MAN Diesel & Turbo

Technical Documentation
Engine
Working Instructions

Engine............................ L48/60B
Works No. of engine........ 1130494
Plant No.......................... 4301126

010.005

6704 B2-1 EN 1 (2)

 MAN Diesel & Turbo

MAN Diesel & Turbo SE

86224 Augsburg
Germany
Phone +49 (0) 821 322-0
Fax +49 (0) 821 322-49 4180
primeserv-aug@mandieselturbo.com
www.mandieselturbo.com/primeserv

Copyright © MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.

2 (2) 6704 B2-1 EN

MAN Diesel & Turbo

Table of contents

Table of contents
1 Introduction
1.1 Preface
1.2 How the working instructions/Work Cards are organized, and how
to use them
1.3 Status/Availability Required Tools/Auxiliary Equipment

2 Work Cards, Classified by Subjects

001 Operating media systems/Pipes
000.03 Operating media systems flushing and cleaning
000.08 Cooling water system Cleaning
000.15 Pipes replacement
000.16 Pipes cleaning, pickling and preservation
000.17 Solderless pipe unions mounting
000.18 Solderless pipe unions Additional parts
002 Operating media/Auxiliary agents
000.04 Lubricating oil assessing and treating
000.05 Lubricating oil/Fuel Carrying out the spot test
000.07 Cooling water inspecting
000.14 Engine or components preservation treatment
000.19 Loctite Products use
003 Machine Elements
000.11 Galvanised Bearings assessing
000.11 Deep Groove Bearing assessing
000.11 Bimetal Bearings (without a third layer) assessing
000.21 Elastomer Seals storage, cleaning and fitting
000.22 Threaded inserts use
000.29 Tightening screwed connections Tightening torques (partial image)
000.30 Tightening screwed connections Tightening torques (table)
000.31 Tightening screwed connections Tightening torques (turning
moments)
000.32 Tightening screwed connections General remarks
000.34 Surface Test By Penetration methods
000.34 Surface Test By Magnetic leakage flux method
000.43 Working and Safety Regulations the use of load carrying
equipment/slings
004 Hydraulic tensioners/High-pressure pump
000.33 Working and Safety Regulations using high-pressure tools/
hydraulic tensioners
009.03 High-pressure pump use
009.05 High-pressure hoses use
009.07 Hydraulic tensioner use
009.08 Hydraulic tensioner dismantling and assembling

6704 B2-1 EN 1 (5)

 MAN Diesel & Turbo

009.13 Hydraulic tensioner (single-) use

Table of contents

009.14 Hydraulic tensioner (single-) dismantling and assembling

009.15 Measuring gauge (measuring device) checking the screw
elongation
009.16 Hydraulic tensioner use
009.17 Hydraulic tensioner dismantling and assembling
009.18 Measuring gauge (measuring device) checking the screw
elongation
005 Operating values/Operating results
000.25 Ignition and compression pressures determining
000.40 Charge air cooler/crankcase Measuring the differential pressure

3 Work Cards, classified into sub-assemblies

000 Sub-assembly overview
Sub-assembly overview
009 Foundations/Bearings
000.09 Position of crankshaft flange in relation to driven flange
determining/checking
012.01 Foundation bolts and foundations inspecting
012 Cylinder crankcase/tie rod
012.02 Crankshaft bearing bolts and cross tie rods inspection, loosening
and tightening
012.03 Crankshaft bearing bolt (external bearing) and cross tie rod
inspection, loosening and tightening
012.04 Cylinder head bolts removal and installation
020 Crankshaft/Coupling bolts
000.10 Crankshaft Measuring crankshaft deflection
020.01 Balance weight bolts inspection, loosening and tightening
020.02 Coupling bolts inspection, loosening and tightening
020.03 Bolts of the crankshaft gearwheel inspection, loosening and
tightening
020.04 Crankshaft oil bore closing
020.05 Balance weight removal and installation
021 Crankshaft bearing/main thrust bearing
021.01 Crankshaft bearing shell inspecting
021.02 Crankshaft bearing shell (external bearing) inspecting
021.03 Main thrust bearing Measure axial clearance/check locating
bearing rings
027 Torsional vibration damper
027.01 Bolts of the torsional vibration damper inspection, loosening and
tightening
027.02 Torsional vibration damper of the crankshaft removal and
installation
027.04 Torsional vibration damper inspecting
030 Connecting rod/Big-end bearing
030.01 Conrod shank bolts inspection, loosening and tightening

2 (5) 6704 B2-1 EN

MAN Diesel & Turbo

030.02 Big-end bearing bolts inspection, loosening and tightening

Table of contents
030.03 Big-end bearing shell (bottom) inspecting
030.04 Big-end bearing shell (top) inspecting
030.05 Connecting rod shank removal and installation
030.08 Big-end bearing cap/connecting rod shank Clean and check
contact surfaces of the big-end bearing shells
030.09 Big-end bearing cap/connecting rod shank Rework contact
surface for big-end bearing shells
034 Piston/Piston rings
034.01 Piston removal and installation
034.02 Piston/Piston rings inspecting
034.03 Piston pin and piston pin bush removing and installing/checking
034.04 Piston dismantling and assembling
034.05 Piston rings assessing
034.07 Piston rings with chrome ceramic coating assessing
050 Top land ring/cylinder liner
050.01 Top land ring removal and installation
050.02 Cylinder liner measure
050.03 Cylinder liner with backing ring removal and installation
050.04 Cylinder liner removal and installation
050.05 Cylinder liner honing
050.06 Sealing groove in the top land ring grinding
055 Cylinder head/Valve seat rings/Safety valve
055.01 Cylinder head bolts inspection, loosening and tightening
055.02 Cylinder head removing and refitting
055.03 Cylinder head Grind seats
055.04 Valve seat rings removal and installation
055.05 Cylinder head with reversing device working/machining
055.06 Sealing face on cylinder head grinding
073 Covering/Crankcase cover
071.01 Casings on coupling side removing and refitting
073.01 Safety valve on crankcase cover checking, detaching and
attaching
100 Control device operating mechanism
100.01 Control device operating mechanism inspecting
102 Camshaft bearing/Camshaft thrust bearing
102.01 Camshaft bearing bolts inspection, loosening and tightening
102.02 Camshaft bearing shells inspecting
102.03 Camshaft (thrust bearing) inspecting
111 Rocker arm casing/control arm
111.01 Valve clearance inspection and adjustment
111.02 Rocker arm casing with rocker arms removing and refitting
112 Push rods
112.01 Push rod removal and installation
113/114 Inlet and exhaust valves

6704 B2-1 EN 3 (5)

 MAN Diesel & Turbo

113.01 Inlet valve removal and installation

Table of contents

113.02 Valve rotator Checking rotating motion

113.03 Inlet and exhaust valves Check and assess valve cone and valve
seating surfaces
113.04 Valve seating surface working/machining
113.05 Valve cone grinding
113.06 Valve guide (inlet valve) inspection, removal and installation
113.09 Valve seating surface inspecting
114.01 Exhaust valve removal and installation
114.03 Valve guide (exhaust valve) inspection, removal and installation
125 Operating device
125.02 Three-way valve M306 checking, overhauling
125.04 Three-way valve M317 checking, overhauling
125.05 3/2-way solenoid valve M329 checking, overhauling
125.08 4/2-Way solenoid valve M392 checking, overhauling
125.08 5/2-way solenoid valve M367 checking, overhauling
125.09 Pressure-reducing valve M409 checking, overhauling
125.10 Compressed air filter M462 checking, overhauling
125.12 Limit switch M745 checking, overhauling
125.14 2/2-way solenoid valve M314/M315/M316 checking, overhauling
125.21 Pressure reducing station M615 checking, overhauling
140 Speed regulation
140.01 Woodward controller PGG 200/PGG-EG 200 servicing and
checking
140.02 Booster Servomotor (two-stage) servicing and checking
140.04 Speed controller removing and refitting
160-162 Starting air pilot valve/Starting valve/Main starting valve
160.01 Starting air pilot valve inspection, removal and installation
160.02 Starting air pilot valve dismantling and assembling
161.01 Starting valve inspection, removal and installation
161.02 Starting valve dismantling and assembling
162.01 Main starting valve dismantling and assembling
200 Fuel injection pump
200.01 Fuel injection pump inspecting
200.02 Fuel injection pump shut off
200.03 Fuel-injection pump Removal and installation
200.04 Fuel injection pump disassembly and assembly
200.05 Fuel injection pump Check and change baffle screws
200.06 Fuel injection pump Measure plunger lift
201.01 Cam follower removing and installing/checking
201.02 Fuel injection pump drive removing and installing or disassembling
and assembling
202 Fuel injection timer
202.01 Fuel injection timer adjusting
203 Governor control linkage

4 (5) 6704 B2-1 EN

MAN Diesel & Turbo

203.01 Governor control linkage servicing and checking

Table of contents
209 Camshaft
209.01 Camshaft inspecting
221 Fuel injection valve
221.01 Fuel injection valve removal and installation
221.02 Fuel injection valve inspecting
221.03 Fuel injection valve dismantling
221.04 Fuel injection valve assembling
221.05 Fuel injection valve Grind sealing faces on threaded piece
280-289 Charge air and exhaust pipe
280.01 Charge air and exhaust pipe for emergency operation converting
280.02 Charge air bypass device disassemble and assemble, renew
sealing elements
289.01 Exhaust pipe checking, detaching and attaching
289.02 Exhaust gas blow-off device disassemble and assemble, renew
sealing elements
300/350 Lubricating oil and cooling water pump
300.01 Lubricating oil pump removing and refitting
300.02 Lubricating oil pump dismantling and assembling
322 Charge air cooler
322.01 Charge air cooler checking and cleaning
419 Indicating device
419.01 Indicator valve open and close
434 Fuel injection pipe /Buffer piston/Fuel pipe
434.01 Fuel injection pipe removing and refitting
434.02 Fuel injection pipe dismantling and assembling
434.03 Fuel injection pipe Grind sealing faces on pressure tube
434.04 Buffer piston dismantling and assembling
434.05 Fuel pipe removing and refitting

4 Appendix
4.1 Insulation
4.2 Lubricating oil pump

6704 B2-1 EN 5 (5)

MAN Diesel & Turbo

Introduction
1 Introduction
2 Work Cards, Classified by Subjects
3 Work Cards, classified into sub-assemblies
4 Appendix

6704 1-1 EN 1 (1)

 MAN Diesel & Turbo 1.1

Preface

Introduction
Preface
Work cards and maintenance The work instructions/Work Cards are closely connected to the engine
schedule maintenance schedule, contained in Volume 010.005 of the Technical Doc-
umentation. While this only specifies the necessary maintenance work in
terms of keywords, the work sequences required in order to maintain the
operational safety and efficiency of the engine are described here step by
step and clarified with the help of images. The Work Cards describe, by way
of introduction, the purpose of the work and, amongst other things, they
contain information regarding the required tools and auxiliary equipment.
Several Work Cards are to be taken into account for most of the work which
is involved.
Work cards are for a specific purpose, i.e. they fulfil the primary information
needs in simple language.
Filing System The Work Cards are classified by subjects/keywords in the first part, and
according to the sub-assembly system of the engine in the second part.
Both parts contain a table of contents of the relevant Work Cards for your
engine.
2007-08-22

Introduction
General

6682 1.1-01 EN 1 (1)

 MAN Diesel & Turbo 1.2

How the working instructions/Work Cards are organized, and how to use them

Introduction
How the working instructions/Work Cards are organized, and how to use them
Make-up In general, the Work Cards contain the following information:

▪ Tips on the significance and purpose of the work,

▪ relevant Work Cards i.e. those Work Cards which contain required or
useful information,
▪ the required tools and auxiliary equipment,
▪ possible supplementary details /technical data and
▪ the individual work sequences beginning with the starting position fol-
lowed by the individual work steps.
Tools are identified with their respective tool number in the illustration and
text, while other parts are identified with their item number.
The index number of the Work Cards, top right in the header, consists of
the three-digit sub-assembly number (or a neutral digit group) and a sequen-
tial number. Example: 021.02
How are the required Work The Work Cards are listed in the directories of sections 2 and 3. The direc-
Cards found? tory in section 2 contains the Work Cards summarised according to the
subjects / keywords, the directory in section 3 contains instructions sorted
according to the sub-assembly system of the engine.
The sub-assembly overview ensures access to the filing system of the
directories in section 3. Through illustrative / graphical representations of
the engine, as well as a tabular overview, it leads to the sub-assembly num-
bers, according to which the Work Cards are sorted.
Safety Instructions Dangers, error sources, technical requirements and supplementary infor-
mation are highlighted by notes. While doing so, the following symbols are
used, depending upon the importance:

Imminent danger
For directly imminent dangers! Possible consequences: Death or severe
injury, total property destruction!

Potentially dangerous situations

For potentially dangerous situations! Possible consequences: Severe
injury!

Possibly dangerous situations

For possibly dangerous situations! Possible consequences: Minor
injuries, possible property damage!
2008-12-05

Introduction

Source of error
General

For tips on error sources.

6682 1.2-02 EN 1 (2)

1.2 MAN Diesel & Turbo

Additional information
Introduction

For application tips and supplementary information.

Clearances and tolerances, Clearances and tolerances, temperatures and pressures are listed in Vol-
temperatures and pressures ume 010.005 Engine - Operating Instructions in section 2.5.

The Work Cards 000.29 and 000.30 together with 000.31 contain the values
for tightening the bolted connections and the associated lubricants.
Ordering Tools Instructions on ordering tools or parts of tools can be taken from Section
4.3 in Volume 010.005 Engine - Operating Instructions or Volume 010.005
Engine - Spare Parts Catalogue.

2008-12-05
Introduction
General

2 (2) 6682 1.2-02 EN

 MAN Diesel & Turbo 1.3

Status/Availability Required Tools/Auxiliary Equipment

Introduction
Tools/aids required
Required tools/auxiliary As an introduction, the Work Cards contain, in the Required tools/auxiliary
equipment equipment section, a list of the tools and equipment required for the descri-
bed maintenance work. See example in the following table.
Quantity Designation Number Status
1 Removal and fitting fixture 322.056 Option
2 Bracket 322.056-1 Option
1 Rail 322.056-4 Option
4 Shackle A0.6 002.452 Standard
1 Combination spanner (set) -- Standard
1 Hexagon screwdriver (set) -- Standard
1 Lifting tackle with rope -- Inventory
Table 1: Example: List of required tools/auxiliary equipment
Status/availability Along with the required amount, the designation and the tool number, the
table also contains details concerning the status/availability of the tools lis-
ted. The following terms are used:
▪ Inventory: refers to a tool/auxiliary equipment which is not included in the
standard scope of supply. We assume that such tools / auxiliary equip-
ment are, in principle, available.
▪ Option: refers to a tool/auxiliary equipment which is not included in the
standard scope of supply. MAN Diesel & Turbo SE can supply these
kinds of tools upon request.
▪ Standard: refers to a standard tool / auxiliary equipment which is con-
tained in the scope of supply for the engine installation or is standard
workshop equipment.
Basic tools The basic tools identified with standard status are not included as part of
the standard scope of supply of MAN Diesel & Turbo SE. The scope of sup-
ply can be expanded to include the basic tools upon request. The compo-
nents of the basic tools are listed in the table below.
Tool Designation Number
Complete basic tool set 009.229
2008-10-28

Introduction
General

6682 1.3-02 EN 1 (6)

1.3 MAN Diesel & Turbo

Tool Designation Number

Introduction

Socket spanner (set) (10x12.5 - 34x12.5) 009.230

Socket spanner insert DIN 3124 - 10x12.5 001.787
Socket spanner insert DIN 3124 - 11x12.5 001.751
Socket spanner insert DIN 3124 - 12x12.5 001.788
Socket spanner insert DIN 3124 - 13x12.5 001.752
Socket spanner insert DIN 3124 - 14x12.5 001.753
socket spanner insert DIN 3124 - 15x12.5 001.789
socket spanner insert DIN 3124 - 16x12.5 001.790
socket spanner insert DIN 3124 - 17x12.5 001.754
socket spanner insert DIN 3124 - 18x12.5 001.798
socket spanner insert DIN 3124 - 19x12.5 001.755
socket spanner insert DIN 3124 - 21x12.5 001.799
socket spanner insert DIN 3124 - 22x12.5 001.756
socket spanner insert DIN 3124 - 24x12.5 001.757
socket spanner insert DIN 3124 - 27x12.5 001.758
socket spanner insert DIN 3124 - 30x12.5 001.759
socket spanner insert DIN 3124 - 32x12.5 001.760
socket spanner insert DIN 3124 - 34x12.5 001.769
socket spanner insert DIN 3124 S - 36x20 001.779
socket spanner insert DIN 3124 S - 41x20 001.780
Cross handle DIN 3122A - 12.5 001.891

Extension DIN 3123B – 12.5x75 001.908

Extension DIN 3123B - 12.5x125 001.911
Extension DIN 3123B - 12.5x250 001.912

Universal joint DIN 3123C - 12.5 001.876 2008-10-28

Introduction
General

2 (6) 6682 1.3-02 EN

 MAN Diesel & Turbo 1.3

Tool Designation Number

Introduction
Ratchet DIN 3122C - 12.5 001.521

Combination spanner (set) (5.5 to 34) 009.231

Combination spanner DIN 3113 AK - 5.5 002.050
Combination spanner DIN 3113 AK - 6 002.051
Combination spanner DIN 3113 AK - 7 002.020
Combination spanner DIN 3113 AK - 8 002.021
Combination spanner DIN 3113 AK - 9 002.052
Combination spanner DIN 3113 AK - 10 002.023
Combination spanner DIN 3113 AK - 11 002.053
Combination spanner DIN 3113 AK - 12 002.054
Combination spanner DIN 3113 AK - 13 002.024
Combination spanner DIN 3113 AK - 14 002.055
Combination spanner DIN 3113 AK - 15 002.025
Combination spanner DIN 3113 AK - 16 002.056
Combination spanner DIN 3113 AK - 17 002.026
Combination spanner DIN 3113 AK - 18 002.057
Combination spanner DIN 3113 AK - 19 002.027
Combination spanner DIN 3113 AK - 20 002.058
Combination spanner DIN 3113 AK - 21 002.059
Combination spanner DIN 3113 BL - 22 002.070
Combination spanner DIN 3113 BL - 24 002.071
Combination spanner DIN 3113 BL - 27 002.072
Combination spanner DIN 3113 BL - 30 002.073
Combination spanner DIN 3113 BL - 32 002.074
Combination spanner DIN 3113 BL - 34 002.075
Single-ended open-jaw spanner DIN 894 - 36 000.566
Single-ended open-jaw spanner DIN 894 - 41 000.567
Single-ended open-jaw spanner DIN 894 - 46 000.568
Single-ended open-jaw spanner DIN 894 - 50 000.569

Hexagon screwdriver A 8.06506 - 0.8x5.5 000.391

Hexagon screwdriver A 8.06506 - 1.2x9 000.393
Hexagon screwdriver A 8.06506 - 2x12 000.395
2008-10-28

Introduction
General

6682 1.3-02 EN 3 (6)

1.3 MAN Diesel & Turbo

Tool Designation Number

Introduction

Philips screwdriver DIN 5262 B-Gr. - 1 000.401

Philips screwdriver DIN 5262 B-Gr. - 2 000.402

Hexagon screwdriver DIN 911 - 3L 000.307

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

Tommy bar DIN 900A - 5 000.507

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

Adapter DIN 3123A - 20x12.5 001.923

Adapter DIN 3123A - 12.5x20 001.927

Locking ring pliers DIN 5254A - 10-25 002.121

Locking ring pliers DIN 5254A - 19-60 002.122
2008-10-28
Introduction
General

4 (6) 6682 1.3-02 EN

 MAN Diesel & Turbo 1.3

Tool Designation Number

Introduction
Locking ring pliers DIN 5256C - 19-60 002.162
Locking ring pliers DIN 5256C - 40-100 002.163

Feeler gauge DIN 2275C - 0.05-1 000.451

Crow bar S 550A - 15 001.391

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

Hammer DIN 1041 - 300L 000.693

2008-10-28

Introduction
General

6682 1.3-02 EN 5 (6)

1.3 MAN Diesel & Turbo

Tool Designation Number

Introduction

Tool box, 5-section, 530x200x200 009.470

Table 2: Basic tools

2008-10-28
Introduction
General

6 (6) 6682 1.3-02 EN

MAN Diesel & Turbo

Work Cards, Classified by Subjects

1 Introduction
2 Work Cards, Classified by Subjects
3 Work Cards, classified into sub-assemblies
4 Appendix

6704 2-1 EN 1 (1)

MAN Diesel & Turbo 001

Operating media systems/Pipes

001 Operating media systems/Pipes
002 Operating media/Auxiliary agents
003 Machine Elements
004 Hydraulic tensioners/High-pressure pump
005 Operating values/Operating results

6704 2.1-1 EN 1 (1)

 MAN Diesel & Turbo 000.03

Operating media systems

Operating media systems/Pipes

flushing and cleaning

Summary
Keep the operating media systems free from impurities and residue, prevent
operating problems / damage.
Flush the operating media systems before commissioning, clean individual
parts before installation. This includes the systems for lubricating oil, fuel,
cooling water and compressed air and, depending on the system:
Flush system(s) (Step 1),
flush system(s) (Step 2),
drain system(s) and
clean components.
Safety requirements
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
1. Lube oil system
The pipe section between the indicator filter and the engine inlet flange
requires careful cleaning. To allow the interior of this pipe to be fully inspec-
ted, it must be separated at each pipe bend using a pair of flanges. As a
basic rule, all the internal welding seams must be smoothed over by grind-
ing.
These pipe components are to be acidified, neutralised and treated with
slushing oil according to Work Card 000.16. This is dissolved by the lubri-
cating oil (e.g. Esso Rustban No. 335, Shell Ensis Oil, Valvoline Tectyl, Tecto
6 SAE 30) which is subsequently added. If installation is to take place later,
the openings are to be sealed with covers. Our commissioning staff are
instructed to check the cleanliness of this pipe before filling the system.

Severe bearing damage can arise by dirt particles entering the engine!
Work Cards, Classified by Subjects

1.1 Flushing the engine's lubricating oil system

Dirt particles will always remain in the pipes in spite of careful installation
and cleaning. This requires thorough flushing of the entire lube oil system
before commissioning. The electrical standby pump or priming pump must
be used for this purpose in engines with attached lube oil pumps. Before /
during and after the flushing process, the oil must be cleaned continuously
by means of a separator.
2010-03-24

1.2 Flushing oil

For the flushing operation, we recommend a special flushing oil with a (low)
General

viscosity of 45-70 cSt / 40°C (e.g. SAE 20). This oil is light so it requires no
preheating.

6682 000.03-01 EN 1 (6)

000.03 MAN Diesel & Turbo

If no flushing oil is available, the operating oil SAE 40 subsequently to be

Operating media systems/Pipes

used for operation can be used for flushing. In these cases, the oil must be
preheated to 40-50°C (preheating units, separator preheater). The engine
cooling water must be preheated to at least 60°C to prevent condensed
water forming (or corrosion in the crankcase). During and after the flushing
operation, the oil must be cleaned continuously by means of a filter and
separator.
1.2.1 First flushing process
Only the pipe system outside the engine is flushed.
The lube oil inlet to the engine must be bypassed. A temporary pipe line that
serves as a return line must be run from the indicator filter to the crankcase.
Automatic filter without con- The filter candles of the automatic filter must be removed, the filter housing
tinuous flushing and bypass lines are to be flushed as well.

Automatic filter with continu- The filter candles in the automatic filter must be removed, the filter housing
ous flushing and the filter bypass pipes must also be flushed.
If there is no downstream indicator filter, the filter candlesneed not be
removed. In this case, there cannot be any pre-cleaning via an indicator
filter, which means the automatic filter is to be used for cleaning in the initial
flushing sequence. Since the dirt particles are returned to the tank by the
automatic filter, segregation of the dirt particles from the circulating oil is
performed here solely through the separator that runs in tandem.
The lubricating oil cooler is to be included in the flushing process. Manual
operation of the temperature control valve alternately flushes the cooler and
its bypass pipe. The lubricating oil separator must be put into operation. All
the oil pipes, especially in the area of welding seams, should be knocked
off throughout the flushing process.
Oil circuit with indicator filter If the maximum differential pressure in the indicator filter is reached, switch
to the other filter chamber and clean the sieve inserts properly. If the con-
tamination of the filter is reduced to a minimum, it is possible to end the
initial flushing process.
The minimum flushing duration of 24 hours must, however, be maintained.
After the flushing sequence is complete, clean the sieve inserts of the indi-
cator filter and check for any damage.
Oil circuit without indicator fil- In this case, the filter candles remain in the automatic filter, because only
ter they provide the filtering. Continue flushing until the filter contamination has
Work Cards, Classified by Subjects

reduced to a minimum, i.e. until the flushing intervals have reduced to max-
imum 1 flushing per hour for automatic filters without continuous flushing
and, in the case of automatic filters with continuous flushing, the displayed
differential pressure has reached a minimum.
The minimum flushing duration of 24 hours must, however, be maintained.

