooves in the cylinder

liner flange, see fig 2, the surface of the engine
frame, see fig 3 and the sealing surface on the
cylinder head, see fig 4 with the use of grinding
paste and the grinding tool.
Fig 4 Grinding tool at cylinder head

08028-0D/H5250/94.08.12
3) Move back and forth the tool and lift it out from
time to time.
4) After grinding, carefully remove all traces of

abrasives and grinding compound.
5) When having ground the contact faces between

cylinder head and cylinder liner, it must be ob-
served that the sealing minimum height above
Fig 2 Grinding tool at cylinder liner
the cylinder liner is according to 500.35.
03.46 - ES0
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 1 (3)
at Low Overhaul Height Edition 05
L21/31

and hydraulic tools according
Description
Dismounting of cylinder unit for inspection and/

or overhaul.
Engine stopped and cooled down.
Related procedure
Inlet and exhaust valve - overhaul and

regrinding of spindel and valve seat 505-01.10
Valve rotator 505-01.15
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35
Inspection of piston 506-01.10
Cylinder liner 506-01.35
Separation of piston and
Fuel injection valve 514-01.10
Working time : 2 1/2 hours Plate no Item no Qty/

Capacity : 2 men
Data

12.35 - ES0
506-01.50 Dismantling of Piston and Cylinder Liner Working Card
Page 2 (3)
Edition 05
at Low Overhaul Heights
L21/31
Removal of Cylinder head Removal of Piston and Piston Rod, Cylinder

Liner and Water Jacket
1) Prepare removing of the cylinder head accord-
ing to working card 505-01.55. 6) Loosen the four bolts for the piston rod by
means of the hydraulic tools and remove the
2) Remove the bolts, which hold the cylinder head nuts.
and water jacket together (see fig 1).
7) Turn the piston into top dead centre.
Note: This means that the cylinder head now
can be removed from the cylinder unit. 8) Mount the turning bracket to the marine head
and counterweight. See fig 2.
3) Mount the lifting tool on the cylinder head.
9) Mount the tool for lifting the piston, see fig 3.
4) Lift the cylinder head and land it carefully on
wooden support.
5) Remove the push rods by hand.
Bolts to be removed
Bolts to be removed
Fig 1 Remove bolts, which hold the cylinder head and water Fig 2 Turning bracket mounted to the marine head and
jacket together counterweight
12.35 - ES0
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 3 (3)
at Low Overhaul Height Edition 05
L21/31
Lifting tool for

cylinder liner
Cylinder liner
Fig 3 Lifting tool for piston

Lifting tool for
cylinder liner
10) Carefully lift the piston and piston rod out of the
cylinder liner and land it on wooden support.
11) Mount the lifting tool for the cylinder liner, see Fig 4 Lifting tool for cylinder liner
fig 4, and lift the cylinder liner out of the engine.
12) Mount the eye bolt in water jacket and lift it

off the engine.
12.35 - ES0
Plate
Page 1 (2) Piston 50602-03
L21/31
Note !
Piston skirt and piston crown
can be ordered ONLY
as a complete unit.
Bemærk !
Stempelskørt og stempelkrone
kan KUN bestilles
som en komplet enhed.
002
026
075
038
087
099
10.27 - ES0 - Tier II

Plate
50602-03 Piston Page 2 (2)
L21/31
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
002 1/C Piston 2/2, Stempel 2/2,

incl. item 075, 087, 099 inkl. item 075, 087, 099
026 1/C Piston pin Stempelpind
038 2/C Retaining ring Sikringsring
075 4/C Thrust piece Trykstykke
087 4/C Stud Tap
099 4/C Nut Møtrik
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder. Qty/C = Qty/Cylinder.
10.27 - ES0 - Tier II

Plate
Page 1 (2) Connecting Rod 50603-02
L21/31
069
008
021
Important !
Ensure that the pin 069
is correctly inserted!
021
033
Vigtigt ! 033 070