If a running in filter is attached to the engine, it must be monitored

continuously for differential pressure and, if necessary, cleaned.
2010-03-24

The inserts with filter candles are to be installed in the automatic filter (if they
General

have been removed), the slide valve for the bypass pipe is to be closed.

2 (6) 6682 000.03-01 EN

 MAN Diesel & Turbo 000.03

1.2.2 Second flushing process

Operating media systems/Pipes

After assembly of the filter candles in the automatic filter, continue the flush-
ing process for about 2 hours.
By installing the pipe line (cleaned) from the indicator filter to the lube oil
inlet on the engine, the engine with its bearing points and injection valves is
now included in the flushing process. The oil tank for run-down lubrication
(if present) should also be included in the flushing circuit.
In order to remove any existing dirt from the lube oil tank for run-down
lubrication, the oil inlet and oil outlet pipes are to be crossed over. Short
temporary hoses should be installed for this purpose. The oil inlet to the
turbocharger is to be closed. The throttle plate fitted in the filling pipe must
be removed. The pressure control valve is to be released.
The engine must be turned over through 2 rotations at half-hourly intervals
during the flushing process. The cylinder lube oil pump may be switched on
only at the time of turning over.
If only low differential pressures build up in the automatic and indicator filter
(1 flushing process per hour), the flushing operation can be terminated.
The minimum flushing duration of 12 hours must, however, be maintained.

If a running in filter is attached to the engine, it must be monitored

continuously for differential pressure and, if necessary, cleaned.

The pipes previously removed must be reconnected.

The flushing processes must be carried out in the presence of personnel
from MAN Diesel & Turbo SE.
1.3 Draining and cleaning the system components
If a special flushing oil has been used, the lube oil system must be drained
completely. Oil that remains in the cooler, filter and separator preheater
must be removed via the drain pipes. The filter inserts must be cleaned
correctly and checked for damage.
If the flushing process has been carried out using the operating oil and the
findings of the oil analysis are satisfactory, the system does not need to be
drained. Work Cards, Classified by Subjects
1.4 Running in filter
If necessary, a running in filter is attached directly to the engine. The running
in filter inserts are to be used from the beginning of the test run in the engine
manufacturer's premises up to the completion of commissioning on-site.
The filter insert must be cleaned in accordance with the manufacturer's
instructions before being used.
Since the running in filter is not switchable, it has a limited service life when
in use (up to approx. 200 operating hours, depending on the condition of
the lubricating oil). The end of the service life is displayed by a differential
2010-03-24

pressure sensor on the running in filter. An extended period of operation

with an activated contamination display can lead to problems in the lube oil
supply. Therefore, when the differential pressure alarm is triggered,
General

increased attention is to be paid to the lube oil pressure in front of the engine,
and the filter insert must be cleaned as soon as possible, in accordance with
the manufacturer's instructions.

6682 000.03-01 EN 3 (6)

000.03 MAN Diesel & Turbo

Remove the filter insert after the system run-in period (normally after com-
Operating media systems/Pipes

pletion of commissioning) - but definitely before taking up continuous operation

of the equipment. The filter housing remains in the engine. After this there will
be no further filtering effect from this running in filter. A corresponding note
on the filter housing points this out.
In the case of constructional changes to the lube oil system, or for other
reasons that require flushing of the lube oil system, the filter insert must be
refitted until the flushing process is complete.
2. Fuel pressure system
The pipe line between the double filter to be installed directly before the
engine and the engine entry point is subject to the same regulations as the
lube oil pipe described under point 1.
2.1 Flushing the Fuel System
This system must also be flushed in two processes in order to entirely
remove the installation dirt from the pipes. Gas oil or diesel oil should be
used for this purpose.
First flushing operation
The entire shipyard or system side pipe system is flushed via the existing
single or double filter in this process.
The automatic filter and the viscosity control unit are to be bypassed using
their bypass pipes.
Close the shut-off valves on all injection pumps.
The fuel flow and return pipe must be connected to each other in front of
the engine. By switching over the three-way cock before the mixing tank,
the return flow is through the flushing line to the heavy fuel service tank. For
this purpose, the tank should not yet contain any heavy fuel. In this case,
after refilling the system with diesel oil or gas oil and after the return flow of
a sufficient amount to the heavy fuel service tank, the three-way cock can
be switched to fuel flow from this tank. This ensures that diesel oil or gas oil
is pumped around the entire system.
The flushing process must be carried out as described in point 1.3.1. Expe-
rience shows that a flushing time of 24 hours must be maintained.
Second flushing operation
Work Cards, Classified by Subjects

The entire system, including the automatic filter and viscosity control unit,
is included.
The flushing process must be carried out until only small differential pres-
sures build up in the filters.
After completing the flushing process, all the filter inserts have to be cleaned
and checked for potential damage. Open the shut off valves for the injection
pumps and close the bypass pipe for the viscosity control unit.
After completion of the second flushing process, after approximately 6
hours from experience, open the shut-off valves for the fuel pumps.
2010-03-24

The flushing processes must be carried out in the presence of personnel

from MAN Diesel & Turbo SE.
General

4 (6) 6682 000.03-01 EN

 MAN Diesel & Turbo 000.03

2.2 Draining and Cleaning the System Components

Operating media systems/Pipes

Drain the sludge from the final preheater, the filter chambers and the mixing
tank through their drain pipes. After 24 hours settling time, the service tank
must also have the sludge drained off.
3. Cooling water system
Ensure that the surfaces exposed to cooling water are free of corrosion and
any other residue before commissioning the engine and injection valve
cooling system.
If rust is detected, the system needs to be cleaned in accordance with Work
Cards 000.08 and 000.16.
The cooling water system must be flushed with fresh water prior to com-
missioning the engine. Add a detergent to the water in order to remove any
residues of the preservative used. Suitable agents are listed alphabetically
in Table 1. Detergents from other manufacturers may also be used provided
they have the same properties. After cleaning, rinse with untreated fresh
water.
In order to filter out coarser impurities, temporary installation of mud traps
is a must. The mesh must be 1 mm for the low and high temperature system.
The smallest gap in the injection valve is 0.5 mm. Provisional installation of
a mud trap with a width of mesh of ≤ 0.25 mm is necessary for flushing the
cooling water system of the injection valves in order to prevent dirt deposits
here and thus avoid reduced heat dissipation.
The integration of two gate valves in each case means that there will be no
water leakage when cleaning or removing the mud traps.
After flushing, the fresh water is to be treated in accordance with the quality
requirements for cooling water (Operating instruction Sheet 3.3.7).
Manufacturer Product Concentration Cleaning Time / Temperature
Drew HDE - 777 4 - 5% 4 h at 50 - 60 °C
Nalfleet MaxiClean 2 2 - 5% 4 h at 60 °C
Unitor Aquabreak 0,05 - 0,5% 4 h at ambient temperature
Seaclean Plus 0,5% 4 h at 50 - 60 °C
Vecom Ultrasonic 4% 12 h at 50 - 60 °C
Multi Cleaner
Work Cards, Classified by Subjects
Table 1: Detergents for removing oily residues

4. Compressed air system

4.1 Installation-side system
The whole system must be carefully cleaned before operating the engine.
All pressure and control pipes must be free of flammable media and slag,
scale and rust.
2010-03-24

High noise levels when blowing by! Always use ear protection!
General

6682 000.03-01 EN 5 (6)

000.03 MAN Diesel & Turbo

Danger of explosion when flammable media are present, e.g. slushing

Operating media systems/Pipes

oil!

The air pipes are cleaned by blowing by 3 or 4 times with compressed air
at a pressure of 30 bar in the starting air tank.
In order to do this, separate the installation-side pipe line from the main
starting valve and attach the pipe line securely to prevent deformation when
blowing. Close the open engine entry point. Also remove the control air pipe
before the engine. The blowing is activated by opening the slide-valve on
the connecting tank.
After the cleaning process, all the pipes that have been removed must be
reconnected.
4.2 Engine-side system
In the case of doubt as to whether the pipes are free from flammable media
(e.g. slushing oil), please proceed as follows before the first "live" actuation
of the emergency/main starting valve:

High noise levels when blowing by! Always use ear protection!

Danger of explosion when flammable media are present, e.g. slushing

oil!

1. Remove the starting pipe in front of the first cylinder and check for flam-
mable media in both directions.
2. Remove the starting valves and blow the air passage out in the direction
of the open pipe.
3. Create a connection for compressed air behind the main starting valve
and slowly begin blowing by the pipe/spaces towards the cylinder for
an extended period (several air cylinder's worth).
Work Cards, Classified by Subjects

4. Leave open for 24 hours in order to allow the solvent residues to evap-
orate.
5. Fit the starting valves and return to the initial state.
2010-03-24
General

6 (6) 6682 000.03-01 EN

 MAN Diesel & Turbo 000.08

Cooling water system

Operating media systems/Pipes

Cleaning

Summary
Remove contamination/residue from operating fluid systems, ensure/re-
establish operating reliability.
Cooling water systems containing deposits or contamination prevent effec-
tive cooling of parts. Contamination and deposits must be regularly elimi-
nated.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.
Cleaning
The cooling water system must be checked for contamination at regular
intervals. Cleaning is required if the degree of contamination is high. This
work should ideally be carried out by a specialist who can provide the right
cleaning agents for the type of deposits and materials in the cooling circuit.
The cleaning should only be carried out by the engine operator if this cannot
be carried out by a specialist.
Oil sludge Oil sludge from lubricating oil that has entered the cooling system or a high
concentration of rust inhibitors can be removed by flushing the system with
fresh water to which some cleaning agent has been added. Suitable clean-
ing agents are listed alphabetically in the table entitled "Cleaning agents for
removing oil sludge". Products by other manufacturers can be used pro-
viding they have similar properties. The manufacturer's instructions for use
must be strictly observed.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew HDE - 777 4 - 5% 4 h at 50 – 60 °C
Nalfleet MaxiClean 2 2 - 5% 4 h at 60 °C
Unitor Aquabreak 0.05 – 0.5% 4 h at ambient temperature
Vecom Ultrasonic 4% 12 h at 50 – 60 °C Work Cards, Classified by Subjects
Multi Cleaner
Table 1: Cleaning agents for removing oil sludge
Lime and rust deposits Lime and rust deposits can form if the water is especially hard or if the
slushing oil concentration is too low. A thin lime scale layer can be left on
the surface as experience has shown that this protects against corrosion. If
however, the thickness of limescale deposits exceeds 0.5 mm, this can
obstruct the transfer of heat and cause thermal overloading of the compo-
nents being cooled.
Rust that has been flushed out may have an abrasive effect on other parts
2010-02-25

of the system, such as the sealing elements of the water pumps. Together
with the elements that are responsible for water hardness, this forms what
is known as ferrous sludge which tends to gather in areas where the flow
General

velocity is low.
Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled

6682 000.08-01 EN 1 (3)

000.08 MAN Diesel & Turbo

"Cleaning agents for removing lime scale and rust deposits". Products by
Operating media systems/Pipes

other manufacturers can be used providing they have similar properties. The
manufacturer's instructions for use must be strictly observed. Prior to clean-
ing, check whether the cleaning agent is suitable for the materials to be
cleaned. The products listed in the table entitled "Cleaning agents for
removing lime scale and rust deposits" are also suitable for stainless steel.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew SAF-Acid 5 - 10% 4 h at 60 - 70 °C
Descale-IT 5 - 10% 4 h at 60 - 70 °C
Ferroclean 10% 4 - 24 h at 60 - 70 °C
Nalfleet Nalfleet 9 - 068 5% 4 h at 60 – 75 °C
Unitor Descalex 5 - 10% 4 - 6 h at approx. 60 °C
Vecom Descalant F 3 – 10% Approx. 4 h at 50 – 60 °C
Table 2: Cleaning agents for removing limescale and rust deposits
In emergencies only Hydrochloric acid diluted in water or aminosulfonic acid may only be used
in exceptional cases if a special cleaning agent that removes limescale
deposits without causing problems is not available. Observe the following
during application:
▪ Stainless steel heat exchangers must never be treated using diluted
hydrochloric acid.
▪ Cooling systems containing non-ferrous metals (aluminium, red bronze,
brass, etc.) must be treated with deactivated aminosulfonic acid. This
acid should be added to water in a concentration of 3 - 5 %. The tem-
perature of the solution should be 40 - 50 °C.
▪ Diluted hydrochloric acid may only be used to clean steel pipes. If
hydrochloric acid is used as the cleaning agent, there is always a danger
that acid will remain in the system, even once the system has been neu-
tralised and flushed. This residual acid promotes pitting. We therefore
recommend you have the cleaning carried out by a specialist.
The carbon dioxide bubbles that form when limescale deposits are dis-
solved can prevent the cleaning agent from reaching boiler scale. It is there-
fore absolutely necessary to circulate the water with the cleaning agent to
flush away the gas bubbles and allow them to escape. The length of the
cleaning process depends on the thickness and composition of the depos-
its. Values are provided for orientation in the table entitled "Detergents for
Work Cards, Classified by Subjects

removing lime scale and rust deposits“.

Following cleaning The cooling system must be flushed several times once it has been cleaned
using cleaning agents. Replace the water during this process. If acids are
used to carry out the cleaning, neutralise the cooling system afterwards with
suitable chemicals then flush. The system can then be refilled with water
that has been prepared accordingly.

Only carry out the cleaning operation once the engine has cooled
down
2010-02-25

Only start the cleaning operation once the engine has cooled down. Hot
engine components must not come into contact with cold water. Open
the venting pipes before refilling the cooling water system. Blocked
General

venting pipes prevent air from escaping which can lead to thermal
overloading of the engine.

2 (3) 6682 000.08-01 EN

 MAN Diesel & Turbo 000.08

Cleaning products can cause damage

Operating media systems/Pipes

The products to be used can endanger health and may be harmful to the
environment.
Follow the manufacturer's handling instructions without fail.

The applicable regulations governing the disposal of cleaning agents or

acids must be observed.

Work Cards, Classified by Subjects

2010-02-25

General

6682 000.08-01 EN 3 (3)

 MAN Diesel & Turbo 000.15

Pipes

Operating media systems/Pipes

replacement

Summary
Insert/replace components, process and install professionally. Pipes must
be replaced/supplemented if necessary. The materials must, therefore, be
selected according to the requirements, and must be properly processed.
This includes: Selection of suitable materials, proper processing and proper
installation.
Preliminary remarks
If pipes in the fuel, lubricating oil, cooling water or starting air system, or on
the pneumatic operating device need to be repaired, modified or replaced,
the instructions in the following paragraph must be observed in order to
avoid malfunction in subsequent operation.
Instructions
Pipe Dimensions/Materials As replacements for pipes on the engine or the operating device, seamless
mild-steel pipes are to be used, in accordance with DIN 2391, or seamless
copper pipes in accordance with DIN 1754, made from St 35 GZF in accord-
ance with DIN 1629 and C-Cu F 25 and/or F 30 in accordance with DIN 17
671 and/or stainless steel pipes made from X6 CR Ni Ti 1810 in accordance
with DIN 2462. Normally pipes of the same dimensions are refitted to the
engine.
Production Pipes with a small diameter can be cold-bent using commercial pipe bend-
ing devices. When using solderless pipe unions in accordance with DIN
2353, heat treatment can, in most cases, be avoided (see Work Card
000.17).
For air pipes in the pneumatic operating device or in the starting system,
only stainless products may be used, i.e. chromated, galvanised or brass
screwed fittings. Particular attention has to be paid to the thread, since,
depending upon the location, both metric and Whitworth threads, in both
cylindrical and conical form can be present.
If hot-bending becomes necessary when using other pipe qualities or larger
Work Cards, Classified by Subjects
dimensions, or if soldering and/or welding is used on the pipes, then the
pipes must be acidified, leached and washed afterwards (see Work Card
000.16).
Production of lube oil pipes Lube oil pipes with larger diameter, especially the pipe after the lube oil
filter(s), are to be manufactured by bending. Connection flanges and sock-
ets must be joined to the pipes by gas welding.
When gas welding is used, the slag on the filler rod jacket is not required.
This is of special importance, since the roots of the welding seam penetrate
to the inside of the pipe, i.e. the joint gap must be completely filled. On the
2007-03-26

inside of the pipe no unfilled butt joints may remain since foreign bodies
could become stuck there. They would not (hardly ever) be eliminated by
General

cleaning the pipes, and could be drawn into the engine bearings during
operation. Operational malfunction caused by damage to the bearings could
result. If prefabricated pipe bends have to be welded in, then intermediate
flange connections are to be used, whereby their number and location are

6682 000.15-01 EN 1 (2)

000.15 MAN Diesel & Turbo

to be selected in such a way that the welding seams inside the pipe line can
Operating media systems/Pipes

be seen clearly, filled up and checked.

The above welded joints can also be made using the TIG welding method.
Both with gas welding and with TIG welded joints, the tack and finished
welding seams must be carried out using the same welding method.
Laying/Support When laying the pipes, ensure that the pipe routing and fastening is as
vibration-free as possible. Pipes must not be supported on oscillating or
vibrating parts. Oscillations harden and embrittle even soft copper pipes
which can result in the formation of cracks.
Work Cards, Classified by Subjects

2007-03-26
General

2 (2) 6682 000.15-01 EN

 MAN Diesel & Turbo 000.16

Pipes

Operating media systems/Pipes

cleaning, pickling and preservation

Summary
Keep operating media systems free from contamination and residues,
ensure/restore operating safety. Pipes that are replaced or added must,
after manufacture/machining, be mechanically or chemically cleaned, and
preserved if required.
Depending on the actual situation, this includes: Mechanical cleaning of the
components, chemical cleaning of the components, a pressure test and
preservation.
Preliminary remark
All pipes which are attached as a replacement on the engine, are to be
cleaned mechanically or chemically after manufacture. If a longer period
arises between cleaning and fitting (spare pipes), the pipes must be pre-
served and sealed at the ends. Sealing plugs or plastic caps in conspicuous
colours are ideal for this to ensure that they are not overlooked.
Normally, mechanical cleaning is performed on cooling water, heating,
exhaust gas and intake air system pipe lines. Mechanical and chemical
cleaning is performed on lube oil, fuel, compressed air, gas, steam and
water condensate system piping. Isolating and regulating units, as well as
other devices in the individual systems may only be fitted after the cleaning
process.
For pipes filled with sand for hot-bending, only completely dry and fine-grain
sand may be used. With damp sand there is a danger of accidents caused
by steam formation. All pipe systems must undergo a compression test,
either in sections, or as a whole system. The entire lube oil, fuel and com-
pressed air system must be thoroughly rinsed before commissioning the
engine installation.
Mechanical Cleaning
Scale and weld splatter is to be removed carefully from the welded joints,
using a chisel, file or grinding wheel. The whole pipe must be tapped with a Work Cards, Classified by Subjects
hammer and blown through with compressed air, as far as possible at the
same time, so that even the smallest particles (of sand for warm-bending)
are removed.
All pipe connections are to be blocked off until assembly.
For pipes, which are cleaned mechanically and chemically, an acid bath is
required. The acid bath device essentially consists of:
▪ a hydrochloric acid bath for steel pipes,
▪ a water bath for washing the acid off,
2007-10-25

▪ an alkaline bath for neutralising and phosphatising,

▪ a sulphuric acid bath for copper pipes.
General

With the hydrochloric acid and sulphuric acid bath, the rising vapour must
be extracted using fans and dispersed via scrubbers. The vapour from the

6682 000.16-01 EN 1 (3)

000.16 MAN Diesel & Turbo

alkaline bath must also be directed outside using a fan. The regional pro-
Operating media systems/Pipes

tection regulations must also be observed.

The water bath needs a water connection and a compressed air connection.
The alkaline bath must be capable of being heated up to 80°C.

Observance of Occupational Safety Regulations

In accordance with occupational safety regulations for handling acids
and alkaline solutions, those who perform acid and alkaline solution
treatments, must wear an acid-resistant suit, rubber boots, rubber gloves
and safety goggles. A water hose must be available in the immediate
vicinity of the acid/alkaline baths for immediate use.

Treatment of Steel Pipes by Pickling

First pickle in the hydrochloric acid bath and then in the tri-sodium phos-
phate bath for neutralising the acid and for simultaneous short-term pres-
ervation.
Hydrochloric acid (HCI) is available commercially at a concentration of
31-33 %, and with less than 1% arsenic.
Mixing ratio for the HCl bath: H20 = 3: 2 (by weight).

Violent Chemical Reaction

Pour the acid into water, not the other way around!

The treatment must not to be performed at a temperature below 20 °C. The

duration is determined by visual inspection.
With pipes with threads, acid corrosion on the crest of the thread must be
monitored. It determines the duration of treatment in this case.
After completion of the pickling procedure, the acid solution adhering to the
pipes must be washed off in the water bath.
The acid solution which remains in the grooves and pores in the surface
texture is neutralised in a tri-sodium phosphate bath, where the pipes are
simultaneously coated with a phosphate layer which protects against cor-
rosion in the short-term.
Work Cards, Classified by Subjects

Mixing ratio for the bath Na3PO4: H2O = 1: 8 (by weight). Treatment temper-
ature 80 °C.
2007-10-25
General

2 (3) 6682 000.16-01 EN

 MAN Diesel & Turbo 000.16

Treatment of Copper Pipes

Operating media systems/Pipes

Copper pipes should not be treated in a hydrochloric acid bath if steel
pipes are to be pickled afterwards.
The reaction of the copper (Cu) with the dilute hydrochloric acid (HCl) the
salt copper chloride, dissociated in the aqueous solution (CuCl2). If a
steel pipe is then placed in the pickling bath again, the base iron in the
steel oxidises by the discharge of its positive charge units, so that iron
ions go into solution, while the copper separates out. The steel pipe is
coated with an adherent layer of copper which is in no way securely
affixed. Copper deposits are undesirable on the internal walls of fuel-
carrying pipes. Washed-off copper particles would cause subsequent
operational malfunctions in the injection elements, such as pumps and
nozzles.

Treatment of Copper Pipes

First pickle in the sulphuric acid bath and then possibly in the tri-sodium
phosphate bath for neutralising the acid, and for phosphatising.
Sulphuric acid (H2SO4) is commercially available at a concentration of 98 %
(concentrated acid). It must be transported in closed tanks.
Mixing ratio for the bath H2SO4 : H2O = 1: 8 (by weight).

Violent Chemical Reaction

Pour acid into water, not the other way around.

Before using, the prepared bath should rest for 24 hours.

Duration of treatment: At the beginning, with copper pipes 1/4 hour, and,
as the ages progressively, increase the duration accordingly.
After taking the pipes out of the sulphuric acid bath the pipes must be rinsed
with water and dried afterwards using a gentle flame.
A neutralisation in the tri-sodium phosphate bath is not necessarily required,
with longer storage, however, it is advisable for the prevention of verdigris
formation.
Pressure Testing of Pipes
Work Cards, Classified by Subjects

Water pipes are pressure tested with water, lube oil, fuel and air pipes with
slushing oil. For the required test pressures see section 2 of the manual.
Preservation of Pipes
When stored for a short period indoors and/or in dry surroundings, phos-
phatisation and an oil film are sufficient for corrosion protection. Also during
long-term storage for service, phosphating before the actual preservation
with slushing oil, lacquer or grease offers a good basic preservation. Pipe
2007-10-25

ends and connection points are to be sealed with coloured plastic caps.
Plastic caps in striking colours have the advantage that they are easier to
General

recognise when fitting the pipes to the engine. They must be removed again
when fitting.

6682 000.16-01 EN 3 (3)

 MAN Diesel & Turbo 000.17

Solderless pipe unions

Operating media systems/Pipes

mounting

Summary
Insert/replace components, process and install professionally. Solderless
pipe unions are preferably used where pipes with a small diameter can be
cold-bent. In this case, pickling and neutralising are not required.
The work/work steps include: Proper processing and installation.
Tools/aids required
Quantity Designation Number Status
1 Tools, Basic Scope 009.229 Option
1 Pipe cutter - Inventory
1 Counterbore - Inventory
1 Machine oil - Inventory

Advantages of solderless pipe unions

Solderless pipe unions are preferably used where pipes with a small diam-
eter can be cold-bent, i.e. where no heat treatment is necessary. The usual
process of pickling and neutralising is then not required.
Copper pipes must be provided with reinforcing sleeves on the inside. See
Work Card 000.18.
Work steps
1. Cut pipe at a right angle and deburr. Pipe cutters (see figure 1) are per-
fect for doing this. The pipe is cut through using a cutting wheel. The
internal edge of the pipe can then be deburred using the 3 blades in the
handle or using a counterbore tool. Remove swarf by blowing out!
2. Oil (do not grease) the threads and the cutting ring and the tapered ring
(4) well. Then slide the nut and ring over the pipe end as shown. If the
cutting and tapered ring cannot be pushed over the pipe end, or if this
is difficult to do, do not expand the ring but reduce the pipe end by
Work Cards, Classified by Subjects
grinding/filing.
3. Screw the cap nut on by hand up to perceptible contact with the cutting
ring and tapered ring. Then push the pipe against the stop in the inner
cone and tighten cap nut by about 1/2 to 3/4 revolution. By doing this,
the cutting and tapered ring grips the pipe. It is no longer necessary to
continue pushing the pipe. Final tightening is performed by a further
tightening of the cap nut by approx. one revolution. Here the ring cuts
into the pipe and a visible collar (6) rises before its cutting edge. A line
(7) marked on the cap nut allows you to monitor the stipulated number
2008-10-28

of turns.
4. Pipes of smaller outside diameter can be fixed in screwed connections
General

without sub-assembly, if they are firmly screwed in to the engine.

Pipes of larger outside diameter and all connections in free pipes are
best pre-assembled in the vice. The open-jaw spanner should have an

6682 000.17-01 EN 1 (4)

000.17 MAN Diesel & Turbo

approx. fifteen fold length of the width across flats (possibly extended
Operating media systems/Pipes

by using a pipe). Otherwise proceed as above. The final tightening is

easier if the cap nut is loosened several times so that oil is once again
admitted between the friction surfaces.
5. Once the final tightening has been successfully performed, loosen the
cap nut and check whether a raised, visible collar (6) fills out the area in
front of the cutting edge, if not, briefly tighten again. It does not matter
if the cutting and tapered ring on the pipe end can be rotated.
After establishing the connection, and after each release process, the
cap nut is to be tightened without using an extension for the spanner
and without using increased force.

Ensure that each pipe end again reaches the same inner cone where pre-
assembly took place.
Work Cards, Classified by Subjects

Figure 1: Required tools - counterbore cutter, pipe cutter and pipe bending
device
2008-10-28
General

2 (4) 6682 000.17-01 EN

 MAN Diesel & Turbo 000.17

Operating media systems/Pipes

1 Cap nut 4 Cutting ring and tapered ring
2 Stop 5 Inner cone
3 Pipe 6 Visible collar
Figure 2: Mode of action and control of pipe unions. Starting condition - in the
middle of the illustration, after tightening - at the bottom, checking - at the top.

Work Cards, Classified by Subjects

2008-10-28

7 Mark
Figure 3: Assembly of pipe unions. Assembly on site - on the left, pre-assembly
General

in the vice - on the right

6682 000.17-01 EN 3 (4)

000.17 MAN Diesel & Turbo

Additional information
Operating media systems/Pipes

The straight pipe end extending into the screw connection must have a
minimum length of double the height (H) of the cap nut.
With longer or more highly stressed pipes, pipe supports are required.
For bending steel and copper pipes, a device with exchangeable rollers (see
figure 1) is recommended. The bend radius R must not be less than double
the outside diameter of the pipe (R = 2 D).

H Height of the cap nut R Bend radius

2H Min. distance to a pipe bend D Outside diameter
Figure 4: Minimum distances/Bend radii
Work Cards, Classified by Subjects

2008-10-28
General

4 (4) 6682 000.17-01 EN

 MAN Diesel & Turbo 000.18

Solderless pipe unions

Operating media systems/Pipes

Additional parts

Summary
Insert/replace components, process and install professionally. Accessories
for solderless pipe unions extend their application range. The following can
be used: Reinforcement sleeves, nozzle inserts and screwed hose connec-
tions.
The work/work steps include: Proper processing and installation.
Preliminary remarks
Solderless pipe unions will be used in conjunction with reinforcing sleeves,
nozzle inserts and screwed hose connections. In this way the application
range can be extended, amongst other things, to copper pipes and hose
connections.
Instructions
Reinforcing sleeves When using solderless screwed connections on soft copper pipes reinforc-
ing sleeves must be used to prevent the pipe the pipe from collapsing when
tightening the cap nut.

1 Reinforcing sleeve
Figure 1: Use of Reinforcing Sleeves. Left top –sleeve inserted, left bottom -
sleeve knocked in. Right factory assembled pipe union Work Cards, Classified by Subjects
Nozzle inserts By using nozzle inserts, the ventilation and bleeding time of the devices can
be adapted to the individual requirements. They can later be inserted into
the pipe fittings, if the cap nut has been released and the pipe pulled out
beforehand. Ensure that the pipe end is shortened by the length of the noz-
zle collar.
2008-10-28

General

6682 000.18-01 EN 1 (2)

000.18 MAN Diesel & Turbo
Operating media systems/Pipes

2 Nozzle insert
Figure 2: Use of nozzle inserts. Left nozzle insert, right factory assembled pipe
union
Screwed hose connections Transitions from pipes to hoses and vice versa will occur frequently within
a compressed air system if moving parts are connected to each other. If the
pipe ends cannot be bent into a perfect standard hose connecting piece, a
screwed hose connection should be used. Sliding the hose onto the smooth
cut pipe end is not allowed. The hose (3) is to be cut at right angles and must
be pushed onto the hose connecting piece up to the stop. The hose must
be prevented from slipping off with a hose clip or hose clamp (4).

3 Hose 4 Hose clamp

Figure 3: Using screwed hose connections
Work Cards, Classified by Subjects

2008-10-28
General

2 (2) 6682 000.18-01 EN

MAN Diesel & Turbo 002

Operating media/Auxiliary agents

001 Operating media systems/Pipes
002 Operating media/Auxiliary agents
003 Machine Elements
004 Hydraulic tensioners/High-pressure pump
005 Operating values/Operating results

6704 2.2-1 EN 1 (1)

 MAN Diesel & Turbo 000.04

Lubricating oil

Operating media/Auxiliary agents

assessing and treating

Summary
Collating and assessing operating media parameters, maintaining the con-
sistency within the permitted range, avoiding/reducing damaging effects.
Lubricating oil must be assessed and continuously maintained at regular
intervals with regard to consistency, in accordance with the maintenance
schedule.
This includes: Analysing oil samples, maintaining and replacing operating
media.
Oil Evaluation
Spot test/oil analysis The condition of the used oil in the engine must be constantly monitored.
At which intervals a spot test should be prepared on filter paper, or an oil
sample is to be taken for examination in a laboratory set up for the purpose
(it would be best to consult the customer service of the supplier in this
regard) is given in the servicing schedule. The oil sample must be taken after
the filter, while the engine is running. This ensures that the result will be
representative for the oil in the engine.
A definitive statement concerning continued use can only be made on the
basis of a full analysis, the values of which are determined by standard test
procedures.
We recommend obtaining a suitable test kit for the routine local examination
of the operating media. MAN SE has developed a test case together with
the company Mar-Tec, which contains easy-to-operate devices. This ena-
bles the bunkered heavy fuel and the parameters required for treatment, and
the condition of the waste lube oil, to be determined with sufficient accuracy.
Supporting documents can be obtained from Mar-Tec., Warnckesweg 6,
22453 Hamburg.
In general, the following values are sufficient for the routine examination of
used oil:
Characteristic value Limit value Measurement method
Work Cards, Classified by Subjects
Viscosity at 40°C mm /s
2
> 110 ISO 3104
< 220
Flash point (PM) °C > 185 ISO 2719
Water content % vol. < 0,2 ISO 3733
(0.5% only permissible for a short period)
TBN % TBN ≥ 50 ISO 3771
(related to fresh oil)
Contamination % by weight in general < 1.5 depends on the available DIN 51 592
dispersing power and viscosity increase IP 316
2007-10-25

Metal content mg/kg depends on engine type and operating con- ASTM 5185-91
ditions
Table 1: Examination of Lube Oil - Parameters/Threshold Values
General

Colour No conclusions concerning the level of contamination can be drawn from

used doped lubricating oil, since very fine soot particles (< 1.0 mm) are
present as a result of the dispersant-detergent-capacity, which lead to

6682 000.04-02 EN 1 (3)

000.04 MAN Diesel & Turbo

intensive black colouring of the oil, even at lower concentrations. The total
Operating media/Auxiliary agents

contamination of the lube oils can be ascertained, amongst others, by using

DIN 51592 or IP 316. The appearance of the spot test also allows conclu-
sions to be drawn.
Fuel in the lubricating oil Fuel in the lubricating oil can be verified by determining the flash point and
the viscosity of the cleaned used oil, in comparison with the values from
fresh oil. Oil change due to thinning of the lubricating oil is necessary if the
oil viscosity falls by one viscosity class, or if the flash point has dropped
below 185 °C. If a laboratory test cannot be performed, the viscosity can be
determined approximately as described below:
Fresh oil samples which exhibit one viscosity class higher and one lower
than the oil in the engine are dripped, together with the used oil, onto an
inclined glass or metal plate at the same temperature. You can determine
from the flow rate whether the used oil has higher or lower viscosity than
the fresh oil.
Water in the lubricating oil If a laboratory test for determining the water content is not possible, a drop
of the used oil is applied to a hot plate. If there is water is in the oil it will
evaporate quickly and disappear with an audible noise upon overcoming
the capillary force force (crackle test). The water content in the oil should be
no more than 0.2%. In the case of water content >0.5 %, an oil change is
required and, if not possible, the water content is to be reduced to <0.2%
by centrifuging carefully and/or temporary heating of the oil. Water in the oil
promotes, amongst other things, corrosion of the polished running gear
components and the formation of oil sludge, i.e. increased viscosity.
Increased water content in lubricating oil is often caused by insufficient tank
and crankcase ventilation. It is therefore necessary to drain the oil sludge
and water from the lowest point of the service and reservoir tanks at regular
intervals.
Air in the lubricating oil Air emulsion (oil has white appearance) or severe surface foaming appears
if there are leaks on the intake side of the pump, through which air reaches
the oil. This compromises, amongst other things, the formation of a hydro-
dynamic lubrication condition in the bearing and promotes ageing of the oil.

Oil Treatment
Oil Treatment The filter installed in the main flow has the task of holding back the particles
of dirt, up to an established width of mesh. The main load is borne by the
Work Cards, Classified by Subjects

automatic filter fitted, in all operational configurations and on all types of

engine. Depending on the application, an indicator filter, designed as double
filter, can also be fitted downstream of the automatic filter. It is required
especially in marine systems with single engine operation, as stipulated in
the classification.
If the correct components are selected, and if the system is serviced in an
optimum way, maintenance of the filter(s) at the intervals as per the diesel
engine will be adequate.
The separator performs the task of clearing the particles of dirt from the
2007-10-25

lubricating oil. The dirt caused by engine operation, such as soot, abrasion
products etc. is eliminated from the system by the separator.
General

In contrast to the lube oil filter, the lube oil separator works in bypass. The
design criterion in this case is the recirculation of the lube oil content within

2 (3) 6682 000.04-02 EN

 MAN Diesel & Turbo 000.04

the time period specified by the diesel engine manufacturer with the corre-

Operating media/Auxiliary agents

sponding approximate value.
The automatically self-draining separators currently available on the market,
recommended for use in the systems described, are highly optimised on a
hydraulic level, in the separation process, as well as on a control technology
level, so that, when selected and used correctly, a balance between the
ingress and removal of impurities is maintained. A minimum requirement on
the operator, by the manufacturer of the diesel engine, is the synchronous
operation of the lube oil separator and the diesel engine.
Oil Change
A definitive prediction of the expected useful life of the oil cannot be since
the engine manufacturers generally do not know the quality of the fuel or
lubricant oil to be used, the operational conditions under which the engine
runs, and also whether proper oil maintenance can be assumed.
An oil change is necessary if the chemical-physical parameters of the oil
filling have changed in such a way that the lubrication, cleaning and neu-
tralisation characteristics are no longer adequate. This can only be ascer-
tained by full analysis.
The parameters specified in Table 1 must be observed.
In an oil change, all the lubricating oil must be drained from the system at
the operating temperature. If the main pipe systems cannot be fully drained,
the entire system must be cleaning with flushing oil before fresh oil is added.

Work Cards, Classified by Subjects

2007-10-25

General

6682 000.04-02 EN 3 (3)

 MAN Diesel & Turbo 000.05

Lubricating oil/Fuel

Operating media/Auxiliary agents

Carrying out the spot test

Summary
Collating and assessing operating media parameters, maintaining the con-
sistency within the permitted range. Spot tests allow the evaluation of
important characteristics with little effort. They are useful as supplements
to lubricating oil and fuel analyses. They cannot, however, substitute them.
The work includes: Preparation and assessment of spot test.
Work Sequence (during the lube oil test)
Immerse a cleaned rod (glass or wire), which should taper to a point, in the
lubricating oil at the operating temperature.
Drip the oil adhering to the rod onto the filter paper and let it dry for a few
hours at room temperature.
Compare the filter paper with the tests shown on the reverse.
Evaluation of the Lube Oil Drip Test
The spot test on filter paper indicates the degree of contamination, the
presence of water or fuel and the current dispersing power of the detergent.
Conclusions can be drawn from this information on the condition of the oil
filling. The spot test must not be regarded as a substitute for an oil analysis.
If the spot test appears abnormal compared to images made using earlier
oil charges that spent the same amount of time in the engine, this indicates
irregularities, e.g. poor combustion, fuel or water leakage, insufficient oil
maintenance, etc. Fig. 1 shows what used doped (HD) oils look like. The
lubricating oil spot shown in sample 1 is slightly contaminated, the oil shown
in sample 5 shows has been used up and an immediate oil change is
required. If the oil spot has the same appearance as sample 4, a compre-
hensive analysis is required to establish beyond doubt the condition of the
oil filling.
Doped lubricating oils contain active ingredients that hold combustion res-
idues in suspension in a finely distributed form and/or prevent these from
accumulating in the engine (effect of the dispersant). The dirt particles are
Work Cards, Classified by Subjects
smaller than the capillaries in the paper which explains why the flow effect
is more pronounced at the outer edges. When the dispersion effect reduces,
dirt particles join together and block the capillaries. The centre of the spot
turns a dark colour. If the edge has a radial appearance, this indicates that
the lubricating oil contains water or fuel.
The oil samples for the spot tests must be taken from the oil circuit at the
specified intervals (also see maintenance schedule) and at the same point
when the engine is running and affixed inside a notebook.
In order to be able to compare the spot tests the same filter paper must be
2009-03-26

used. The spot tests shown were carried out using the filter paper specified
above.
General

6682 000.05-01 EN 1 (2)

000.05 MAN Diesel & Turbo
Operating media/Auxiliary agents

Figure 1: Spot tests of doped lubricating oils - Sample 1: slightly contaminated - Sample 4: analysis required
- Sample 5: oil change required

Fuel drop test

The spot test on the filter paper indicates the type of fuel, i.e. whether dis-
tillate or mixed fuel. In the case of heavy fuels, the appearance of the spot
test indicates the compatibility of the mixed components. It is recommen-
ded to record the spot tests for each new bunkering in a notebook.
Work Cards, Classified by Subjects

2009-03-26
General

2 (2) 6682 000.05-01 EN

 MAN Diesel & Turbo 000.07

Cooling water

Operating media/Auxiliary agents

inspecting

Summary
Acquire and check typical values of the service media to prevent or limit
damage.
The fresh water used to fill the cooling water circuits must satisfy the spec-
ifications. The cooling water in the system must be checked regularly in
accordance with the maintenance schedule.
The following work/steps is/are necessary:
Acquisition of typical values for the operating fluid,
evaluation of the operating fluid and checking the concentration of the rust
inhibitor.
Tools/equipment required
Equipment for checking the The following equipment can be used:
fresh water quality
▪ MAN Diesel & Turbo water testing kit or a similar testing kit containing
all the instruments and chemicals required to determine the water hard-
ness, pH value and chlorine content (obtainable from MAN Diesel &
Turbo or Mar-Tec Marine, Hamburg)
Equipment for testing the When using chemical additives:
concentration of additives
▪ Testing equipment in accordance with the supplier's recommendations.
Testing kits from the supplier also include equipment that can be used
to determine the fresh water quality.

Testing the typical values of water

Abbreviated specification
Water for filling Circulating water
Typical value/property
and refilling (without additive) (with additive)
Water type Fresh water, free of foreign matter Treated cooling water
Work Cards, Classified by Subjects
Total hardness ≤ 10°dGH 1)
≤ 10°dGH 1)
pH value 6.5 - 8 at 20 °C ≥ 7.5 at 20 °C
Chloride ion content ≤ 50 mg/l ≤ 50 mg/l 2)
Table 1: Quality specifications for cooling water (abbreviated version)
1)
dGH German hardness
1°dGh = 10 mg/l CaO
= 17.9 mg/l CaCO3
= 0.179 mmol/L
2010-02-25

2)
1mg/l = 1 ppm
General

6682 000.07-01 EN 1 (2)

000.07 MAN Diesel & Turbo

Testing the concentration of rust inhibitors

Operating media/Auxiliary agents

Abbreviated specification
Slushing oil Concentration
Chemical additives according to the quality specification in Volume 010.005 Engine - Operating Instruc-
tions, Chapter 3, Sheet 3.3.7
Anti-freeze according to the quality specification in Volume 010.005 Engine - Operating Instruc-
tions, Chapter 3, Sheet 3.3.7
Table 2: Concentration of the cooling water additive
Testing the concentration of The concentration should be tested every week, and/or according to the
chemical additives maintenance schedule, using the testing instruments, reagents and instruc-
tions of the relevant supplier .
Chemical slushing oils can only provide effective protection if the right con-
centration is precisely maintained. This is why the concentrations recom-
mended by MAN Diesel (quality specifications in Volume 010.005 Engine –
Operating Instructions, Chapter 3, Sheet 3.3.7) must be observed in every
case. These recommended concentrations may not be the same as those
specified by the manufacturer.
Testing the concentration of The concentration must be checked in accordance with the manufacturer's
anti-freeze instructions or the test can be outsourced to a suitable laboratory. If in doubt
you should consult MAN Diesel.
Testing We test cooling water for customers in our laboratory. To carry out the test
we will need a representative sample of roughly 0.5 l.
Work Cards, Classified by Subjects

2010-02-25
General

2 (2) 6682 000.07-01 EN

 MAN Diesel & Turbo 000.14

Engine or components

Operating media/Auxiliary agents

preservation treatment

Summary
Adopt measures to counteract corrosion, carry out/repeat protective meas-
ures.
Corrosion protection and preservation measures are adopted with specific
targets, not only with regard to a suitable slushing oil, but also the type of
application and the intervals for renewal inspection.
This includes:
Selection of a suitable slushing oil,
anti-corrosion measures for new engines and spare parts and
preservation of engines and engine components in the event of stoppage.
Corrosion Protection
Most corrosion on polished metal surfaces is caused by the effects of the
weather, the type and extent of which varies depending on the climate
(continental, industrial, oceanic, tropical climate). Corrosion which origi-
nates, for example, in pipes, fittings and heat exchangers through contact
with water remaining in the system or due to air humidity can be overlooked
and first becomes apparent when a fault occurs. The application of a cov-
ering coat on the metal surface is the most common means of preservation.
The preservative must have a thick continuous layer which adheres to the
surface well, displaces water and is not affected by corrosive media.
Protection for a limited period Even the best preservation provides protection for a limited period only. A
check is absolutely necessary at stipulated time intervals, so that the pres-
ervation treatment can be repeated in good time.
The addition of vapour-phase anti-corrosion oil (VCI) has proved to be
effective for internal preservation. Owing to their properties, these oils con-
tinuously deliver small quantities of gaseous inhibitors, so that a vapour-
phase develops in a closed space that provides additional preservation if
required. Nevertheless, it is important that the crankcase is completely
closed off and that the preserved engine, or the engine's individual parts,
are stored in a dry, well-ventilated room where the temperature is regulated. Work Cards, Classified by Subjects
Rust inhibitor
Depending on the intended purpose and the existing conditions, there are
various different slushing oils which can be classified as follows:
1. Slushing oil with added solvent
This is a mineral oil based wax or oil to which, for example, white spirit is
added as a solvent, and which is applied, without heating, to the metal sur-
face to be protected by immersing, spraying or brushing. After the solvent
has evaporated, a protective layer is left behind which can be wiped down
2009-12-08

or washed off. If the inner preservation of the engine is carried out using this,
cleaning prior to commissioning is not required if the protective coating is
dissolved by the lubricating oil during operation. These protective agents
General

are also suitable for individual engine parts and the external preservation of
complete engines.

6682 000.14-02 EN 1 (7)

000.14 MAN Diesel & Turbo

The solvents are flammable and can develop explosive vapours!

Operating media/Auxiliary agents

2. Anti-corrosion grease
This protective grease is applied using a paintbrush, or is rubbed onto the
metal surface. If the grease is oil-soluble and was only applied sparingly,
the protective layer can be left in the preserved inner parts when commis-
sioning the engine, provided that the engine was closed off and no dust or
dirt has settled inside.
The external or individual parts of the engine preserved with grease must
always be cleaned before commissioning. This can be easily carried out by
washing with an oil-dissolving liquid (e.g. diesel fuel). Nevertheless, you
must ensure that the washing liquid does not penetrate the engine and mix
with the lubricating oil.
3. Anti-Corrosion Oils
These protective oils are mineral oils with corrosion inhibiting substances
which are suitable for spraying or painting onto individual engine parts or, if
the engine is assembled, for preserving the internal parts. It is also possible
to operate the thoroughly cleaned engine with the oil for a short time, which
also provides good preservation of the oil system.
4. Anti-Corrosion coating wax, vapour-phase slushing oil or paper are other
products with which individual parts can be preserved.
Preservation of new engines and spare parts
Before dispatch, the engines undergo preservation in the factory. This pres-
ervation treatment means that the engines can be stored outside under a
tarpaulin for 12 months. If an engine is to remain in storage for longer, the
preservation treatment must be repeated. This can be carried out as descri-
bed below. Preservation of the complete engine is normally only necessary
for four-stroke engines.
1. Remove covers on the crankcase, gearboxes of the camshaft drive and
on the camshaft. If there are hygroscopic bags (silica gel) in the crank-
case, remove them.
Work Cards, Classified by Subjects

2. Remove the valve protecting cap and remove all pipe seals (turbo-
charger, pipes for fuel, lubricating oil, cooling water and starter air).
3. Fill the pipes for fuel and lubricating oil, and the nozzle cooling system,
with anti-corrosion oil. If a handpump is fitted, fill the lubricating oil sys-
tem with corrosion-inhibiting oil.
4. Generously spray the crankcase, all running gear parts, wheels in the
camshaft drive, camshaft, valve drive, all pipe openings and openings
in the exhaust gas turbocharger with corrosion-inhibiting oil. If possible,
rotate the running gear with turning gear or turning bar several times,
2009-12-08

while refilling the fuel pipe with corrosion-inhibiting oil. If the running
gear cannot be turned, fill the injection pumps, pipes and injectors with
fresh corrosion-inhibiting oil by actuating the shut-off lever. The filling
General

lever must, at the same time, be positioned to full.

2 (7) 6682 000.14-02 EN

 MAN Diesel & Turbo 000.14

5. If necessary, hang hygroscopic bags (e.g. silica gel by BASF, D-67063

Operating media/Auxiliary agents

Ludwigshafen/Rhine) in the crankcase to prevent condensation. Con-
densation is therefore to be expected until the corrosion-inhibiting oil
has fully dripped off into the engine. The bags must be distributed inside
the engine, hanging in sleeves open at the bottom. The number of the
bags distributed in the engine should be recorded in the operating log
sheets, so that, prior to commissioning the engine it can be ensured that
they have all been removed.
6. Refit all covers and seal the engine airtight. To do so, seal all openings
with grease-free paper and adhesive tape, close off the pipe connec-
tions with plastic caps or wooden stoppers. All gaps and bores in the
engine must be treated with corrosion-inhibiting oil and then closed off,
since cleaning at a later date would require additional expenditure.