Vær opmærksom på
at stiften er korrekt sat i!
082
094
057
10.27 - ES0
Plate
50603-02 Connecting Rod Page 2 (2)
L21/31
Item Item
008 1/C Bush for connecting Plejlstangsbøsning

rod
021 4/C Screw for connecting Plejlstangsskrue

rod
033 4/C Cylindrical pin Cylindrisk stift
057 2/C Nut Møtrik
069 4/C Nut Møtrik
070 1/C Connecting rod shaft Plejlstangsskaft
082 1/C Marine head, complete Marinehoved, komplet

incl. item 021, 033, 057, inkl. item 021, 033, 057,
069, 094 069, 094
094 2/C Screw for connecting Plejlstangsskrue

rod
10.27 - ES0
Plate
Page 1 (2) Connecting Rod Bearing 50604-02
L21/31
003
10.27 - ES0
Plate
50604-02 Connecting Rod Bearing Page 2 (2)
L21/31
Item Item
003 1/C Connecting rod Plejlstangsleje 2/2

bearing 2/2
10.27 - ES0I
Plate
Page 1 (2) Piston Rings 50605-02
L21/31
009
010
022
10.27 - ES0
Plate
50605-02 Piston Rings Page 2 (2)
L21/31
Item Item
009 1/C Piston ring Stempelring
010 1/C Piston ring Stempelring
022 1/C Oil scraper ring Olieskrabering
10.27 - ES0
Plate
Page 1 (2) Cylinder Liner 50610-12
L21/31
031
209
210
092
018
08028-0D/H5250/94.08.12
055
08.21 - ES0 - 2-part

Plate
50610-12 Cylinder Liner Page 2 (2)
L21/31
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
018 1/C Cylinder liner Cylinderforing
031 1/C Sealing ring Tætningsring
055 2/C O-ring O-ring
092 1/C Flame ring Flammering
08028-0D/H5250/94.08.12
* = Only available as part of a spare parts kit / * = Kun tilgængelig som en del af et reservedelssæt /
not avail separately ikke tilgængelig alene
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
08.21 - ES0 - 2-part

Piston, Connecting Rod and Cylinder Liner: Section 506

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Section 506

Piston, Connecting Rod and Cylinder Liner

Piston, Connecting Rod and Cylinder Liner 506.01

Disassembly, Assembly of Piston Connecting Rod 506-01.05

The piston, which is oil-cooled and of the composite

Fig 2 Connecting rod.

The connecting rod is of the marine head type.

Cylinder liner/cooling water jacket/fire land ring

The cylinder liners, made of special centrifugal cast

Fig 3 Interaction of fire land ring and stepped piston.

Interaction stepped piston/Fire land ring

The fire land ring which projects above the cylinder

Safety precautions Special tools

Stopped engine Plate no Item no Note

Description Hand tools

Disassembly of piston and connecting rod for Wooden wedge, 2 pieces.

Disassembly of cylinder unit 505-01.01

Inspection or/and overhaul of piston 506-01.10

Manpower Replacement and wearing parts

Working time : 1 hour Plate no Item no Qty/Cyl.

Data for pressure and tolerance (Page 500.35)

Separation of Piston and Connecting Rod Fittings of Piston Rings

If the rings are opened further than necessary, there

Before fitting the coil spring loaded scraper ring, the

Ascertain correct assembling by checking the back

Adequate clearance is present if the feeler gauge

To prevent gas leakage through coinciding ring joints,

Marking of Piston and Scraper Rings

Fig 2 Marking of piston and scraper ring

Safety precautions Special tools

Stopped engine Plate no Item no Note

Description Hand tools

Piston has been dismantled from

Mounting of piston and

Replacement and wearing parts

Data for pressure and tolerance (Page 500.35)

- The cylinder liner must be honed according to

Note: Piston crown and piston skirt shall normally not

The piston crown must be scrapped if: Piston ring 6

A) The wear limit on the testing mandrel is ex- Piston ring 5

B) The clearance between the new piston/scraper Table 1 Nominal size

A) Testing Mandrel for Ring Grooves B) Clearance Ring/Groove

If the wear limit on the testing mandrel is ex-

Maximum vertical clearance

The handle is marked

Fig 1 Wear limits for ring grooves

Safety precautions Special tools

Stopped engine Plate no Item no Note

Cleaning, inspection and test measurement of

Starting position Hand tools

Connecting rod has been Inside micrometer (140 mm).

Mounting of piston and

Manpower Replacement and wearing parts

Working time : 3/4 hour Plate no Item no Qty/

Data for pressure and tolerance (Page 500.35)

Visual Inspection of Faces

3) Inspect the joint faces.

Damages, in the form of visible wear marks

Wear marks and cracks are visible, but not

Bearing damages caused by incorrect running con

In these cases, the bearing shells must be exchan-