Turning the drive gear

The engine running gear must not be turned after being closed airtight.

Preservation of Engines during Standstill

The purpose of the procedure described is to conserve engines when they
are shut down for an indeterminate period. This procedure may not always
be the same due to the design of the pipe systems and the engine room,
the engine type and auxiliary systems used.
The following temperature and humidity values in the engine room and con-
trol room must be observed to protect the mechanical and electronic equip-
ment:
Temperature min. 10°C
Humidity ≤ 50% RH
Work steps to be carried out Engine
before
stopping the engine
The engine must be switched over from heavy fuel oil (HFO) to marine diesel
oil (MDO) operation before switching it off. The engine must be operated for
roughly 1 hour at full load or for 2 hours at 75% load in marine diesel oil
operation. In doing so, observe the instructions in Section 3.4.1 and 3.4.2
Work Cards, Classified by Subjects
(see Volume 010.005 Engine – Operating Instructions).
Turbocharger
The turbocharger must be cleaned on the turbine and compressor side
before shutting it down. In doing so, observe the instructions in the turbo-
charger documentation (see Volume 010.200 Turbocharger)
Work steps to be carried out A prerequisite for effective preservation is that all internal and external parts
prior to of the engine are thoroughly cleaned before treating with a protective agent.
conservation Scheduled maintenance and overhaul work is to be performed in accord-
2009-12-08

ance with the maintenance schedule and recorded in the operating log
sheets.
1. All the fuel in the engine must be drained off. The fuel service tank must
General

be cleaned thoroughly. Instead of fuel, a low-viscosity anti-corrosion oil,

to SAE group 10 to 20, is poured into the service tank (e.g. Fuchs Anti-

6682 000.14-02 EN 3 (7)

000.14 MAN Diesel & Turbo

corit 1), this provides sufficient internal preservation for pipes carrying
Operating media/Auxiliary agents

fuel and engine parts supplying fuel.

2. Operate the engine for approx. 30 min with the anti-corrosion oil, so that
all pipes and the injection system are filled with anti-corrosion oil. Before
shutting off the engine, spray a small quantity of the low-viscosity anti-
corrosion oil into the intake pipe (of the exhaust gas turbocharger).
3. All lubricating oil in the cooler and filter must be drained off. Lubricating
oil lines must be blown out. The oil pan, lubricating oil tank and lubri-
cating oil service tank must be thoroughly cleaned. The lubricating oil
system must then be filled with anti-corrosion oil of the same viscosity
as the lubricating oil used. In this case, it must be ensured, by selecting
an appropriate fill level, that oil is drawn in by the lubricating oil pumps
bubble-free.
4. After shutting off the engine, likewise spray a small quantity of anti-cor-
rosion oil (approx. 0.5l) into the main starter air pipe and control air pipe

Danger of explosion! Do not start the engine!

On no account must you start an engine in this condition! Danger of
explosion! Attach a warning sign and blow out the pipes before the next
start, in accordance with Work Card 000.03!

5. After stopping the system, all pressure gauges must indicate zero. The
engine is to be secured against unintentional turning of the running gear.
The turning gear is to be engaged (if present).
6. Preservation of the coolant areas is not necessary if an anti-corrosion
oil has been added to the coolant during operation. If a chemical additive
has been used, the coolant must be changed and an anti-corrosion oil
at approx. 3-5% concentration is to be added and the engine to be
operated with it. If the engine is out of service for a prolonged period,
or if there is a danger of frost, the coolant must be fully drained from the
engine, turbocharger and the coolers of the individual circuits and you
must ensure that the drain cocks remain constantly open with the engine
switched off. When draining the coolant, the coolant compartment in
the coolant pump must also be drained. The injection valves must be
removed and drained separately.
7. All external polished engine parts must be coated or sprayed with an
Work Cards, Classified by Subjects

anti-corrosion agent. This applies in particular to the control linkage and

control rods of the injection pumps. The crankshaft exit from the cylinder
crankcase is to be closed off with grease.

Preservation of New Engines and Spare Parts

Engines, which were already in operation and where a short
commissioning for preservation is not possible, can be preserved as
described in the section "Preservation of New Engines and Spare Parts".
You must ensure, at the same time, that prior to preservation, the fuel,
lube oil and coolant are drained off. All engine parts must also be
2009-12-08

carefully cleaned.

8. Spray out the crankcase with an anti-corrosion agent (e.g. Fuchs Anti-
General

corit 6120-42 DFV or Valvoline Tectyl 51111). In addition, preserve the

camshaft with an anti-corrosion agent that leaves a waxy layer (e.g.

4 (7) 6682 000.14-02 EN

 MAN Diesel & Turbo 000.14

Valvoline Tectyl 542). In addition, add 5 - 6 litres of a VCI oil to the

Operating media/Auxiliary agents

crankcase.
9. The silencer is to be covered with foil and the exhaust gas pipe sealed
to avoid a draught through the engine.
10. The preservation must be renewed every 6 months.

Recommended anti-corrosion agents

Anti-corrosion agent a Anti-corrosion agent b Anti-corrosion agent c
Corrosion Protection Multipurpose oil (with increased Anti-corrosion oil, soluble in
Anti-corrosion oil, emulsifiable
corrosion protection) fuel/oil
Type of coating wash, spray, dip, coat wash, spray, coat or spray flush
without air
Drying time Non-drying Non-drying Non-drying
Durability of corrosion 3 months 3 months 24 months
protection with roofed
storage
Compatibility with Fuel and lubricating oil Fuel and lubricating oil Cooling water that has been
fuel/oil treated with anti-corrosion
agent (c) is not compatible
with chemicals used for the
treatment of cooling water
Removability of coat- Diesel fuel, petroleum, neu- Same as anti-corrosion Neutral cleaner, diluted alka-
ing tral cleaner, diluted alkaline agent (a) line cleaner, solvent as liquid
cleaner, cloth or gaseous phase
Area of application Engine lubricating oil during Anti-corrosion agent with Flush cooling water system
and comments acceptance run, flushing of roughly 10 cSt/20°C: (30°), drain completely, blow
lubricating oil system, speed Mounted surfaces, parts of out if required as condensate
governor and other compo- fuel system, e.g. pressure is highly corrosive. Pressure
nents with their own lubricat- test of fuel injectors test of cooling chambers.
ing oil circuit Anti-corrosion agent with
roughly 70-90 cSt/50°C:
Machined or smooth surfa-
ces, e.g. bearing surfaces
Preferred anti-corro- Esso run-in oil 40 Esso-Rust-Ban 335 Esso-Rust-Ban 310
sion agent Fuchs Renolin MR40 (85 cSt/20°C) (for pressure test)
Shell Ensis engine oil 40 Esso-Nuto 460 Fuchs-Anticorit MKR
Shell Helix Plus (5W-40) Fuchs-Anticorit 1 Henkel P3-multan 70-3
(9 cSt/20°C) Shell oil 9156 Work Cards, Classified by Subjects
Shell-Ensis Oil N
Valvoline corrosion protec-
tion 6 SAE 30
Table 1: Recommended anti-corrosion agents (Part 1)
Anti-corrosion agent d Anti-corrosion agent e Anti-corrosion agent f
Anti-corrosion agent with thixo-
Corrosion Protection tropic properties (oily protective Anti-corrosion agent, soft waxy Anti-corrosion agent, hard waxy
film with low flow characteris- film film
tics)
2009-12-08

Type of coating spray, dip, coat or spray spray, dip, coat or spray spray, dip, coat or spray
without air without air without air
Drying time Non-drying See data sheet See data sheet
General

Durability of corrosion 6-12 months 6 months to 3 years 3 years, 12 months if stored

protection with roofed outdoors
storage

6682 000.14-02 EN 5 (7)

000.14 MAN Diesel & Turbo

Anti-corrosion agent d Anti-corrosion agent e Anti-corrosion agent f

Operating media/Auxiliary agents

Anti-corrosion agent with thixo-

Corrosion Protection tropic properties (oily protective Anti-corrosion agent, soft waxy Anti-corrosion agent, hard waxy
film with low flow characteris- film film
tics)
Compatibility with Fuel and lubricating oil Fuel and lubricating oil Insoluble in fuel and lubricat-
fuel/oil ing oil
Removability of coat- Same as anti-corrosion Diesel fuel and petroleum Same as anti-corrosion
ing agent (a) agent (e)
Area of application Turbocharger assembly, Internal machined surfaces in External machined surfaces,
and comments interior surfaces and bores, fuel and lubricating oil sys- tie rods and tools. The coat-
vertical machined surfaces, tem. Contains solvents! A ing must be removed before
polished screws, etc. component must therefore initial operation.
not be packaged, insulated
or have a second coating
applied until the solvent has
been fully degassed.
Preferred anti-corro- Bantleon-Cortec VCI 369 Esso-Rust-Ban 395 Esso-Rust-Ban 397
sion agent Fuchs-Anticorit 6120-42E Shell-Ensis Fluid H Fuchs-Anticorit BW 366
(65 cSt/20°C) Valvoline Tectyl 502 C Valvoline Tectyl 846
(solvent free) Valvoline Tectyl 542
Fuchs-Anticorit 15N
(50 cSt/20°C)
Esso-Rust-Ban 391
(6.5 cSt/20°C)
Table 2: Recommended anti-corrosion agents (Part 2)
Anti-corrosion agent g Anti-corrosion agent h Anti-corrosion agent i
Corrosion Protection Anti-corrosion agent with water-
repelling and anti hand sweat Anti-corrosion grease Paint colour
properties
Type of coating spray, dip, coat or spray Dip (in heated state), coat Coat, spray without air
without air
Drying time Non-drying Non-drying See data sheet
Durability of corrosion 9-18 months 12 months to 5 years ---
protection with roofed when stored in enclosed 3 months to 2 years when
storage rooms stored outdoors
Compatibility with Fuel and lubricating oil Fuel and lubricating oil Insoluble in fuel and lubricat-
fuel/oil ing oil
Work Cards, Classified by Subjects

Removability of coat- Same as anti-corrosion Same as anti-corrosion Stripping agent

ing agent (e) agent (e), cloth
Area of application Precisely machined surfaces, Moving connections to pre- Unmachined surfaces. Not
and comments tools, measuring devices. vent seizing, e.g. connec- for machined surfaces and
Contains solvents! Note tions, rolling bearings internal spaces that must be
degassing requirement (see checked for leak-tightness!
anti-corrosion agent (e))
Preferred anti-corro- Fuchs-Anticorit 6120-42DFV Dinitrol-Pasta 1053 Engine:
sion agent (6.2 cSt/20°C) Shell corrosion protection Wetterwart
Shell-Ensis Fluid E grease SL-2304 RAL6019
Valvoline Tectyl 511M Valvoline Tectyl 858C Wetterwart
2009-12-08

Valvoline Tectyl 472 SL-2233 RAL6019

Turbocharger:
Wetterwart
General

Silicoterm 655E
Table 3: Recommended anti-corrosion agents (Part 3)

6 (7) 6682 000.14-02 EN

 MAN Diesel & Turbo 000.14

Anti-corrosion agent l Anti-corrosion agent m

Operating media/Auxiliary agents

Corrosion Protection Vapour phase corrosion-inhibit- Corrosion-inhibiting oil with VCI
ing oil active substances
Type of coating spray spray
Drying time --- ---
Durability of corrosion --- 18 months
protection with roofed
storage
Compatibility with Fuel and lubricating oil ---
fuel/oil
Removability of coat- --- Cloth
ing
Area of application Large internal airtight Large individual components
and comments spaces. The vapour phase of (frames, springs, ...)
the inhibitors occurs at low In engines instead of (f) with
temperatures and a protec- low demand
tive film is formed.
Quantity approx. 300 cm3/m3
Internal space
Distance between anti-corro-
sion agent and surface being
protected: max. 30 cm
Preferred anti-corro- Branorol 32/10 Bantleon-Cortec VCI 369
sion agent Branorost VCI paper
R for ferrous metals only
N for ferrous metals only,
neutral in relation to non-fer-
rous metals
U for ferrous and non-ferrous
metals
C for non-ferrous metals only
Fuchs-Anticorit VCI 0-40
Shell Vapour Phase Inhibitor
Valvoline Tectyl 859A (oily)
Table 4: Recommended anti-corrosion agents (Part 4)

Work Cards, Classified by Subjects

2009-12-08

General

6682 000.14-02 EN 7 (7)

 MAN Diesel & Turbo 000.19

Loctite Products

Operating media/Auxiliary agents

use

Summary
Use of auxiliary equipment, proper processing and mounting. Loctite is a
liquid plastic which hardens into a tough layer between close-fitting metal
parts. Loctite products can be used for fixing, sealing and adhesive purpo-
ses. Selection according to Tables 1 to 3.
The work/work steps include: Proper assembly, disassembly and reassem-
bly.
Preliminary remarks
The filling material LOCTITE is a liquid plastic which hardens automatically
between close-fitting metal parts to form a tough layer, anchors itself in the
machining grooves and considerably increases the surface contact of two
parts. Versions of varying strength are to be used for gaps of different sizes.
According to specification, LOCTITE products can be used for fastening,
sealing and glueing.

Within the crankcase, LOCTITE may not be used as a substitute for screw
locking devices, feather keys etc. provided by the design process.

With bolted connections, which are tightened under torque control, LOC-
TITE 222 and 243 are to be used if necessary, since the lubrication facility
of both these products corresponds to that of oil.
The curing time of LOCTITE can be shortened by using the activator T, or
by heating the joint. For recommended products see Tables 1, 2 and 3.

Loctite may not be stored for longer than approx. 1 year at ambient
temperature. Longer storage periods change the properties to the point
of becoming unusable. The expiry date must, therefore, be observed!

Work Cards, Classified by Subjects

Work Sequence 1 - Assembly
Work steps 1. Carefully wash down the joint points on the parts using quick-acting
cleanser LOCTITE 706 (vaporisation time approx. 3 min) or other suita-
ble cleaning agents, to remove dirt and grease.
2. If necessary, apply activator T from a spray bottle and allow to dry for
approx. 3 min. The filling material hardens more quickly when using the
activator (see table).
2007-09-06

3. Apply a thin layer of the corresponding LOCTITE product (see table) to

one of the two adherent surfaces.
General

6682 000.19-01 EN 1 (4)

000.19 MAN Diesel & Turbo

With interference fit assemblies and larger parts, both surfaces must be
Operating media/Auxiliary agents

coated thinly and evenly. With larger surfaces, the applied LOCTITE can
be spread using a clean paintbrush or a spatula. With blind holes the bore
is moistened to prevent the compressed air pressing away the liquid
LOCTITE product during assembly.
The bottle contents must not come into contact with metal parts until
being used!

4. Join both the parts in the correct location.

5. Wipe away and remove the filling material outside the connection while
ensuring that the position of the parts is not changed.
6. Wait for curing time (see instructions) and finish the assembly of the
parts.
7. If necessary, heat the connection point to approx. 120 ºC to obtain the
ultimate strength more quickly.

Work Sequence 2 - Dismantling

1. Try and see whether the connection can be released using normal tools
and manual force.
2. If this is not possible, heat the connection to approx. 200 °C and then
release the parts (Caution. Danger of fire!).

Work Sequence 3 - Reassembly

▪ Thoroughly remove the old LOCTITE layer on both parts mechanically,
while ensuring that the bonding surfaces are not damaged. The layer
cannot be removed using chemical agents.
▪ Carefully degrease the parts and fit as per work sequence 1.

It is possible to perform a cleanliness check using the radiation from a

UV lamp. Even the smallest traces of LOCTITE will fluoresce.

Loctite Product 222 243 245 270 272 275 648

Work Cards, Classified by Subjects

Ref. No. 04.10170 -9222 -9243 -9245 -9270 -9272 -9275 -9648
Product colour purple blue blue green red- green green
orange
Application temperature range 150 150 150 150 200 150 175
°C
Viscosity (mPa. x s) 90 - 180 200 - 400 550-1000 400 - 600 4000- 550-1100 300 - 600
15000
Gap: favourable
max.
2007-09-06

for threads up to max. M36 M36 M36-M80 M20 M48 M20-M80 M20
Strength cate-
General

gories: *)
Compression 1)
N/mm2 3-9 6 - 14 6 - 14 11 - 20 14 - 20 10 - 20 16 - 30
shear strength

2 (4) 6682 000.19-01 EN

 MAN Diesel & Turbo 000.19

Loctite Product 222 243 245 270 272 275 648

Operating media/Auxiliary agents

Breakaway tor- 2)
Nm 8 - 20 14 - 34 13 - 33 25 - 54 18 - 28 25 - 55 30 - 55
que
max. continuing torque Nm -- -- -- 45 - 70 20 - 31 35 - 65 40 - 60
Hardening open waiting
time
for steel max. hrs. 24 24 24 24 24 24 24
for non-ferrous max. min. 5 1 5 5 5 1
metal
Handling Min. 15 - 30 15 - 30 30 - 60 15 - 30 10 - 20 3-5
strength
Ultimate max. hrs. 12 12 12 12 12 12
strength
Special properties KTW BAM high strength
approval approval difficult to remove
low medium strength
strength
Table 1: Loctite Products for Securing Threads
*....... 1) DIN 54452, 2)
DIN 54454

Thread seal Surface sealing

Loctite Product 620 577 586 518
Ref. No. 04.10170. -9620 -9577 -9586 -9518
Product colour max. min. green yellow red red
Application temperature range °C 230 150 150 150
Viscosity (mPa. x s) 800 - 1600 4000 - 8000 4000 - 6000 25000 - 50000
Gap: favourable -- -- --
max. -- -- -- 0,5
for threads up to max. M60 M80 M60 M20
Strength categories: *)
Compression shear 1)
N/mm2 20 - 35 5 - 13 10 - 25 4 - 14
strength
Breakaway torque 2)
Nm 20 - 45 9 - 25 25 - 55 5 - 13 Work Cards, Classified by Subjects
max. continuing torque Nm -- -- 30 - 55 --
Hardening open waiting time
for steel max. hrs. 24 24 24 24
for non-ferrous max. min. 5 1 60 1
metal
Handling Min. 60 - 120 15 - 30 120 30
strength
Ultimate max. hrs. 24 12 24 12
2007-09-06

strength
Special properties DVGW BAM
approval approval
General

Table 2: Loctite Products for Sealing Threads and Surfaces

*....... 1) DIN 54452, 2)
DIN 54454

6682 000.19-01 EN 3 (4)

000.19 MAN Diesel & Turbo
Operating media/Auxiliary agents

Shaft/Hub Even surface

Loctite Product 603 620 307 3)
406 496
Ref. No. 04.10170. - 9603 - 9620 -9307 -9406 -9496
Product colour max. min. green green yellowish transparent transparent
Application temperature range °C 150 230 120 80 80
Viscosity (mPa. x s) 100 - 150 800 - 1600 800 - 3200 10 - 30 100 - 120
Gap: favourable 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 categories:
*)
Compression shear 1)
N/mm2 16 - 25 20 - 35 15 - 30 1) 12 - 25 1) 12 - 25 1)
strength
Breakaway torque 2)
Nm 40 - 60 20 - 45 12 - 32 2) 18 - 26 2) 20 - 30 2)
max. continuing torque Nm 40 - 60 -- -- -- --
Hardening open waiting time
for steel max. hrs. 24 24 24 Sec.- Sec.
for non-ferrous max. min. 5 5 max. 5 Bond. Bond.
metal
Handling Min. 20 60 - 120 10 - 20
strength
Ultimate max. hrs. 12 24 24 12 12
strength
Special properties for materials
difficult to
bond
e.g. Vitron
Table 3: Loctite Products for Bonding
1)
Tensile strength N/mm2, 2) Tensile shear strength N/mm2, 3) with activator 7471
Work Cards, Classified by Subjects

2007-09-06
General

4 (4) 6682 000.19-01 EN

MAN Diesel & Turbo 003

Machine Elements
001 Operating media systems/Pipes
002 Operating media/Auxiliary agents
003 Machine Elements
004 Hydraulic tensioners/High-pressure pump
005 Operating values/Operating results

6704 2.3-1 EN 1 (1)

 MAN Diesel & Turbo 000.11

Galvanised Bearings

Machine Elements
assessing

Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/wear condition. Bearing shells must be
checked on a regular basis. Usually, only the loaded bearing shell is
checked. From the wear condition and appearance of the bearing shell run-
ning surface, conclusions can be drawn regarding the load conditions, the
lubricating oil maintenance etc.
The work/work steps include: Measuring of components and assessing
surface/wear condition.
Corresponding Work Cards
Work card Work card Work card
000.10

General

1 Anti-corrosion layer
2 Running layer
3 Nickel dam
4 Bearing metal
5 Steel support shell

Figure 1: Galvanised Bearings - Structure

Galvanised bearings (compound bearings) are used for the crankshaft bear-
ings and big-end bearings of four-stroke engines, which are made from a
steel support shell, a bearing metal layer of leaded bronze or aluminium tin
bronze and a galvanised running layer.
Work Cards, Classified by Subjects
The soft running layer has better running in and emergency running prop-
erties than the leaded bronze or aluminium tin bronze layer. This running
layer must, therefore, remain serviceable for as long as possible and no
additional work is permitted. Since every bearing must adapt itself after
refitting, bearings which are running correctly should be opened up as little
as possible.
Galvanised bearings have a long service life if the lubricating oil is carefully
filtered and separated. This means that cleaning the filters and separators,
and checking the oil, are very important.
2008-10-28

Damaged bearing shells (upper or lower shell) can be replaced individually

or in pairs.
General

After refitting worn bearing shells, or after replacement, the bearing caps
must be felt by hand, after approx. 30 min. idling and after approx. 5 hours

6682 000.11-01 EN 1 (8)

000.11 MAN Diesel & Turbo

with increasing engine load, to detect any unacceptable increase in tem-

Machine Elements

perature (compare to the adjacent bearings).

Undersized bearings (with smaller diameter) ready for installation can be
supplied for reworked crank pins.
Wear Limits
Bearing shells, the running surface of which show wear of more than 30%
must be replaced. Bearing shells, the running surface of which show wear
of approx. 20% are also to be replaced, if, at the same time, extensive
overhaul work is being performed on the engine.

Figure 2: Degree of Wear of the Running Surface

Bearing shells which have already been in service for 30 000 operational
hours should, in general, be replaced when the engine is being overhauled.
If the bearing shells already show signs of wear on the bearing metal running
layer after approx. 5000 operational hours or the running surface is worn by
about 20%, this indicates dirt accumulation and insufficient cleaning of the
lubricating oil.
Bearing Illustrations
In the following pictures the dismantled bearing shells can be assessed, and
they also give an indication of reuse possibility or whether replacement with
new bearings is required.
Normal Contact Pattern with Existing Running Layer
Work Cards, Classified by Subjects

Figure 3: Normal Contact Pattern

The mainly grey running surface in the main load area is smooth and reflects
slightly. The bearing can be used again.
Normal Contact Pattern with Partially Worn Running Layer
2008-10-28
General

2 (8) 6682 000.11-01 EN

 MAN Diesel & Turbo 000.11

Machine Elements
Figure 4: Partially Worn Running Layer
After the running layer is worn out a reddish brown contact pattern is seen
in lead bronze bearings. With aluminium tin bronze bearings a variation is
seen between the lighter and darker zone. The lighter zone indicates a fresh
contact pattern, the darker zone is created by surface oxidation which does
not adversely affect performance. The bearing can be reused and must only
be replaced once the aforementioned features listed under 'wear limits’ are
evident.
Mirror effect on both edges of the bearing

Figure 5: Mirror effect

The bearing becomes slightly rounded by the running-in process. Slight
mirroring on the edges of the bearings will normally disappear after a longer
running time. The bearing can be reused, provided figure 6 (edge loading)
is not applicable.
Edge Loading (on one side or both sides)

Figure 6: Edge loading Work Cards, Classified by Subjects

A bearing which only carries load on the edges is not permitted. Possible
causes could be deviations in the pin geometry or incorrect location of the
bearing bore, which must be corrected. The bearing must be replaced if the
edge loading is significant.
Load on the One Side
2008-10-28

General

Figure 7: Load on the One Side

A one sided contact pattern may be seen in the case of external bearings
and is also acceptable provided the crank web deflection is in order (cause:

6682 000.11-01 EN 3 (8)

000.11 MAN Diesel & Turbo

Weight of the flywheel or of the vibration damper). One sided load is not
Machine Elements

permitted for intermediate bearings. In this case the causes, e.g. pin gyra-
tion, deformation of the bearing support, uneven tie rod preload, dirt on back
of the bearing, must be remedied. If there is pronounced one-sided load
then the bearing must be changed.
Load Marks on the Bearing Shell Joint (on one side or both sides)

Figure 8: Load Marks on the Bearing Shell Joint

When pronounced load marks occur near the bearing joint face, there is a
danger that the crank journal on the parting lines could break away from the
lubricating film. For this reason, a bearing should be exposed by approx.
10°, calculated from the joint face. Should load marks still appear close to
the joint face, then the cause must be remedied. In the event of load marks
on only one side, the back of the bearing should be checked for dirt or oil
carbon. In addition, the bearing support could be misaligned. If there are
load marks on both sides see figures 20 (cold shuts on the back of the
bearing) and 21 (bearing spread). Bearings with heavy loading close to the
joint face should be replaced.
Scoring and Embedding of Foreign Bodies in the Running Layer

Figure 9: Scores and Foreign Bodies in the Running Layer

Hard dirt particles, carried by the circulating oil, make scores through the
running layer and often get embedded. Depending on the hardness of the
foreign bodies the bearing journal may become scored. Light scores, which
do not break through the running layer are not dangerous. The bearings can
Work Cards, Classified by Subjects

continue to be used. Scores which are wider than 1 mm interfere with the
structure of the wedge-shaped lube oil film. Bearings with several wide
scores in the lower shells of the crankshaft bearing or the upper shell of the
big-end bearing, which reach the lead bronze or aluminium tin bronze layer,
must be changed, especially if the scores are very close to the bearing edge.
If wide scores are seen in the bearing shells, the surface of the bearing jour-
nal must be checked. Depending on the situation, the pin should be
smoothed or reworked using emery cloth or an oil stone, or mechanically
with a portable regrinding device (Specialist firms). The cause of scoring
must be remedied. The complete lube oil circuit, including separator, lube
2008-10-28

oil filter and lube oil pipes between the filter and engine must be checked
(scale, weld beads etc.). If other bearings are supplied with oil from this
bearing, they should definitely be checked.
General

Cracks in the Running layer

4 (8) 6682 000.11-01 EN

 MAN Diesel & Turbo 000.11

Machine Elements
Figure 10: Cracks
The odd crack in the running layer is not dangerous to the bearing. The
bearing should only be replaced if there is a notable build-up of cracks in
the loaded zone.
"Bark Beetle"

Figure 11: Bark Beetle

When the accumulation of a lot of small cracks becomes recognisable in
the loaded zone of the running layer (often paving stone type) as result of
material fatigue, disintegration or erosion of the crack areas (similar to the
bark beetle on trees) the bearing should be changed.
Peeling of the Running Layer

Figure 12: Peeling of the Running Layer

If the running layer has begun to peel at points on the surface, then the
bearing must be replaced. Only in the case of small individual areas of dam-
age (smaller than 2 cm2) can the bearing continue to be used, provided the
binding of the remaining running layer immediately adjacent to the area of Work Cards, Classified by Subjects
damage is good condition (check carefully with a sharp tool, e.g. a pocket
knife).
Running Layer Heavily Smudged
2008-10-28

Figure 13: Smudging of the Running Layer

If the soft running layer is smudged over a large area (creep deformation)
General

and if it has possibly already been penetrated in the middle, this implies
insufficient oil, which could possibly be caused by insufficient prelubrication

6682 000.11-01 EN 5 (8)

000.11 MAN Diesel & Turbo

before the start. The cause of insufficient oil must be remedied and the
Machine Elements

bearing must be replaced.

Rough Running of the Bearing Metal Layer

Figure 14: Rough Running

Bearings with very rough bearing metal should be replaced, particularly
because of increased pin wear. Moreover, the bearing journal must be
smoothed.
Spallings on the bearing metal layer

Figure 15: Spallings

Bearings with spallings on the bearing metal layer must be replaced. The
bearing journal must be checked, smoothed or reworked.
Overheating of the Bearing Metal Layer

Figure 16: Overheating of the Running Layer

If the bearing metal shows overheating characteristics (blue-violet) or even
net-shaped heat cracks, the bearing must be replaced. The bearing journal
Work Cards, Classified by Subjects

must undergo a magnetic crack inspection. If any cracks are apparent, the
bearing journal must be reground until it is "crack free", taking the surface
quality, ovality and taper into account. If no cracks or hardening have been
detected, smoothing of the pin is sufficient.
Electroerosion
2008-10-28

Figure 17: Electroerosion

General

If generator installations are not sufficiently earthed, this can lead to stray
electrical currents and possibly to electro-erosion in the bearing. The run-
ning layer will be roughened as if cracked. The cracks sometimes appear at

6 (8) 6682 000.11-01 EN

 MAN Diesel & Turbo 000.11

an angle to the running direction. In more severe cases of erosion, the jour-

Machine Elements
nal surface is also visibly rough. The cause of the damage must be deter-
mined and remedied. The bearing must be replaced and, where necessary,
the journal smoothed or reworked.
Corrosion

Figure 18: Corrosion

Signs of running surface corrosion are surface discolouration as a result of
chemical changes in the bearing material and corrosive, usually localised,
material removal. The lubricating oil should be examined for contamination
by water, acids etc. If the corrosion is advanced, the bearing must be
replaced. The bearing journal, which is also often attacked, must be
smoothed or reworked.
Cold shuts on the bearing shell joint

Figure 19: Cold shuts on the bearing shell joint

Cold shuts or pitting rings on the joint faces of the bearing shell indicate
relative movement, due to the loss of preload or inadequate bearing pro-
trusion. The causes of the damage must be remedied. In less serious cases,
when refitting the bearing shells, ensure that only the cold welded material
which has deposited is carefully removed. Moreover, the back of the bearing
is to be checked for cold shuts (see figure 20). In serious cases (large
amounts of material application and removal) the bearing shells must be
replaced.
Cold shuts on the back of the bearing Work Cards, Classified by Subjects

Figure 20: Cold shuts on the back of the bearing

Large numbers of cold shuts on the back of the bearing, which are spread
2008-10-28

over more than 5% of the total area, are not acceptable. The bearing must
be replaced. Screw pretension, bearing protrusion, bearing spread (see fig-
ure 21) and condition of the bearing locating bore must be checked. The
General

bearing protrusion can only be ascertained approximately on-site by loos-

ening the bearing bolts on one side. The cold shuts in the bearing locating
bore must be checked for cracks. If cracks are detected, the engine man-

6682 000.11-01 EN 7 (8)

000.11 MAN Diesel & Turbo

ufacturer must be contacted. If no cracks have been detected, before the

Machine Elements

bearing is reassembled surplus material in the bearing locating bore must

be carefully removed and, if the bearing is to be reused, any on the back of
the bearing must also be removed carefully.
Bearing Spread

D Bearing diameter
S Spread

Figure 21: Bearing Spread

Bearing shells must have a positive spread so that once built in they are
perfectly positioned in the locating hole. The spread depends on the diam-
eter of the bearing and, when new, can be several millimetres. Even when
bearings are worn there should still be enough remaining spread so that
when installing the bearing in the bearing locating hole it is necessary to
exert considerable pressure on both joint surfaces. Bearing shells which can
be very easily placed in the bore (spread zero or negative) may not continue
to be used. A "spreading out" of the shell is not permitted.
Work Cards, Classified by Subjects

2008-10-28
General

8 (8) 6682 000.11-01 EN

 MAN Diesel & Turbo 000.11

Deep Groove Bearing

Machine Elements
assessing

Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/wear condition. Bearing shells must be
checked on a regular basis. Usually, only the loaded bearing shell is
checked. From the wear condition and appearance of the bearing shell run-
ning surface, conclusions can be drawn regarding the load conditions, the
lube oil maintenance etc.
The work/work steps include: Measuring of components and assessing
surface/wear condition.
Corresponding Work Cards
Work card Work card Work card
000.10

General
The deep groove bearings used in the crankshaft and big-end bearings
based on aluminium or lead bronze have the structure as shown in figure 1.
The soft running layer has better running in and emergency running prop-
erties than the bearing metal shell. This is why the running layer must remain
functional for as long as possible and any rework to the running layer should
be avoided. Since every bearing must adapt itself after refitting, bearings
which are running correctly should be opened up as little as possible.
Deep groove bearings, with careful filtering and separating the lube oil, have
a very long useful life. This means that cleaning the filters and separators,
and checking the oil, are very important.
If the bearing metal layer of the bearing shells is clearly visible after approx.
5,000 operational hours or 20% of the running surface is worn, this indicates
serious stress due to dirt particles and inadequate cleaning of the lube oil.
Bearing shells with advanced wear can be replaced individually (upper or
lower shell) or together.
Work Cards, Classified by Subjects
After refitting worn bearing shells, or after replacement, the bearing caps
must be felt by hand, after approx. 30 min. idling and after approx. 5 hours
with increasing engine load, to detect any unacceptable increase in tem-
perature (compare to the adjacent bearings).
Undersized bearings are available for reworked crankshafts. These are sub-
ject to the same evaluation criteria as normal bearings.
2008-10-28

General

6682 000.11-02 EN 1 (6)

000.11 MAN Diesel & Turbo
Machine Elements

1 Running layer (approx. 75%)

Bearing metal cross piece
2
(approx. 25%)
3 Nickel dam (max. 5%)
4 Steel support shell

Figure 1: Structure of a Deep Groove Bearing

Wear Criteria
In new condition the running surface accounts for approx. 75% galvanised
running layer and approx. 25% bearing metal cross pieces. The decisive
factor for wear in the deep groove bearing is the ratio width of the bearing
metal cross piece to the width of the groove and the extension of the worn
area. To assess the degree of wear of the running surface, a magnifying glass with
a magnifying power of 5 is required. For every assessment of the groove con-
dition, it is important to compare the running surface in the area with the
least load since the groove condition here is almost new.
An assessment of the bearing shells can be carried out with the aid of the
image sequence. It indicates whether a bearing can be reused or whether
it must be replaced.
1. No or little Wear. Continued Use
Work Cards, Classified by Subjects

Figure 2: Wear not critical

1. The groove geometry corresponds to the new condition. The running
layer is fully preserved within the grooves. Dark spots on the running
2008-10-28

layer are mainly embedded particles of oily carbon deposits. (See figure
left)
Assessing: The ratio bearing metal cross piece to running layer is approx.
General

25% to 75%. Continued use!

2 (6) 6682 000.11-02 EN

 MAN Diesel & Turbo 000.11

1. The running layer is evenly worn approx. 0.005 mm out of the grooves.

Machine Elements
The bearing metal cross piece shows no sign of wear. Dark spots on the
running layer are mainly embedded particles of oily carbon deposits.
(see figure right)
Assessing: Because of the wear of the running layer the bearing metal cross
pieces seem slightly wider. Continued use!

Figure 3: Wear not critical

1. Embedding of small impurities over the entire running surface. No major
modification of the bearing metal cross piece (see figure left)
Assessing: Continued use!
1. The running layer was dragged and spread over the bearing metal cross
pieces. The bearing metal cross pieces are partially concealed (see fig-
ure right)
Assessing: Continued use!
2. Wear of bearing metal cross pieces. Replace depending on extent of wear

Work Cards, Classified by Subjects

Figure 4: Wear of Bearing Metal Cross Pieces

1. The bearing is worn to such an extent at some spots, that the ratio run-
ning layer groove to bearing metal cross pieces is approx. 50% to 50%.
The width of the bearing metal cross pieces has increased from 25%
(new condition) to 50 %. There is still running layer inside the grooves
2008-10-28

(see figure left)

Assessing: The bearing is functional as long as the extension of the worn
parts does not reach the limits indicated in figure 6.
General

If wear is expected within the next maintenance interval as described in

point 2, the bearing must be replaced for safety reasons.

6682 000.11-02 EN 3 (6)

000.11 MAN Diesel & Turbo

1. The bearing metal cross pieces are worn locally. No grooves or running
Machine Elements

layer present (see figure right)

Assessing: If the wear reaches the limits indicated in figure 6, the bearing
must be replaced.
3. Wear on running layer. Replace depending on extent of wear

Figure 5: Wear on running layer

1. Running layer outbreaks in the grooves through local overload (see fig-
ure left)
Assessing: The bearing is functional as long as the extension of the worn
parts does not reach the limits indicated in figure 7.
If wear is expected within the next maintenance interval as described in
point 2, the bearing must be replaced for safety reasons.
1. Empty grooves. In some areas, empty grooves become visible after
washing the broken running layer. Locally, the bearing metal cross
pieces may already be worn. (see figure right)
Assessing: If the wear reaches the limits indicated in figure 7, the bearing
must be replaced.
Work Cards, Classified by Subjects

2008-10-28
General

4 (6) 6682 000.11-02 EN

 MAN Diesel & Turbo 000.11

Machine Elements
A max. 30% of shell circum- B max. 50% of shell circumfer-
ference ence
C max. 5% of shell circumfer- D max. 35% of shell circumfer-
ence ence
E max. 70% of shell width F max. 35% of shell width
G max. 20% of shell width H max. 10% of shell width
Wear ratio 50% to 50% Bearing metal cross pieces
worn
Figure 6: Extent of Wear

Work Cards, Classified by Subjects

2008-10-28

General

6682 000.11-02 EN 5 (6)

000.11 MAN Diesel & Turbo
Machine Elements

I max. 25% of shell circum- B max. 50% of shell circumfer-

ference ence
E max. 70% of shell width F max. 35% of shell width
K max. 10% of shell circum- L max. 40% of shell circumfer-
ference ence
M max. 40% of shell width N max. 30% of shell width
O max. 15% of shell width Bearing metal cross pieces
worn
Running layer outbreaks Empty grooves

Figure 7: Extent of Wear

Work Cards, Classified by Subjects

2008-10-28
General

6 (6) 6682 000.11-02 EN

 MAN Diesel & Turbo 000.11

Bimetal Bearings (without a third layer)

Machine Elements
assessing

Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/wear condition. The bearing shells
(bimetal bearings) are used in crankshaft and big-end bearings as well as in
the camshaft bearings. They have to be checked or replaced according to
the maintenance schedule on a regular basis.
The work/work steps include: Measuring of components and assessing
surface/wear condition.
Corresponding Work Cards
Work card Work card Work card
000.10

General

1 Bearing metal
2 Al - Binding layer
3 Steel support shell

Figure 1: Bearing Structure

Roll-bonded bimetal bearings with the material combination steel/alumi-
nium alloy (AlSn20) are used both as main and big-end bearings and cam-
shaft bearings. Visible assessment of the extent of wear of a bimetal com-
posite bearing shell is not possible in normal wearing conditions (see figure
below). In contrast to trimetal composite bearings with galvanised running
Work Cards, Classified by Subjects
layer, bimetal bearings contain no optical indicators which facilitate assess-
ing the degree of wear by the discolouration of the sliding surface. Assess-
ment of the extent of wear is only possible by measuring the thickness of
the bearing shell wall and comparing the current measured value with that
of the initial condition. Measuring bearing clearance does not produce any
reliable indication of bearing wear, since the acceptable wear values are
measured in hundredth of a millimetre.
Assessment of Running Behaviour and Replacement Criteria
2008-10-28

General

6682 000.11-03 EN 1 (3)

000.11 MAN Diesel & Turbo
Machine Elements

Figure 2: Measuring of Wall Thickness

The bearing shell must be replaced when the wear limits contained in the
sheet “Technical Data: Dimensions, clearances, tolerances" are reached.

The wall thickness (A) must always be measured in the area with the main
load or perpendicularly to the joint face.

1. Contact pattern even over the entire bearing width

Figure 3: Contact Pattern Normal

1. Isolated, superficial dirt marks caused by foreign bodies do not influence
continued operational safety (see figure 3 - left).
Assessing: If the wall thickness is within the permitted wear value, the bear-
Work Cards, Classified by Subjects

ing can continue to be used.

1. Running surface slightly scored. If the scores are only visible, but neither
measurable nor perceptible, the bearing can continue to be used. If the
wall thickness has reached the lowest tolerance value, the bearing shell
must be replaced (see figure 3 - right).
Assessing: If the scores are clearly perceptible or measurable, the bearing
shell must be replaced.
2. Contact pattern with seizure traces
2008-10-28
General

2 (3) 6682 000.11-03 EN

 MAN Diesel & Turbo 000.11

Machine Elements
Figure 4: Contact pattern with seizure traces
1. The contact pattern shows a clear edge loading with seizure traces in
the sliding layer. Before mounting a new bearing shell, the reason for
the edge loading must be discovered and remedied where possible (see
figure 4 - left).
Assessing: The bearing cannot continue to be used.
1. The contact pattern shows large area damage with differing degrees of
seizure marks. Before mounting a new bearing shell the reason for this
damage must be remedied (see figure 4 - right).
Assessing: The bearing cannot continue to be used.
3. Bearing metal spallings

Figure 5: Contact pattern with spallings Work Cards, Classified by Subjects

The loaded area of the bearing shell shows signs of bearing metal spallings
caused by fatigue of the sliding layer (see figure 5).
Assessing: The bearing cannot continue to be used.
2008-10-28

General

6682 000.11-03 EN 3 (3)

MAN Diesel & Turbo 000.21

Elastomer Seals

Machine Elements
storage, cleaning and fitting

Summary
Insert/replace components, process and install professionally. Elastomer
seals (rubber products) are to be stored properly and replaced during over-
haul work.
The work/work steps include: Storage of components/auxiliary equipment,
cleaning of components and proper mounting.
Preliminary remarks
When servicing or carrying out overhaul work, the natural or artificial rubber
seals must be replaced. Undamaged seals, in perfect condition, may only
be reused in an emergency. It is recommended to immediately re-order
seals used, to ensure that they are to hand when needed.
The following sections are extracts from DIN 7716 and ISO 2230-1973.
Storage of Elastomer Seals
The life of rubber products is influenced by oxygen, ozone, heat, light,
humidity, solvents and mechanical load. The functionality of rubber seals
when fitted is therefore dependent on correct storage, amongst other fac-
tors. The following indications should be noted in particular:
1. The store-room should be cool, dry, free from dust and adequately ven-
tilated.
2. The storage temperature should not be less than -10 °C, or more than
+25 °C. Neoprene items (Chloroprene rubber) should not be stored at
temperatures less than +12 °C.
3. Rubber items in heated storage rooms should be protected from sour-
ces of heat. The distance between the source of heat and the stored
items must be at least 1 m. If the rooms are heated by hot air a greater
distance is required (danger of drying out).
4. Rubber items should not be stored in humid rooms. Relative humidity
should be less than 65%.
Work Cards, Classified by Subjects
5. Rubber items should be protected from direct sunlight and strong arti-
ficial light which has a high UV content. The effects of ozone are par-
ticularly damaging. You must therefore ensure that the storage location
is not close to fluorescent tubes or other light sources having high ultra-
violet radiation. Because of the effects of ozone, rubber items should
not be stored close to electrical installations, engines and generators.
6. Rubber items should not be stored in the same storage room as sol-
vents, fuels, anti-seize agents, slushing oils, chemicals, acids, disinfec-
tants and similar substances.
7. Rubber items must be tension-free, i.e. stored without tension, com-
pression or deformation of any kind (e.g. O-ring seals should not be
General

stored hanging on hooks, since they would be in danger of being per-

manently deformed, or of developing cracks).

6682 000.21-01 EN 1 (3)

000.21 MAN Diesel & Turbo

8. Rubber items of various compositions e.g. Perbunan and silicone rubber

Machine Elements

should not come into contact with each other. This is particularly impor-
tant for parts which have different colours. Also avoid contact with cop-
per and materials containing manganese.
9. Rubber items should be packed (shrink wrapped) in polyethylene plastic
bags or similar (foils should not contain any plasticisers). To avoid con-
fusion, the bag should be labelled with details of the elastomer type (e.g.
Perbunan, silicone) and the date of manufacture. Moreover, the bags
should be stored in cardboard containers to protect them from light.
Observe points 6-7.
10. Newly delivered rubber items should be stored separately from those
already in storage so that the oldest are used first.

In the event of fire / heating above 315 °C of FKM fluoro rubber (Trade
names Viton, Fluorel, Techoflon, Dai-el) poisonous fumes are produced.
Hydrogen fluoride vapour, in the presence of water, produces fluorhydric
acid (hydrofluoric acid) which causes serious chemical burns which are
difficult to heal.
When extinguishing fires, the appropriate breathing apparatus, face
masks and protective clothing must be used.
Observe appropriate disposal methods.

Cleaning
Rubber items are cleaned in warm soapy water and dried at room temper-
ature. If necessary, seals which have been stored for a long period can be
cleaned in a 1.5% sodium bicarbonate solution. Any cleaning solution res-
idue should rinsed off with normal tap water (not sea water!).
Solvents such as trichloroethylene, carbon tetrachloride and hydrocarbons
must not be used for cleaning. Sharp utensils, wire brushes, emery paper
etc. are not suitable for cleaning either, since these will damage the seals.
Assembly
Generally accepted principles The installation of rubber items requires particular care. The following points
should be noted in particular during installation.
Work Cards, Classified by Subjects

O-ring seals ▪ During installation, sealing rings should not be expanded by more than
30% of the inner diameter for a short period of time.
▪ Sealing rings should not be twisted during installation (take care with
rings of large diameter and small cross section). Some sealing rings have
a circumferential line which must be visible continuously around the
entire circumference.
▪ Sealing rings must not be slipped over sharp edges, threads, slots etc.
If necessary sharp edges should be covered.
▪ When slipping over the sealing rings, they should not come into contact
with slushing oil. Cylinder liners in the installation area of the sealing
rings must be free of slushing oil. The solvent used for cleaning must be
General

completely dried off.

▪ The installation location of the sealing rings must be smeared with a
suitable anti-seize agent (see below).

2 (3) 6682 000.21-01 EN

MAN Diesel & Turbo 000.21

Radial sealing rings Sealing lips on radial shaft sealing rings must always be directed towards

Machine Elements
the medium to be sealed.
Anti-seize agent Components and sealing rings should be treated with a suitable anti-seize
agent before assembly. Only the lubricating greases listed in the table are
permitted for the different rubber products. Other anti-seize agents and/or
installation aids may only be used after consultation with the manufacturer
of the seals.
For radial shaft sealing rings, only the anti-seize agents listed below or those
stipulated by the manufacturer may be used.
Inappropriate material can lead to the premature failure of the seals.
Lithium soap lubricating greases are, in general, multi-purpose greases, for
lubricating roller and plain bearings (e.g. multi-purpose grease MAN 257-
NLGI 2). Greases containing silicon are particularly suitable as such.

Sealing ring Lubricating grease

Quality lithium soap containing silicone
Perbunan NBR X X
Silicone VMQ X –
Viton FKM X X
Butyl rubber IIR X X
Neoprene CR X X
Table 1: Anti-seize agents for Elastomer Seals

Work Cards, Classified by Subjects

General

6682 000.21-01 EN 3 (3)

 MAN Diesel & Turbo 000.22

Threaded inserts

Machine Elements
use

Summary
Insert/replace components, process and install professionally. Threaded
inserts are used for manufacturing lock-proof threads in components made
of grey cast iron or alloy. Damaged threads can be repaired.
The work/work steps include: Proper assembly and, if necessary, disas-
sembly.
Tools/aids required
Conventional twist drills, diameter corresponding to the required threaded
insert and the according to the manufacture.
Also by the manufacturer of the threaded inserts:
▪ Special thread drill bit,
▪ Screwing-in tool, if necessary, boring tool,
▪ Pin breaker or punch.
▪ Standard tools

Preliminary remarks
Threaded inserts serve, for example, for making wear-resistant threads in
components made from grey cast iron or alloy, etc. On the other hand, a
damaged thread bore can be repaired such that the same screw size can
continue to be used. In order to do so, the old thread must be drilled out, a
new thread must be cut and a suitable threaded insert must be screwed in.
Threaded inserts are available in two designs: Type A - standard version
(non-locking) and type B - self-locking version (one thread hexagonally sha-
ped). See the following figure.
Work Sequence 1 - Installation
Drilling Conventional twist drills are to be used for drilling. Information regarding the
diameter and drilling depth can be taken from the manufacturer's product
Work Cards, Classified by Subjects
range lists. Do not, under any circumstances, countersink the core hole;
slight deburring is, however, allowed.
Thread cutting The thread of the locating hole must only be cut using special thread drills
(see figure 3). The thread depth must correspond to the length of the threa-
ded insert plus 0.3 ... 0.8 x P (P = pitch) (F in figure 2 too short).
2008-10-28

General

6682 000.22-01 EN 1 (3)

000.22 MAN Diesel & Turbo

A ∅ of threaded insert
Machine Elements

B Length threaded insert

C Carrier pin
D Notch
Threaded insert type A
K
(inside continuously round)
Threaded insert type B
J (1 thread pitch hexagonal on
inside)
Figure 1: Threaded insert type A - non-locking (left), type B - self-locking (right)

E Core hole diameter

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

Figure 2: Twist drill/hole

Diameter of the special thread

G
drill, suitable for A

Figure 3: Special thread drill

Work Cards, Classified by Subjects

C Carrier pin
H Screwing-in tool

Figure 4: Screwing-in tool

2008-10-28
General

2 (3) 6682 000.22-01 EN

 MAN Diesel & Turbo 000.22

Machine Elements
L Pin breaker/punch
M Boring tool

Figure 5: left – pin breaker/punch, right – boring tool

Installation The screwing-in tool (H) is used for fitting. The threaded insert is inserted
into the preloading cartridge of the tool with the carrier pin laying in the
installation direction. The spindle carrier pin is gripped by turning the spindle
and the insert is inserted into the preloading cartridge until the first thread
is located in the last thread pitch of the cartridge. Then place the tool onto
the hole in line and continue to turn the spindle. This then fits the threaded
insert into the locating thread (see figure 4).
The threaded insert must lie 0.3 ... 0.8 x P below the surface. It can only sit
in a fully cut thread.
Pin breaking The carrier pin (C) is only used for the installation. Afterwards it must be
removed with a special pin breaker (figure 5) or a punch. The tool is to be
placed in the thread on the carrier pin of the fitted threaded insert. By means
of a short strong blow on the tool mandrel, the carrier pin breaks off at the
notch provided for this purpose (D).
Breaking the pin is not absolutely necessary for blind holes. Provided the
carrier pin is not removed, the maximum screw-in depth of the bolt/screw
must be observed.
Work Sequence 2 - Removal
If, in exceptional cases, the threaded insert has to be removed, this can be
done using an boring tool as illustrated in figure 6. The tool is pressed firmly
into the thread with its wedge-shaped part and turned left until the insert
releases/until it can be screwed out.

Work Cards, Classified by Subjects

2008-10-28

General

6682 000.22-01 EN 3 (3)

 MAN Diesel & Turbo 000.29

Tightening screwed connections

Machine Elements
Tightening torques (partial image)

Summary
Determine tightening torque for important screwed connections, ensure
operational safety.
Screwed connections which have been tightened using the hydraulic ten-
sioners, to torsional torque or in accordance with turning angle must be
tensioned and detensioned using the prescribed values.
Work Cards 000.29 and 000.30 contain the necessary information.
Explanations
The illustrations in Work Card 000.29 serve for identification purposes con-
cerning the position and proximity of the parts to be connected. The illus-
trations have identification numbers, for example 020-1, which are listed in
numerical order in Work Card 000.30. The identification numbers also indi-
cate the tightening torques and the corresponding Work Cards.

Work Cards, Classified by Subjects

2009-04-16

L48/60B

6704 000.29-01 EN 1 (11)

000.29 MAN Diesel & Turbo
Machine Elements
Work Cards, Classified by Subjects

2009-04-16
L48/60B

Figure 1: Cross-section of the engine

2 (11) 6704 000.29-01 EN

 MAN Diesel & Turbo 000.29

Machine Elements
Work Cards, Classified by Subjects

Figure 2: Engine support - semi-flexible /flexible (inclined bearing)/flexible (cone bearing)

2009-04-16

L48/60B

6704 000.29-01 EN 3 (11)

000.29 MAN Diesel & Turbo
Machine Elements
Work Cards, Classified by Subjects

2009-04-16

Figure 3: Cylinder crankcase/crankshaft extension (coupling side)/torsional vibration damper/covering

(coupling side)/additional mass (camshaft)/lubricating oil pump/cooling water pump/flywheel arrangement
L48/60B

4 (11) 6704 000.29-01 EN

 MAN Diesel & Turbo 000.29

Machine Elements
Figure 4: Camshaft drive /camshaft thrust bearings

Work Cards, Classified by Subjects

2009-04-16

L48/60B

6704 000.29-01 EN 5 (11)

000.29 MAN Diesel & Turbo
Machine Elements

Figure 5: Inlet and exhaust cam followers /automatic blocking of the eccentric shaft
Work Cards, Classified by Subjects

2009-04-16
L48/60B

6 (11) 6704 000.29-01 EN

 MAN Diesel & Turbo 000.29

Machine Elements
Work Cards, Classified by Subjects

Figure 6: Starting valve / fuel injection pump / fuel injection pipe

2009-04-16

L48/60B

6704 000.29-01 EN 7 (11)

000.29 MAN Diesel & Turbo
Machine Elements
Work Cards, Classified by Subjects

Figure 7: Drive for speed governor / Intermediate gearbox / speed governor 2009-04-16
L48/60B

8 (11) 6704 000.29-01 EN

 MAN Diesel & Turbo 000.29

Machine Elements
Work Cards, Classified by Subjects
2009-04-16

L48/60B

Figure 8: Charge air pipe /exhaust pipe

6704 000.29-01 EN 9 (11)

000.29 MAN Diesel & Turbo
Machine Elements
Work Cards, Classified by Subjects

2009-04-16
L48/60B

Figure 9: Installing the turbocharger / charge air cooler

10 (11) 6704 000.29-01 EN

 MAN Diesel & Turbo 000.29

Machine Elements
Figure 10: Crankcase covering

Work Cards, Classified by Subjects

2009-04-16

L48/60B

6704 000.29-01 EN 11 (11)

 MAN Diesel & Turbo 000.30

Tightening screwed connections

Machine Elements
Tightening torques (table)

Summary
Determine tightening torque for important screwed connections, ensure
operational safety.
Screwed connections which have been tightened using the hydraulic ten-
sioners, to torsional torque or in accordance with turning angle must be
tensioned and detensioned using the prescribed values.
Work Cards 000.29 and 000.30 contain the necessary information.

Work Cards, Classified by Subjects

2009-04-15

L48/60B

6704 000.30-01 EN 1 (11)

000.30 MAN Diesel & Turbo

Tightening torques
Machine Elements
Work Cards, Classified by Subjects

2009-04-15
L48/60B

2 (11) 6704 000.30-01 EN

 Machine Elements
000.30

3 (11)
Work Cards, Classified by Subjects
L48/60B

6704 000.30-01 EN
MAN Diesel & Turbo
2009-04-15
 Work Cards, Classified by Subjects Machine Elements

4 (11)
L48/60B
000.30

6704 000.30-01 EN
MAN Diesel & Turbo

2009-04-15
 Machine Elements
000.30

5 (11)
Work Cards, Classified by Subjects
L48/60B

6704 000.30-01 EN
MAN Diesel & Turbo
2009-04-15
 Work Cards, Classified by Subjects Machine Elements

6 (11)
L48/60B
000.30

6704 000.30-01 EN
MAN Diesel & Turbo

2009-04-15
 Machine Elements
000.30

7 (11)
Work Cards, Classified by Subjects
L48/60B

6704 000.30-01 EN
MAN Diesel & Turbo
2009-04-15
 Work Cards, Classified by Subjects Machine Elements

8 (11)
L48/60B
000.30

6704 000.30-01 EN
MAN Diesel & Turbo

2009-04-15
 Machine Elements
000.30

9 (11)
Work Cards, Classified by Subjects
L48/60B

6704 000.30-01 EN
MAN Diesel & Turbo
2009-04-15
 Work Cards, Classified by Subjects Machine Elements

10 (11)
L48/60B
000.30

6704 000.30-01 EN
MAN Diesel & Turbo

2009-04-15
 Machine Elements
000.30

11 (11)
Work Cards, Classified by Subjects
L48/60B

6704 000.30-01 EN
MAN Diesel & Turbo
2009-04-15
 MAN Diesel & Turbo 000.31

Tightening screwed connections

Machine Elements
Tightening torques (turning moments)

Summary
Provide tightening torques for important bolted connections, ensure opera-
tional safety. Bolted connections should be tightened using a torque wrench
if at all possible. For especially important connections, the values are speci-
fied in Work Card 000.30. Approximate values for other bolts are stated
here.
Work Cards 000.29 and 000.30 contain the necessary information.
Tightening Torques
Tightening of bolted connec- If other bolted connections other than those listed in Work Card 000.30 are
tions according to torque tightened using torque wrenches, approximate torque values can be taken
from Table 2. The following must be observed when doing so:
▪ Apart from the applied tightening torque, the clamping force of a
screwed connection depends on the anti-seize agent used, the surface
quality of the base and the thread and the material combination. It is
therefore essential that these conditions are fulfilled in their entirety.
▪ The tightening torques for the various threads can be taken from Table
2, depending on the coefficient of friction μ, i.e. depending on the selec-
ted anti-seize agent. The torque values apply to a screw material of
strength category 8.8 and in utilisation of approx. 70 % of the yield point.
Conversion factors must be used for other strength classes, by which
the tightening torque taken from the table must be multiplied. The
strength class is stamped on the screw 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 depending on the strength
class of the bolts
The following applies approximately for the coefficient of friction µ:
μ = 0.08 for anti-seize agent containing molybdenum disulphide (MoS2) Work Cards, Classified by Subjects
(MOLYKOTE Paste Type G-n or HSC and
Optimoly-Paste White T)
μ = 0.14 for surfaces without post-treatment, slightly oiled
or lubricated using Loctite
(see Work Card 000.19)
2007-08-29

Thread Tightening torque in Nm Thread Tightening torque in Nm

Rated dimension Coefficient of friction μ Rated dimension Coefficient of friction μ
General

0,08 0,14 0,08 0,14

M5 4 6 M 24 475 690
M6 7 10 M 24x2 500 750

6682 000.31-01 EN 1 (2)

000.31 MAN Diesel & Turbo

M8 17 25 M 27 700 1020
Machine Elements

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 strength class 8.8
Work Cards, Classified by Subjects

2007-08-29
General

2 (2) 6682 000.31-01 EN

 MAN Diesel & Turbo 000.32

Tightening screwed connections

Machine Elements
General remarks

Summary
Impart the necessary knowledge, ensure the operational safety of bolted
connections. Different methods of tightening bolted connections must be
used depending on the purpose of the connection and its significance. The
following are used: Tightening without specification, tightening to torque,
tightening to torsion angle, tightening to length change, tightening with
hydraulic tensioning tools.
Work Cards 000.29 and 000.30 contain the necessary information.
Corresponding Work Cards
Work card Work card Work card
000.29 000.30 000.31

General remarks
Tightening with standard Different methods of tightening bolted connections are used depending on
tools the purpose of the connection and its significance. When there are no spec-
ifications for the tightening of screwed connections of average significance,
use normal ring spanners, socket spanneres or open-jaw wrenches without
any extensions.

Self-locking hexagon nuts must only be used once! After use for
assembly, they must be replaced by new self-locking hexagon nuts!

Tightening to torque Bolted connections for which a specific tightening torque is specified in
Work Cards 000.29 and 000.30 must be tightened using a torque wrench.
The specified anti-seize agent must be adhered to during fitting, since dif-
ferent forces are exerted in the screwed connection at the same torque
value, depending on the lubricant used. The manufacturer's specifications
are decisive for the pre-treatment of the bolted connection and for the Work Cards, Classified by Subjects
application of the anti-seize agent.
If torque wrenches are also used to release bolted connections, it must be
ensured that the maximum torque capacity of the wrench is not exceeded
(risk of damage). Extension pipes must not be used under any circumstan-
ces. Torque wrenches must also be regularly checked for correct read-out/
setting.
If other bolted connections other than those listed in Work Card 000.30 are
tightened with torque wrenches, approximate torque values can be taken
from Work Card 000.31.
2007-03-26

Tightening to torsion angle or Bolted connections for the tightening of which a specific torsion angle is
torque and torsion angle stipulated, must firstly be tightened with a torque wrench to the stated tor-
que or with an open-jaw spanner, ring spanner or socket spanner until the
General

nut or bolt fits tightly. Secondly, the nut or bolt must continue to be tightened
by the stipulated torsion angle.

6682 000.32-01 EN 1 (2)

000.32 MAN Diesel & Turbo

Tightening to the elongation The procedure in which the screwed connections were primarily, or exclu-
Machine Elements

of the bolt sively, tightened by reference to the elongation of the bolt/pressing of the
parts to be tensioned has been discarded in favour of other methods. Today,
the change in length/pressing is only measured as a checking dimension,
in addition to tightening with hydraulic tensioners.
Disadvantages of the previ- The following disadvantages of tightening bolted connections with ring
ously stated methods spanners, open-jaw spanners or socket spanners or with torque wrenches
must be stated:
▪ Extremely high lateral forces are introduced into the connection
▪ Effective pretension depends on the anti-seize agents used and/or the
frictional conditions
▪ These procedures can no longer be applied to bolted connections which
have larger nominal diameters
Tightening with hydraulic ten- The disadvantages listed above are not applicable to the tightening of bolted
sioners connections using hydraulic tensioners. The procedure can even be applied
to the largest of bolts, with a high degree of reliability. Screws, bolts or axes
are hydraulically extended and, after tightening or releasing the nuts, they
are detensioned. See Work Cards "Hydraulic tensioner - Use" and safety
regulations.
Work Cards, Classified by Subjects

2007-03-26
General

2 (2) 6682 000.32-01 EN

 MAN Diesel & Turbo 000.34

Surface Test By

Machine Elements
Penetration methods

Summary
Inspection of components for cracks/surface defects. Evaluation regarding
usability/reworking possibilities/tightness. Surface inspections are carried
out on high quality and highly stressed components, in order to ensure their
perfect condition, or to correctly classify existing damage.
The work/work steps include: Cleaning components and preparing for test-
ing, inspecting parts/components.
Tools/aids required
Quantity Designation Number Status
1 Wire brush - Inventory
1 Special cleaning agent - Inventory
1 Penetrant - Inventory
1 Developer - Inventory
1 Protective clothing - Inventory

Application areas
Surface inspections using the penetration method are based on the intro-
duction of liquid media having a low surface tension and high capillary
effect. They can be seen in pores and cracks up to a size of approx. 0.25
μm, provided they have a connection to the test surface. The penetration
method can be used for almost all materials and at a temperature range of
approx. -5° to 50° C. With special testing equipment, this method can also
be used on surfaces having temperatures up to 175° C. Surface defects
(hereafter referred to as faults) can be displayed independently of their type
and direction as well as independently of the geometry of the test object.
Other non-destructive test methods can only be applied with restrictions
under the requirements stated above.
Fluorescent penetrating oils are used in a similar method. These require an Work Cards, Classified by Subjects
additional emulsifying process. The evaluation of surface faults is carried
out under UV light.
In all cases the manufacturer's instructions must be observed during use.
The following information illustrates the procedure and the main application
options.
Work Sequence 1 - Precleaning of the Components to be Tested
Various cleaning methods can be applied, depending on the type and qual-
ity of the component to be tested. Generally the surface to be tested must
2008-10-28

have a polished metal finish, must be clean and free of grease. All types of
coating and deposits, such as galvanic coatings, rust and scale layers must
be removed. This is necessary so that the penetrant can fully wet the surface
General

and penetrate surface faults.

6682 000.34-01 EN 1 (7)

000.34 MAN Diesel & Turbo
Machine Elements

1 Mechanical (Wire brush) 3 Chemical (Degreasing using hot

steam)
2 Mechanical (e.g. sandblasting) 4 Chemical (Cleaning agent)
Figure 1: Options for the precleaning of the components to be tested
(Illustration source: Helling)

Work Sequence 2 - Introduction of the Penetrant

The penetrant can be applied to the component to be tested in various ways.
You must ensure that the test surface remains fully wet throughout the entire
penetration period. Adequate penetration duration depends on the charac-
teristics of the penetrant, the test temperature and the material of the com-
ponent to be tested. For castings, this is generally within a range 3 ... 5
minutes, for homogeneous metals 10 ... 20 minutes.
Work Cards, Classified by Subjects

1 Immersion bath 3 Spraying (spray can)

2 Brushing on 4 Spraying (Compressed air gun)
Figure 2: Options for application of the penetrant
2008-10-28

Work Sequence 3 - Intermediate Cleaning of the Component Surface

General

The excess penetrant clinging to the component surface must be fully

removed. In doing so, you must ensure that the penetrant remains in posi-

2 (7) 6682 000.34-01 EN

 MAN Diesel & Turbo 000.34

tion in any faults that are detected. The cleaning method depends on the

Machine Elements
penetrant used.

1 water soaked, non-fraying cloth or 3 Rinsing with water

sponge
2 Cleaning with a brush 4 Special cleaning agents (com-
patible with the penetrant)
Figure 3: Intermediate cleaning options

Work Sequence 4 - Drying of the Cleaned Component Surface

After removal of the excess penetrant, the component surface to be tested
must be dried as quickly as possible. In doing so, you must ensure that the
penetrant located in any faults does not dry in. The entire drying process
can be omitted if a wet developer with water is used as the carrying agent
for the development process.

Work Cards, Classified by Subjects

1 Air drying 3 Compressed air (water and oil free)

2008-10-28

2 dry, non-fraying cloth 4 Warm air

Figure 4: Component drying options
General

6682 000.34-01 EN 3 (7)

000.34 MAN Diesel & Turbo

Work Sequence 5 - Development Process

Machine Elements

The developer must be applied as evenly as possible in a thin layer on the

component surface to be tested. In addition to wet developers based on
water or solvent, dry developers are also used. In general, the development
duration corresponds to the penetration duration of the penetrant.

1 Water-based wet developer 3 Solvent-based wet developer

(Immersion) (compressed air gun)
2 Solvent-based wet developer 4 Solvent-based wet developer
(aerosol can) (electrostatic/airless)
Figure 5: Options for the application of the developer

Work Sequence 6 - Results Evaluation

The developer (white) draws the penetrant (red) out of any faults and shows
them as coloured bleed-outs. The size, type and shape of the bleedings
allow conclusions to be drawn as to the origin of the fault. Such fault indi-
cations are shown as a schematic diagram in figure 7.
Work Cards, Classified by Subjects

2008-10-28
General

4 (7) 6682 000.34-01 EN

 MAN Diesel & Turbo 000.34

Machine Elements
1 visual inspection 3 photograph
2 Documentation on transparency 4 Documentation by photographs
film or video recording
Figure 6: Options for recording the test result

1 Cold cracks 6 Cluster porosity

2 Hot cracks 7 Spongy structure
3 Grinding cracks 8 Porosity (heavy bleeding)
4 Cracks (heavy bleeding) 9 Stress corrosion cracking
5 Porosity
Figure 7: Fault indications Work Cards, Classified by Subjects
2008-10-28

General

6682 000.34-01 EN 5 (7)

000.34 MAN Diesel & Turbo
Machine Elements

Figure 8: Valve cone with stress cracks in the fillet

Work Cards, Classified by Subjects

Figure 9: Valve cone with cracks in the valve seat armouring

2008-10-28
General

6 (7) 6682 000.34-01 EN

 MAN Diesel & Turbo 000.34

Recommended Manufacturers for Testing Chemicals (Special Cleaning Agents/Penetrants/

Machine Elements
Developers)
Manufacturer Special cleaning agent Penetrant Developer
Tiede Tiede-PEN RL-40 Tiede-PEN PWL-1 Tiede-PEN DL-20
Bahnhofstraße 94-98
D-73457 Esslingen
MR Chemie GmbH MR 79 MR 68 NF MR 70
Nordstraße 61-63
D-59427 Unna
Brent GmbH ARDROX ARDROX ARDROX
Rostocker Straße 40 9PR88 9VF2 9D1B
D-41199 Mönchengladbach
Helling KG GmbH & CO. NPU VP 30 D 70
Sylvesterallee 2
D-22525 Hamburg
Table 1: Manufacturers/Testing Chemicals

Figure 10: Testing Chemicals of Various Manufacturers (Special Cleaning

Agents/Penetrants/Developers Respectively)
Work Cards, Classified by Subjects
2008-10-28

General

6682 000.34-01 EN 7 (7)

 MAN Diesel & Turbo 000.34

Surface Test By

Machine Elements
Magnetic leakage flux method

Summary
Inspection of components for cracks/surface defects. Evaluation regarding
usability/reworking possibilities/tightness. Surface inspections are carried
out on high quality and highly stressed components, in order to ensure their
perfect condition, or to correctly classify existing damage.
The work/work steps include: Cleaning components and preparing for test-
ing, inspecting parts/components.
Tools/aids required
Quantity Designation Number Status
1 Yoke magnetising equipment - Inventory
1 Permanent magnetisation device - Inventory
1 UV light source - Inventory
1 Magnetic powder (dry) - Inventory
1 Magnetic powder (in suspension) - Inventory
1 Special cleaning agent - Inventory
1 Special paint - Inventory

Application areas
Surface examinations, carried out according to the magnetic particle
inspection method, cause ferromagnetic discontinuities and thus leakage
fields in the faulty areas of magnetised ferromagnetic materials which have
been flooded by a magnetic field. These go beyond the component surface.
The presence of a magnetic discontinuity or a leakage field is verified by the
application of fine ferromagnetic powder onto the component surface, the
powder being partially held by the magnetic leakage field. The magnetic
powder accumulation reveals the contour of the fault and generally indicates
the location, size, shape and extent of the field.
The magnetic powder is applied to the test surface as a dry powder or in a
Work Cards, Classified by Subjects
liquid suspension (water, oil, paraffin). These are ferromagnetic materials
such as iron, nickel and cobalt alloys. The ferromagnetic characteristics of
these materials disappear above a certain temperature, the so-called Curie
point. For most ferromagnetic materials this point is approx. 760° C.
The magnetic field in the component to be tested can be generated in sev-
eral different ways. Apart from coil magnetisation, self-magnetisation and
induced magnetisation, the most widespread magnetisation method is yoke
magnetisation. In all cases the manufacturer's instructions must be
observed during use. The following information illustrates the yoke mag-
2008-10-28

netisation procedure and the basic application options.

General

6682 000.34-02 EN 1 (5)

000.34 MAN Diesel & Turbo
Machine Elements

Figure 1: AC yoke magnetising device (by Helling)

Work Cards, Classified by Subjects

Figure 2: Permanent magnet with special paint and magnetic powder in spray
cans (by Helling)

Yoke magnetisation
2008-10-28
General

2 (5) 6682 000.34-02 EN

 MAN Diesel & Turbo 000.34

Machine Elements
Figure 3: Field line path in yoke magnetisation
In yoke magnetisation we generally differentiate between two types of mag-
netisation. The magnetic field can be generated using a permanent magnet
or solenoid.
Preferentially, faults of this type are displayed whose longitudinal direction
runs at right angles to the connecting line between the magnetic poles
(transverse to the field direction). It is therefore necessary to perform the
test a second time in a transverse direction (see figure 4/B and 4/C).

Component without faults

A (homogeneous magnetic field -
no fault display)
Component with faults in the field
B direction (homogeneous mag-
netic field - no fault display)
Component with faults trans-
verse to the field direction (inho-
C
mogeneous magnetic leakage
field - clear fault display)

Figure 4: Field lines in the magnetised component

The component to be tested must be cleaned and freed from all types of
Work Cards, Classified by Subjects
coatings and covering which may impede the alignment of the magnetic
powder or which may lead to incorrect fault displays.
In general, narrow detachments, such as cracks and gaps, are indicated
more precisely than wide faults such as slag, porosity or blow holes. Faults
lying below the surface are indicated inaccurately, becoming increasingly
obscure the deeper they are. The magnetic powder test is therefore mainly
used for detecting surface faults or faults near the surface.
Application of the magnetic powder
2008-10-28

The magnetic powder can be applied in a dry or wet process. Both proce-
dures differ in their application options and, in part, in their display sensi-
General

tivity.

6682 000.34-02 EN 3 (5)

000.34 MAN Diesel & Turbo
Machine Elements

Figure 5: Bead formation in the magnetic powder due to magnetic leakage

fields
Dry process In the dry process, the magnetic powder is sprinkled onto the component
surface to be tested by means of a light jet of air. This can be carried out
using a spray gun or a spray can. The use of dry powders requires the sur-
face of the component to be tested to be absolutely dry and free from
grease. Surface roughness can be slightly higher than in the wet process.
In the dry process, relatively thick powder beads are formed, leading to a
clear fault display.
The dry process is advantageous for testing components that cannot not
be wetted with water or testing oil or on hot component surfaces.
Wet process In the wet process, the magnetic powder is flushed onto the component
surface to be tested in a carrier liquid. Water or testing oil is used as the
carrier agent, depending on the application. The mobility of the individual
magnetic powder particles is substantially increased by the use of such
magnetic particle suspensions. The particles "swim" to the faults. This,
however, assumes the constant movement of the carrying agent in order to
prevent the magnetic powder from being deposited.
The concentration of magnetic powder in the carrying agent is also decisive
for the test result. In general, magnetic particle suspensions with higher
concentrations have a deeper effect, thus displaying faults more quickly.
Weaker concentrations, however, have increased display sensitivity, how-
ever are slower in the formation of the powder beads. The concentration of
non-fluorescent magnetic particle suspensions is between 6 ... 24 g/l and
fluorescent magnetic particle suspensions between 0.25 ... 2.5 g/l.
The application of the magnetic particle suspensions onto the component
surface to be tested is by spray bottle or spray can. The suspension is
poured on adjacent to the point to be tested so that it can slowly run across
the component surface to be tested.
Work Cards, Classified by Subjects

Carrying Out the Magnetic Powder Test

First of all the cleaned component surface is given a visual inspection and
coated with a fast-drying special paint, if necessary, to achieve an improved
contrast with the magnetic powder. The application of the magnetic powder
and the magnetisation take place simultaneously. The time required for
flushing or spraying depends on the amount of powder applied per unit time,
the concentration of the suspension, the grain size, the shape of the com-
ponent surface to be tested and the size of the faults to be detected. In
general, the flushing or spraying must have been completed before the
2008-10-28

magnetic field is deactivated in order not to destroy the powder beads

formed over the faults.
General

Very fine separations, such as grinding and hardening cracks, can only be
reliably detected using the wet process with less concentrated magnetic
particle suspensions and a smaller grain size.

4 (5) 6682 000.34-02 EN

 MAN Diesel & Turbo 000.34

Finally, the test area is examined for powder accumulation and the possible

Machine Elements
fault indications are evaluated, marked and fixed if necessary. Depending
on the use of the component, test agent residues are removed and the
component is demagnetised.
Magnetic Powder Indications
During the magnetic powder test, an image of the fault pattern is given by
the bead formation at the fault locations, but no information is provided as
to the fault depth. As already described, clear magnetic powder images are
provided of component surface faults, while faults underneath the compo-
nent surface only result in indistinct indications.

Figure 6: Valve cone with stress cracks in the fillet

False indications are a special problem in magnetic powder testing. These
are powder accumulations which occur in places that are not faulty. False
displays occur, for example, at sharp cross section transitions or in cold- Work Cards, Classified by Subjects
formed areas. A certain amount of experience is required in such cases to
be able to differentiate between a false display and a genuine fault indica-
tion.
Demagnetisation
After magnetisation, residual magnetism remains in the test object, which
can lead to malfunctions, depending on the use of the component. To
demagnetise, the component is subjected to an alternating magnetic field
of decreasing strength. Experience shows that the field strength may only
2008-10-28

decrease by max. 10 % with each alternation. At the beginning of the

demagnetisation process, the field strength must be selected to be greater
or equal to the field strength used for the test.
General

6682 000.34-02 EN 5 (5)

 MAN Diesel & Turbo 000.43

Working and Safety Regulations

Machine Elements
the use of load carrying equipment/slings

Summary
Impart the necessary knowledge, ensure safe use (of load carrying equip-
ment).
In order to use the load carrying equipment/slings in a safe manner the reg-
ulations for use must be observed.
The following must be observed:
Danger of accidents,
Safety regulations and
Maintenance regulations.
Corresponding Work Cards
Work card Work card Work card
000.34

Preliminary remarks
The following must be observed in order to use the load carrying equipment/
slings safely:
▪ the regulations for use,
▪ the maintenance regulations and
▪ the safety regulations

Safety Regulations
▪ Observe the Work Cards and safety regulations.
▪ Remove dirt from the contact faces of engine parts or load carrying
equipment, check the thread and clean if necessary.
▪ Only use tools in perfect working order. Overhaul or replace faulty/
doubtful components.
▪ Use the stipulated tensioning values and lubricants.
Work Cards, Classified by Subjects

Storage and Care of Tools

▪ The load carrying equipment must be stored in a stable condition.
▪ In order to prevent damage and corrosion the tools must be protected
from dust, dirt, chemicals and liquids.
▪ Always use genuine spare parts when carrying out overhaul work since
perfect function and carrying capacity depends upon this.
2008-09-15

▪ Check the load carrying equipment regularly for correct condition.

Before and after extensive maintenance work, a crack check (see Work
Card 000.34) in the main load area of the load carrying equipment must
General

be carried out.

6682 000.43-01 EN 1 (4)

000.43 MAN Diesel & Turbo

Basic Safety Information

Machine Elements

Obligations and Liability The basic prerequisite for safe handling and fault-free operation of load
carrying equipment is a knowledge of the basic safety information and
safety regulations.
These Operating Instructions, particularly the safety instructions, must be
observed by everyone working on, or with, the load carrying equipment.
Furthermore, locally applicable rules and regulations for accident prevention
must be observed.
Intended use The load carrying/slings are exclusively intended for the lifting and lowering
of the components or sub-assemblies on the diesel engine listed by MAN
Diesel & Turbo SE.
Improper use Any use other than that stated above is not allowed. Dangers could arise
from improper use.
Improper use of this type is, e.g. the load take up of non-quoted components
or sub-assemblies
Dangers arising from han- The load carrying equipment/slings are designed according to state-of-the-
dling load carrying equipment art technology principles and approved safety rules. However, its use may
still present a danger to life and limb for the user or third parties, or have
adverse affects on the load carrying equipment or other material property.
Load carrying equipment/slings must only be used:
▪ for its intended purpose,
▪ in safe and perfect condition.
Malfunctions which could impair safety must be remedied immediately.

Visual check of load carrying equipment/slings

Load carrying equipment/slings must be subjected to a general visual
check for damage and wear after each load cycle (load changeover from
lifting or setting down).

Regular checking of load carrying equipment/slings

At regular intervals (approx. 50 load cycles) the load carrying equipment/
slings must be checked (general visual check, check for damage and
wear and magnetic crack testing of all components of the device). This
Work Cards, Classified by Subjects

must be recorded in writing in the operating log!

Replacing load carrying equipment/slings

After 15 years from the date of manufacture the load carrying equipment/
slings must be de-commissioned and be replaced by new ones! A written
record of the load cycles must be kept in the operation logbook!

Guarantee and liability In general, our "General Terms of Sales and Supply" apply. These are avail-
able to the plant operator upon signature of the contract, at the latest. In
2008-09-15

addition, for warranty and liability, only those regulations are applicable
which are produced by the contract relationship between MAN Diesel &
Turbo and the user and/or the customer. Guarantee and liability claims in
General

case of personal injury or material damage are excluded if they originate

from one or more of the following causes:
▪ Non-intended use of the load carrying equipment/slings

2 (4) 6682 000.43-01 EN

 MAN Diesel & Turbo 000.43

▪ Incorrect installation, commissioning, operation and maintenance of the

Machine Elements
load carrying equipment/slings
▪ Operation of the load carrying equipment with faulty safety equipment
or incorrectly mounted or faulty components, safety and protection
equipment
▪ Non-observance of the information in the Operating Instructions with
respect to transport, storage, installation, commissioning, operation,
maintenance and setting up of the load carrying equipment/slings
▪ Unilateral constructional modifications to the load carrying equipment/
slings
▪ Poor monitoring and checking of load carrying equipment and compo-
nents subject to wear
▪ Incorrectly carried out repair work
▪ Non-observance of the maximum permissible operating duration of load
carrying equipment/slings
▪ Catastrophic incidents due to external influences and force majeure
Organisational Measures In addition to the Operating Instructions, generally applicable legal and other
binding regulations for accident prevention and environmental protection
must be observed and pointed out!
Such obligations on the plant operator include:
▪ The provision/wearing of personal protective equipment
▪ All the load carrying equipment/slings must be checked regularly.
▪ The staff entrusted with working on the load carrying equipment/slings
must be instructed, before beginning work, concerning the Operating
Instructions and the safety information contained therein.
Safety Equipment Each time, prior to using the load carrying equipment/slings you must
ensure that all safety equipment has been properly installed and is in full
working order.
Informal Safety Measures The Operating Instruction manual must always be stored near to the load
carrying equipment/slings.
In addition to the Operating Instructions, the generally applicable and local
regulations for accident prevention and environmental protection must be Work Cards, Classified by Subjects
provided and observed.
Staff Training Only trained and instructed staff may work on, and with, the load carrying
equipment/slings. The responsibilities of the staff for operation, changing
over and maintenance must be clearly defined. Staff being trained must only
work on the load carrying equipment/slings under the supervision of an
experienced person.
Safety Measures in Normal Before using the load carrying equipment/slings, ensure that no one is
Operating Mode endangered by doing so. At least once per load cycle, inspect the load car-
rying equipment for externally recognisable damage and functionality of the
2008-09-15

safety equipment.
General

6682 000.43-01 EN 3 (4)

000.43 MAN Diesel & Turbo

Particular Danger Points

Machine Elements

Hot component surfaces

Touch hot component surfaces only wearing safety gloves or protective
clothing!
If surfaces are to be touched without protective gloves or protective
clothing, allow them to cool down first.

Damaged components
After each time the load carrying equipment they must be cleaned and
checked for damage.
Damaged and worn load carrying equipment or components must not
be used, under any circumstances, and they must be replaced
immediately.

Heavy weight of the components or sub-assemblies to be lifted

The following must be noted in particular because of, amongst other
things, the heavy weight of the components or sub-assemblies to be
lifted by the load carrying equipment/slings:
Do not stand under suspended loads. Keep third parties away from the
danger zone.
Observe the maximum permissible capacities of the crane or lifting
tackle.
Observe the maximum permissible carrying capacity of the load carrying
equipment/slings.

Handling the load carrying equipment, environmental conditions

Danger of damaging the components under low headroom removal
conditions.
Danger of crushing when applying the load carrying equipment and when
putting down or placing/fitting of components or sub-assemblies.
Exceeding the tilting moment or unexpected load movement when
selecting the wrong attachment point.

Maintenance and Service, ▪ Carry out the stipulated setting, maintenance and inspection work
Troubleshooting according to schedule.
Work Cards, Classified by Subjects

▪ Secure the load carrying equipment/slings or lifting tackle against unex-

pected commissioning/movement.
Constructional modifications ▪ Load carrying equipment/slings which are not in perfect condition must
on load carrying equipment/ be replaced immediately! Only use genuine spare and wear parts! In the
slings case of externally sourced parts there is no guarantee that they have
been designed and manufactured to withstand the stress, and that they
comply with the safety conditions as required.
▪ No modifications, attachments or conversions may be carried out on the
2008-09-15

load carrying equipment/slings without the manufacturer's approval.

▪ Any conversion work requires the written approval of MAN Diesel &
Turbo SE.
General

4 (4) 6682 000.43-01 EN

MAN Diesel & Turbo 004

Hydraulic tensioners/High-pressure pump

001 Operating media systems/Pipes
002 Operating media/Auxiliary agents
003 Machine Elements
004 Hydraulic tensioners/High-pressure pump
005 Operating values/Operating results

6704 2.4-1 EN 1 (1)

 MAN Diesel & Turbo 000.33

Working and Safety Regulations

Hydraulic tensioners/High-pressure pump

using high-pressure tools/hydraulic tensioners

Summary
Impart the necessary knowledge, ensure safe use (of high-pressure tools).
Hydraulic tensioners, high-pressure hose and the high-pressure pump are
tools that can be used safely, despite high-pressures, if the instructions for
use are observed.
The following are to be observed: Accident hazards, safety regulations and
maintenance instructions.
Preliminary remarks
Hydraulic tensioners, high-pressure hoses and the high-pressure pump are
tools which can be used safely without malfunctioning, despite high oper-
ating pressures, if the following instructions are observed.
▪ Instructions for use
▪ Instructions for repair
▪ Safety Regulations

Safety Regulations
▪ Observe the Work Cards and safety regulations.
▪ Remove dirt from the contact faces of engine parts or tools, check the
thread and clean if necessary.
▪ Only use tools in perfect working order. Overhaul or replace faulty/
doubtful components.
▪ Use the stipulated tensioning values and anti-seize agents.
▪ Use low-viscosity slushing oil as hydraulic fluid (no lubricating oil, no
fuel).
▪ The locking ring (fluted threaded ring) must be screwed up to the stop
after engaging the hose coupling.
Work Cards, Classified by Subjects
▪ The hose couplings, to which no hoses are connected, must be closed
off with blind plugs.
▪ Wear safety goggles.
▪ Keep people away from the area of the extensions of the bolt or press
axes.
▪ If possible, keep a safe distance from presses and high-pressure hoses.
▪ Slowly increase the pressure regulating valve setting, do not exceed the
stated pressure.
2007-07-19

▪ No hard blows to loaded bolts, nuts and presses.

▪ Do not kink high-pressure hoses, the minimum bending diameter is 400
General

mm.
▪ After each tensioning process ensure that the piston is reset. Descrip-
tion in the Work Cards for the hydraulic tensioners.

6682 000.33-01 EN 1 (6)

000.33 MAN Diesel & Turbo

▪ When loosening hydraulically tightened bolts, the stipulated tensioning

Hydraulic tensioners/High-pressure pump

pressure must not be exceeded by max. 5 %.

▪ When checking hydraulically tightened bolts, the release pressure may
be max. 7 % under or max. 5 % above the stipulated tensioning pressure
(see Work Card 000.30).
If the release pressure is too low (max. 7 % below the stipulated value), the
cause must be determined (carelessness during tightening, wear, intensive
setting of the bolted connection).
If the release pressure is 10 % or more below the stipulated value, MAN
Diesel & Turbo SE, Augsburg must be informed in order to determine check-
ing measures.
If the release pressure is too high (if tensioning pressure plus 5 % is insuf-
ficient for releasing), the cause must be eliminated as far as possible (bolted
connection damaged/corroded/blocked by paint, tensioner damaged/
incorrectly fitted).
If the connection cannot be released, despite improvement measures, the
tensioning pressure may only be increased up to the releasing point if MAN
Diesel & Turbo SE, Augsburg, has certifiably agreed to this process (risk of
overstressing the bolt/deformation of components). As an alternative, the
nut can be split and replaced, with the bolt.
Storage and Care of Tools
▪ Store tools at 15 to 25 °C if possible, so that plastic parts do not age
prematurely and the hydraulic fluid remains adequately fluid. Plastic
seals must be protected from the effects of light.
▪ Dust, dirt, chemicals and liquids must be kept away from tools to avoid
damage to the sealing faces.
▪ Presses and high-pressure hoses must be bled (air) for storage.
▪ Do not kink high-pressure hoses. Couplings to be interconnected.
▪ When carrying out overhaul work, only ever use genuine spare parts,
since perfect operation depends, for example, on the correct hardness
of the O-ring seals.
▪ Check the pump pressure gauge regularly for correct read-out.
Work Cards, Classified by Subjects

Basic Safety Information

Obligations and Liability ▪ The basic prerequisite for safe handling and fault-free operation of
hydraulic tensioners is a knowledge of the basic safety information and
safety regulations.
▪ These Operating Instructions, particularly the safety instructions, must
be observed by everyone working on, or with, the hydraulic tensioners.
▪ Furthermore, locally applicable rules and regulations for accident pre-
vention must be observed.
2007-07-19

Dangers in handling the The hydraulic tensioner is designed according to state-of-the-art technol-
hydraulic tensioner ogy principles and approved safety rules. However, its use may still present
General

a danger to life and limb for the user or third parties, or have adverse affects
on the hydraulic tensioner or other material property. The hydraulic ten-
sioner must only be used:

2 (6) 6682 000.33-01 EN

 MAN Diesel & Turbo 000.33

▪ for its intended purpose,

Hydraulic tensioners/High-pressure pump

▪ in safe and perfect condition.
Malfunctions which could impair safety must be remedied immediately.
Checking and recording the After each load cycle (load change when tightening or untightening), the
load cycles hydraulic tensioner must undergo a general visual inspection and the thread
must be checked for damage and wear.

The hydraulic tensioner must be checked (general visual inspection,

checking of the thread for damage and wear and magnetic crack test of
all its components) at regular intervals (approx. 100 load cycles) and a
written record of the results must be kept!

After 2,500 load cycles, the hydraulic tensioner must be removed from
service and replaced by a new one! A written record of the load cycles
must be kept in the operation logbook!

Guarantee and liability In general, our "General Terms of Sales and Supply" apply. These are avail-
able to the plant operator upon signature of the contract, at the latest. Guar-
antee and liability claims in case of personal injury or material damage are
excluded if they originate from one or more of the following causes:
▪ Use of the hydraulic tensioner other than for the intended purpose
▪ Incorrect installation, commissioning, operation and maintenance of the
hydraulic tensioner
▪ Operation of the hydraulic tensioner with faulty safety equipment or
incorrectly mounted or faulty components, safety and protection equip-
ment
▪ Non-observance of the information in the Operating Instructions with
respect to transport, storage, installation, commissioning, operation,
maintenance and setting up of the hydraulic tensioner
▪ Unauthorised structural changes to the hydraulic tensioner
▪ Unauthorised modification to the operating pressure
▪ Insufficient monitoring of the hydraulic tensioner and components sub-
ject to wear Work Cards, Classified by Subjects
▪ Incorrectly carried out repair work
▪ Non-observance of the maximum permissible load cycles of the
hydraulic tensioner
▪ Catastrophic incidents due to external influences and force majeure
Intended use The hydraulic tensioner is used for tightening and untightening the bolted
tensional connections on the diesel engine, as specified by MAN Diesel &
Turbo SE, Augsburg. This is carried out using a high operating pressure or
tensioning pressure and their limits, as stipulated for bolted connections.
2007-07-19

Improper use Any uses other than those stated above are not allowed. Dangers could arise
from improper use.
General

Such improper use includes:

▪ Any kind of bolted connections not referred to

6682 000.33-01 EN 3 (6)

000.33 MAN Diesel & Turbo

▪ High-strength bolted connections in steel construction

Hydraulic tensioners/High-pressure pump

▪ Tensional bolted connections in other areas

Organisational Measures In addition to the Operating Instructions, generally applicable legal and other
binding regulations for accident prevention and environmental protection
must be observed and adhered to!
Such obligations on the plant operator include:
▪ The provision/wearing of personal protective equipment
▪ All the hydraulic equipment involved must be checked regularly.
▪ The staff entrusted with working on the hydraulic tensioner must be
instructed, before beginning work, concerning the Operating Instruc-
tions and the safety information contained therein.
Safety Equipment Each time, prior to commissioning the hydraulic tensioner, you must ensure
that all safety equipment has been properly installed and is in full working
order.
Informal Safety Measures The Operating Instructions must be kept close to the hydraulic tensioner.

In addition to the Operating Instructions, the generally applicable and local

regulations for accident prevention and environmental protection must be
provided and observed.
Staff Training Only trained and instructed staff may work on, and with, the hydraulic ten-
sioner. The responsibilities of the staff for operation, changing over and
maintenance must be clearly defined. Staff being trained must only work on
the hydraulic tensioner under the supervision of an experienced person.
Safety Measures in Normal Before commissioning the hydraulic tensioner, ensure that no one is endan-
Operating Mode gered by doing so. At least once per load cycle, inspect the hydraulic ten-
sioner for externally recognisable damage and functionality of the safety
equipment.

During pressure build-up, ensure that the permitted operating/

tensioning pressure of the corresponding hydraulic tensioner and the
bolted connection to be tightened is observed!
For the max. pump operating pressure, no additional pressure restriction
is applied for the hydraulic tensioner/cylinder at low operating pressure.
In this application, pay particular attention to the pressure gauge!
Work Cards, Classified by Subjects

Take care with the presence of residual mechanic, hydraulic and

pneumatic energy on the hydraulic tensioner, and take the relevant
measures when training the operating staff.

Particular Danger Points Service life of hydraulic hoses and seals

▪ Observe the information concerning service life provided by the hose

manufacturer!
2007-07-19

Hose connections
▪ Hose connections must be checked before operation.
General

▪ The connections must be engaged and locked.

▪ Hoses may only be uncoupled when the hydraulic system has been
depressurised.

4 (6) 6682 000.33-01 EN

 MAN Diesel & Turbo 000.33

Damaged hoses

Hydraulic tensioners/High-pressure pump

▪ High-pressure hoses are subject to an operating pressure of 1,500 bar
(burst pressure >3,300 bar) and are sheathed by a protective hose.
Check for damage before commissioning.
▪ Do not kink the hoses. Minimum bend diameter of high-pressure hose
pipes is 400 mm.
▪ Use only those hoses approved by MAN Diesel & Turbo SE, Augsburg!
Crushing of limbs between the tensioning cylinder and the thrust piece
▪ When screwing onto the screw, do not reach into the contact face of
the tensioning cylinder and the thrust piece.
▪ During pressure application, do not reach into the contact face of the
tensioning cylinder and the thrust piece!
Hot component surfaces
▪ Touch hot component surfaces only wearing safety gloves or protective
clothing!
▪ If surfaces are to be touched without protective gloves or protective
clothing, allow them to cool down first.
Bolt fracture
▪ Do not stand in the direction of force i.e. not in the bolt axis during pres-
sure build-up
Damaged components
▪ After each tensioning process the threads must be cleaned and checked
for damage
▪ Damaged and worn parts (tension screw, tension nut etc.) must not be
used, under any circumstances, and they must be replaced immedi-
ately.
The following must be particularly observed due to high pressure and force:
▪ Danger of fracture of highly-stressed parts when pressure builds up in
the device (during tightening, untightening and checking). Broken parts
fly off in the direction of the force, i.e. in the extension of the bolt or press
axis. This danger arises during pressurising or when a tensioner under
full pressure is stressed by heavy impacts. Work Cards, Classified by Subjects
▪ Risk of very fine or sharp jets of hydraulic oil being released due to leak-
age at the sealing elements, bursting of hoses or failure of fittings. Skin
and eye injuries are possible at a distance of up to 1 m.
▪ Tensioning processes carried out incorrectly can lead to the fracture of
running gear bolts and can cause severe machine damage. The follow-
ing are possible causes: Incorrect pressure during pressurising, failure
to connect a hose, failure to engage the hose coupling, tensioning proc-
ess not checked (length not measured, number of holes not observed
when turning the nut).
2007-07-19

Hydraulic tensioner system ▪ Work on hydraulic equipment must only be carried out by staff having
special skills and experience with hydraulic systems!
General

▪ All cables, hoses and bolted connections must be regularly checked for
leakage and externally detectable damage! Repair any damage imme-
diately! Oil spurts can lead to injuries and fires.

6682 000.33-01 EN 5 (6)

000.33 MAN Diesel & Turbo

▪ Before beginning repair work, assembly and installation, you must

Hydraulic tensioners/High-pressure pump

depressurise the hoses to be dismantled in accordance with the sub-

assembly descriptions!
▪ Only use hydraulic fluids stipulated by MAN Diesel & Turbo SE, Augs-
burg.
▪ High-pressure hoses must be professionally routed and assembled! Do
not mix up the connections! The fittings, length and quality of the hoses
must comply with requirements.
▪ Wear safety goggles and protective gloves when working on, or with,
the hydraulic tensioning cylinder. Do not stand in the direct vicinity of
the device during pressure build-up.
Maintenance and Service, ▪ Carry out the stipulated setting, maintenance and inspection work
Troubleshooting according to schedule.

▪ Secure the hydraulic tensioner against accidental commissioning.

Structural Changes to the ▪ No modifications, attachments or conversions may be carried out on the
Hydraulic tensioner hydraulic tensioner without the manufacturer's approval.

▪ Any conversion work requires the written approval of MAN Diesel &
Turbo SE, Augsburg
▪ Hydraulic tensioner components which are not in perfect condition must
be replaced immediately! Only use genuine spare and wear parts! In the
case of externally sourced parts, there is no guarantee that they have
been designed and manufactured to withstand the stress, and that they
comply with the safety conditions as required.
Work Cards, Classified by Subjects

2007-07-19
General

6 (6) 6682 000.33-01 EN

 MAN Diesel & Turbo 009.03

High-pressure pump

Hydraulic tensioners/High-pressure pump

use

Summary
Impart the necessary knowledge, ensure adequate application. The high-
pressure pump produces the pressure required for tightening and releasing
the large bolted connections using the hydraulic tensioner. It is driven by
compressed air and produces pressures up to 1,500 bar at low delivery
rates.
Information is imparted concerning: Technical data, commissioning, shut-
down, maintenance and behaviour in the case of failures.
Tools/aids required
Quantity Designation Number Status
1 High-pressure pump 009.342 Standard
1 Tools, Basic Scope 009.229 Option
1 Slushing oil (viscosity 6-16 mm²/s) - Inventory

Technical data
Designation Information
Pressure range 0 - 1500 bar
Test pressure 1500 bar
Compressed air connection 7 - 15 bar
Oil filling 5 Liter
Quality Korrosionsschutzöl
Dimensions 431x317x405 mm
Weight 30,5 kg

Structure/Mode of action
For tightening and releasing large bolted connections the following is nee- Work Cards, Classified by Subjects
ded:
▪ high-pressure pump,
▪ specific pressure resistant hose lines and
▪ hydraulic tensioners, if necessary with resetting devices.
The high-pressure pump feeds a relatively small volume of liquid (if required,
at a pressure of up to 1,500 bar) through the pluggable hose pipes to one
or more tensioners.
If the piston of the hydraulic tensioner is screwed onto the thread of the
2007-04-25

screw, the liquid raises the piston in the casing and extends the screw, whilst
the hydraulic tensioner is supported by the surrounding parts of the screw.
General

The high-pressure pump is operated by compressed air. The air is directed

through control elements to a piston. This piston can be pressurised from
both sides and is equipped with pistons of smaller diameter on both sides
which draw in hydraulic oil from the surrounding reservoir, or which feed it

6682 009.03-05 EN 1 (6)

009.03 MAN Diesel & Turbo

to the distributor on the opposite side. As soon as the piston reaches an

Hydraulic tensioners/High-pressure pump

end position, the air flow is directed to the other side of the piston by a pilot
valve, and the pumping and suction action is repeated. The effective pres-
sure of the air is normally reduced in order to produce a pressure of 1500
bar on the hydraulic side. An outlet pressure of 1500 bar must not be excee-
ded.
Commissioning

Observe safety instructions in Work Card 000.33!

Work steps 1. Check oil level indicator (5) in the high-pressure pump, open oil filler
neck (1) and add slushing oil if necessary.

When adding slushing oil, pour oil through the basket strainer, since
malfunctions can be caused by foreign material.

2. Connect the high-pressure pump to hydraulic tensioner with a high-

pressure hose.
3. Set shut-off valve (A) to position II / OUT OF SERVICE.
4. Connect the compressed air hose to hose connection (6).
5. Adjust the pressure regulating valve (C) so that pressure gauge (7)
shows approx. 1 bar.
6. Open the relief valve (B) (counter-clockwise) to release the oil side of the
high-pressure pump.
7. Ensure that all connection hoses are properly connected and close off
the hose connections (4) which are not in use with a blind plug (lock the
sliding sleeve of coupling with the stop ring).
8. Put shut-off valve (A) to position I / OPERATION- High-pressure pump
starts.
9. Close relief valve (B) (clockwise).
Work Cards, Classified by Subjects

When connecting the high-pressure hose and the hydraulic tensioner,

ensure that they are completely filled with slushing oil and bled.

10. Gradually turn the pressure-regulating valve (C) for compressed air in a
clockwise direction until the desired pressure is indicated on the oil
pressure gauge (3) (there is a delay depending on the size of the
hydraulic tensioner).
2007-04-25

The high-pressure pump runs up to the adjusted oil pressure, leakage

General

losses are automatically compensated by re-pumping.

2 (6) 6682 009.03-05 EN

 MAN Diesel & Turbo 009.03

Shutdown

Hydraulic tensioners/High-pressure pump

Work steps 1. Set shut-off valve (A) to position II / OUT OF SERVICE, thus venting the air
system of the high-pressure pump.
2. Open vent valve (B) in order to make the oil side of the high-pressure
pump pressure-free (oil pressure gauge (3) will fall to zero). The pressure
reduction in the high-pressure hose will take place more slowly. After
the pressure release, the high-pressure hose has to remain connected
to the high-pressure pump with the relief valve open for approx. 3
minutes. Otherwise an internal pressure may remain which will block the
hose coupling (See Work Card 009.05 for troubleshooting).
3. Release the quick-acting coupling on the high-pressure hose.

Never open the quick-acting coupling while under pressure. - Risk of

accident! Oil pressure gauge (3) must indicate zero!

When more screw connections are tensioned one after the other at the
same pressure, the pressure regulating valve (C) remains at the set value.
Re-adjustments are not necessary.

4. Drain slushing oil from the hydraulic tensioner while the high-pressure
hose is still connected to hose coupling (4) (See Work Card for each
hydraulic tensioner for a description of this procedure).
5. Disconnect high-pressure hose.

Maintenance
The components and connections of the high-pressure pump have to be
checked regularly for leakage and overhauled if necessary. The set of wear
parts (2) for the high-pressure pump and pressure regulating valve (C) is
fixed behind the side plate.
Check the oil level on the oil level indicator (5) and add oil if necessary prior
to every start. Never run high-pressure pump without oil, to avoid air being
sucked in. Drain oil once a year and fill with new slushing oil. Clean the oil Work Cards, Classified by Subjects
chamber when changing oil.
To drain water from the compressed air filter at the compressed air regulator
(C) remove the side plate and screw in the screw plug by a few turns, so
that water can drain out. Tighten locking bolt afterwards. See manufactur-
er's manual.
In the case of operating faults
Compressed air part 1. High-pressure pump works only at a pressure of > 1.5 ... 2 bar
Reason: Friction of the control slide seal too high
2007-04-25

Remedy: Lubricate or renew O-ring seals on the pilot valve

General

6682 009.03-05 EN 3 (6)

009.03 MAN Diesel & Turbo

2. The pump does not run or runs only very slowly

Hydraulic tensioners/High-pressure pump

Reason 1: Compressed air system leaking

Remedy: Replace O-ring seal
Reason 2: Venting system frozen up
Remedy: Heat the high-pressure pump to approx. 20 °C
3. The pump does not generate any pressure, or remains at dead centre
Reason: Air system frozen up or functional problem
Remedy: Renew O-ring seals on the pilot valve or air piston
4. Condensate escaping from silencer of the vent
Reason: Compressed air filter full of water
Remedy: Drain the compressed air filter
Hydraulic part 1. Pump working but not feeding
Reason 1: Air in suction pipe
Remedy: Vent the hydraulic system
Reason 2: Suction filter choked
Remedy: Clean suction filter
2. Hydraulic oil escaping from the silencer
Reason: Piston seal worn and leaking
Remedy: Renew seal
Work Cards, Classified by Subjects

2007-04-25
General

4 (6) 6682 009.03-05 EN

 MAN Diesel & Turbo 009.03

1 Oil filler neck with basket strainer 6 Hose connection (compressed

Hydraulic tensioners/High-pressure pump
Work Cards, Classified by Subjects
air)
2 Set of wear parts 7 Compressed air pressure gauge
3 Oil pressure gauge A Shut-off valve
4 Hose connection (tensioner) B Relief valve
5 Oil level indicator C Pressure regulating valve
Figure 1: High-pressure pump, by GERUS, type HP25
2007-04-25

General

6682 009.03-05 EN 5 (6)

009.03 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump

A Shut-off valve C Pressure regulating valve

B Relief valve
Figure 2: Functional diagram of the high-pressure pump
Work Cards, Classified by Subjects

2007-04-25
General

6 (6) 6682 009.03-05 EN

 MAN Diesel & Turbo 009.05

High-pressure hoses

Hydraulic tensioners/High-pressure pump

use

Summary
Impart the necessary knowledge, ensure safe use (of high-pressure tools).
High-pressure hoses are required for connecting the hydraulic tensioners
to the high-pressure pump. They transmit high pressure.
Information is imparted concerning: Proper use/application and pressuris-
ing the non-return valve.
Tools/aids required
Quantity Designation Number Status
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

Make-up
For the connection of the high-pressure pump with hydraulic tensioner,
special pressure-resistant hose pipes are used. They consist of a steel wire-
braided plastic interior hose and an external protective hose, which will
catch the emerging fluid jet in the case of leakage.
Permitted operating pressure:
with constant load 1500 bar
with sudden load 900 bar
Minimum burst pressure 3,300 bar

Use Work Cards, Classified by Subjects

For the connection of the high pressure pump there are quick-acting cou-
plings on both sides, which have to be secured with an additional threaded
ring against unintentional loosening. After the coupling is engaged, the cor-
rugated threaded ring must be screwed up to the stop.

Observe safety instructions in Work Card 000.33! Consider the maximum

usability quoted by the manufacturer.
2009-07-20

Opening the check valve After the use of high pressure hoses, i.e. after switching off the high pressure
pump and opening the release valve, the hoses must remain connected for
General

approx. 3 minutes. Otherwise internal pressure may remain, which would

block the hose coupling. Under certain circumstances the hose cannot be
re-connected to the coupling. In this case, open the check valve with the

6682 009.05-01 EN 1 (2)

009.05 MAN Diesel & Turbo

opener (009.026) (see Fig. 2). Other tools must not be used, since damage
Hydraulic tensioners/High-pressure pump

could occur.
The high pressure hoses are equipped with check valves on both sides. This
stops them from leaking when in storage.

Figure 1: High pressure hose with mounted opener (bottom left)

Hydraulic nipple on the high pres-

1
sure hose
2 Threaded piece for clamping
3 Threaded piece to open the valve

Figure 2: Using the opener

Work Cards, Classified by Subjects

2009-07-20
General

2 (2) 6682 009.05-01 EN

 MAN Diesel & Turbo 009.07

Hydraulic tensioner

Hydraulic tensioners/High-pressure pump

use

Summary
Impart the necessary knowledge, ensure adequate application. Hydraulic
tensioners are used for extending bolts with respect to the components to
be connected. In this condition, nuts can be tightened or loosened without
applying force. The piston is pressed back into the initial position by the cup
springs.
The work/work steps include: Releasing and tensioning.
Tools/aids required
Quantity Designation Number Status
1 Hydraulic tensioner 009.347 Standard
1 Hydraulic tensioner 009.346 Standard
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic tensioner 009.208 Standard
1 Open-jaw wrench 55 000.570 Standard
1 Tommy bar, 6 000.261 Standard

Corresponding Work Cards

Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.08

Technical data
Designation Information
Effective stroke 3,5 mm
Test pressure 1050 bar
Work Cards, Classified by Subjects
Nominal pressure 1000 bar
Tool number 009.208 009.346/009.347
Effective piston area 2 x 20,23 = 40,46 cm²

Preliminary remark
The screw is elongated with respect to the components to be connected by
using pistons and casing of the hydraulic tensioner, supplemented with the
thrust piece and tension nut. This is carried out by pressing slushing oil
2008-06-19

behind the piston using the high-pressure pump. When the pressure is high
enough, the bolt nut is accessible and can be releaseed or adjusted accord-
General

ing to specifications.

6682 009.07-01 EN 1 (5)

009.07 MAN Diesel & Turbo

Hydraulic tensioners, like high-pressure hoses, must be completely filled

Hydraulic tensioners/High-pressure pump

with slushing oil before use. They must be bled if necessary. A leak test
should be carried out occasionally (see Work Card 009.08).
Work sequence 1 - Releasing a bolt
Starting position The screw thread is cleaned.

Work steps 1. Place pressure pad (4) over the nut (6).

2. Check with an open-jaw wrench (000.570) whether the tension nut (3) is
screwed tightly on the hydraulic tensioner (1).
3. Screw the hydraulic tensioner (1) onto bolt (7), ensuring that thrust piece
(4) is centred. See Fig. 1.

Insert tommy bar in the hole (B) for screwing on.

4. After application, turn back the hydraulic tensioner (1), including the
tensioning nut (3) by the reverse turning angle applicable to each of the
threaded connections (see Work Card 000.30). See Fig. 1.
5. Connect high-pressure hose to hydraulic tensioner (1) and high-pres-
sure pump.
6. Set high-pressure pump in operation (see Work Card 009.03) and close
the gap (A) that resulted from the turning back.

When releasing, ensure that no one is in the extended axis of the bolt to
be released!

7. Pump the hydraulic tensioner (1) until the nut (6) can be released.

The pressure must be max. 7% below or max. 5% above the tensioning

pressure (see Work Cards 000.30)!
Work Cards, Classified by Subjects

8. Using a tommy bar (5), turn back the nut (6) through the cut-out in the
thrust piece (4) (turn-back angle see Work Card 000.30).
9. Release the pressure, uncouple the high pressure hose from hydraulic
tensioner (1) and high pressure pump.

The hydraulic tensioner returns to the zero position automatically by a

set of cup springs (2) (reset duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
2008-06-19

open (see Work Card 009.03).

10. Remove tensioner.

General

2 (5) 6682 009.07-01 EN

 MAN Diesel & Turbo 009.07

Preliminary remark

Hydraulic tensioners/High-pressure pump

The screw is elongated with respect to the components to be connected by
using pistons and casing of the hydraulic tensioner, supplemented with the
thrust piece and tension nut. This is carried out by pressing slushing oil
behind the piston using the high-pressure pump. When the pressure is high
enough, the bolt nut is accessible and can be releaseed or adjusted accord-
ing to specifications.
Hydraulic tensioners, like high-pressure hoses, must be completely filled
with slushing oil before use. They must be bled if necessary. A leak test
should be carried out occasionally (see Work Card 009.08).
Work sequence 2 - Tightening a bolt
Starting position Nut is screwed on and tightened hand-tight. The screw thread is cleaned.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Place pressure pad (4) over the nut (6).

2. Check with an open-jaw wrench (000.570) whether the tension nut (3) is
screwed tightly on the hydraulic tensioner (1).
3. Screw the hydraulic tensioner (1) onto bolt (7), ensuring that thrust piece
(4) is centred. See Fig. 2.

Insert tommy bar in the hole (B) for screwing on.

4. Connect high-pressure hose to hydraulic tensioner (1) and high-pres-

sure pump.
5. Set high-pressure pump in operation (see Work Card 009.03) and ten-
sion the screw (7) with specified clamping pressure (see Work Card
000.30). Work Cards, Classified by Subjects
When tightening, ensure that no one is in the extended axis of the bolt
to be tightened!

6. Using a tommy bar (5) tighten the nut (6) hand-tight through the cut-out
in the thrust piece (4).
7. Release the pressure, separate the high-pressure hose from the
hydraulic tensioner (1) and the high-pressure pump.
2008-06-19

The hydraulic tensioner returns to the zero position automatically by a

General

set of cup springs (2) (reset duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

6682 009.07-01 EN 3 (5)

009.07 MAN Diesel & Turbo

8. Remove tensioner.
Hydraulic tensioners/High-pressure pump

1 Hydraulic tensioner
2 Cup spring
3 Tension nut
4 Thrust piece
5 Tommy bar
6 Nut
7 Bolt
A Gap
B Hole for tommy bar

Figure 1: Release the screw with attached tensioner (figure shows hydraulic
tensioner with tool number 009.346)
Work Cards, Classified by Subjects

2008-06-19
General

4 (5) 6682 009.07-01 EN

 MAN Diesel & Turbo 009.07

Hydraulic tensioners/High-pressure pump

1 Hydraulic tensioner
2 Cup spring
3 Tension nut
4 Thrust piece
5 Tommy bar
6 Nut
7 Bolt
B Hole for tommy bar

Figure 2: Tension the screw by using attached tensioner (figure shows hydraulic
tensioner with tool number 009.346)

Work Cards, Classified by Subjects

2008-06-19

General

6682 009.07-01 EN 5 (5)

 MAN Diesel & Turbo 009.08

Hydraulic tensioner

Hydraulic tensioners/High-pressure pump

dismantling and assembling

Summary
Impart the necessary knowledge, ensure the correct execution of the work.
Hydraulic tensioners must be completely filled with hydraulic fluid when
used. They must be bled, if necessary, and checked for leakage occasion-
ally. If they leak, the sealing rings must be replaced.
The work/work steps include:
Bleeding,
checking for tightness,
disassembling and assembling and
renewing sealing rings/sealing elements.
Tools/aids required
Quantity Designation Number Status
1 Hydraulic tensioner 009.347 Standard
1 Hydraulic tensioner 009.346 Standard
1 High-pressure pump 009.342 Standard
1 High-pressure pump 009.338 Standard
1 High-pressure hose 009.306 Standard
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 Standard
1 Hexagon screw driver 12 000.299 Standard
1 Tools, Basic Scope 009.229 Standard
1 Slushing oil - Inventory
1 Molecular gold grease (anti-seize agent) - Inventory

Corresponding Work Cards Work Cards, Classified by Subjects

Work card Work card Work card
000.30 000.33 009.03
009.05 009.07

Tool No./Spare Part No.

No. Designation Tool No. Tool No.
- Hydraulic tensioner, complete 009.346 009.347
2007-04-23

1 Hydraulic nipple 009.346-1 009.347-1

2 Sealing ring 009.346-2 009.347-2
General

3 Threaded piece 009.346-3 009.347-3

4 Nut 009.346-16 009.347-25

6682 009.08-01 EN 1 (7)

009.08 MAN Diesel & Turbo

No. Designation Tool No. Tool No.

Hydraulic tensioners/High-pressure pump

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 Cup 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 remark
Hydraulic tensioners, like high-pressure hoses, must be completely filled
with slushing oil before use. They must be bled if necessary. Check for
leakage occasionally.
The hydraulic tensioner must be completely disassembled if backing rings /
O-ring seals are to be renewed and if there are damages. When dismantling,
all the backing rings /O-ring seals should be renewed. Due to the high working
pressures and the critical clearances and surfaces, please be warned about any
advanced interventions/ repairs. We recommend that the device be overhauled
by MAN Diesel & Turbo SE or an authorised service facility.
Work Sequence 1 - Dismantling the Hydraulic tensioner
Starting position Hexagon screwdriver is clamped in the vice.

Work steps 1. Place the piston (9) on clamped hexagon screwdriver (000.299).

2. Release and unscrew the tension nut (16) using open-jaw wrench
(000.570).
3. Remove cup springs (8).
Work Cards, Classified by Subjects

4. Connect high-pressure hose (009.306) to hydraulic tensioner.

5. Open non-return valve on high-pressure hose with push-on fixture
(009.026) (see Work Card 009.05).

If non-return valves are not open, the casing (7) cannot be extracted.

6. Remove casing (7).

2007-04-23

7. Uncouple hydraulic hose from hydraulic nipple (1).

General

8. Fit piston (9) on clamped hexagon screwdriver.

9. Loosen and unscrew the nut (4) using an open-jaw wrench (000.568).

2 (7) 6682 009.08-01 EN

 MAN Diesel & Turbo 009.08

Screwed connection of nut and piston has a left-hand thread!

Hydraulic tensioners/High-pressure pump

10. Remove the sealing ring (15).
11. Pull out piston (5) and casing (6).
12. Thread eye bolt (001.404) into piston (5) and detach it from the casing
(6).
13. Remove backing rings (11 and 13) and O-ring seals (12 and 14).
14. Clean all individual parts and check for damage and replace if neces-
sary.
15. Blow oil bores in the piston (9) out with compressed air.

Work sequence 2 - Assembling the hydraulic tensioner

Starting position All individual parts are cleaned and checked for damage or renewed if nec-
essary. Hexagon screwdriver clamped in a vice.
Work steps 1. Check new backing rings (11 and 13) and O-ring seals (12 and 14) for
integrity.
2. Apply backing rings (13) and O-ring seals (14) with slushing oil and place
in the appropriate grooves, ensuring that they are tensioned uniformly
over the entire periphery and not twisted. See Fig. 1.

Ensure proper position of backing ring and O-ring seal! O-ring seal
always on pressure side, backing ring on the other side, trough in the
backing ring pointing to O-ring seal! Refer to figure 1/Detail "Y" and "Z".

3. Apply slushing oil to backing rings (11) and place them in the appropriate
grooves.
4. Apply slushing oil oil to O-ring seals (12), press them together to a kidney
shape and place in appropriate grooves, ensuring that they are not twis-
ted. See Figs. 1 and 3.
Work Cards, Classified by Subjects
Ensure proper position of backing ring and O-ring seal! O-ring seal
always on pressure side, backing ring on the other side, trough in the
backing ring pointing to O-ring seal! Refer to figure 1/Detail "X" and "Z".

5. Apply a thin coat of Molecular Gold-Grease anti-seize agent to the run-

ning surface of piston (5 and 9) and casing (6 and 7).

Backing rings, O-ring seals and grooves must remain free!

2007-04-23

General

6. Press piston (5) into casing (6).

7. Set casing (6) and piston (5) together on the piston (9) and push them
on.

6682 009.08-01 EN 3 (7)

009.08 MAN Diesel & Turbo

8. Place the piston (9) on clamped hexagon screwdriver (000.299).

Hydraulic tensioners/High-pressure pump

9. Place new sealing ring (15) on piston (9). See Fig. 1.

10. Screw the nut (4) onto the piston (9) up to the stop and tighten with open-
jaw wrench (000.568).

Screwed connection of nut and piston has a left-hand thread!

11. Connect high-pressure hose (009.306) to hydraulic nipple (1).

12. Open non-return valve on high-pressure hose with push-on fixture
(009.026) (see Work Card 009.05).

If non-return valves are not open, the casing (7) cannot be fitted.

13. Fit the casing (7) up to the stop on piston (9). See Fig. 1.
14. Disconnect high-pressure hose from the hydraulic tensioner.
15. Assemble cup springs (8), ensuring the correct sequence. See Fig. 1.
16. Screw tension nut (16) onto piston (9) and tighten it by hand.
17. Set piston (9) on clamped hexagon screwdriver and screw on tension
nut (16) using an open-jaw wrench (000.570) until it fits in position. See
Fig. 2.

Cup springs must be compressed a little.

18. Attach hydraulic tensioner to a suitable bolt (see corresponding Work

Card) such that hydraulic nipple (1) points upwards.
19. Connect high-pressure hose to hydraulic tensioner and high-pressure
pump (009.338).
Work Cards, Classified by Subjects

20. Put high-pressure pump in operation (see Work Card 009.03) and pump
the hydraulic tensioner.

Make sure that the specified clamping pressure of the selected bolt is
not exceeded (see Work Card 000.30)!

21. Release the pressure.

2007-04-23
General

4 (7) 6682 009.08-01 EN

 MAN Diesel & Turbo 009.08

The hydraulic tensioner returns to the zero position automatically by the

Hydraulic tensioners/High-pressure pump

set of cup springs (resetting duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).
When resetting the piston by the cup springs, existing air escapes
through the high-pressure hose.

22. Disconnect high-pressure hose.

23. Vent high-pressure hose with push-on fixture (see Work Card 009.05).
24. Connect high-pressure hose again.
25. Pump hydraulic tensioner up to the tensioning pressure specified for this
bolt (see Work Card 000.30). Hold pressure for five minutes.

After pumping up the hydraulic tensioner, no visible leakage should arise

within this period.

26. Release pressure, uncouple high-pressure hose from hydraulic ten-

sioner and high-pressure pump.
27. Remove tensioner.

Work Cards, Classified by Subjects

2007-04-23

General

6682 009.08-01 EN 5 (7)

009.08 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump

1 Hydraulic nipple 9 Piston

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

7 Casing
Work Cards, Classified by Subjects

8 Cup spring
9 Piston
10 Tension nut

Figure 2: Hydraulic tensioner with tension nut screwed on

2007-04-23
General

6 (7) 6682 009.08-01 EN

 MAN Diesel & Turbo 009.08

Hydraulic tensioners/High-pressure pump

Figure 3: Kidney-shaped compression of a O-ring seal

Work Cards, Classified by Subjects

2007-04-23

General

6682 009.08-01 EN 7 (7)

 MAN Diesel & Turbo 009.13

Hydraulic tensioner (single-)

Hydraulic tensioners/High-pressure pump

use

Summary
Impart the necessary knowledge, ensure adequate application. Hydraulic
tensioners are used for undercut bolts with respect to the components to
be connected. In this condition, nuts can be tightened or loosened without
applying force.
The work/work steps include: Releasing and tensioning.
Tools/aids required
Quantity Designation Number Status
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic tensioner 009.079 Standard
1 Hydraulic tensioner 009.063 Standard
1 Hydraulic tensioner 009.062 Standard
1 Hydraulic tensioner 009.053 Standard
1 Tommy bars (set) - Standard

Corresponding Work Cards

Work card Work card Work card
000.30 000.33 009.03
009.05 009.14

Technical data
Designation Information
Tool No. 009.053 48/60;48/60B;48/60CR;L40/54;51/60DF
effective piston area (cm²) 115,40
Work Cards, Classified by Subjects
Effective stroke (mm) 8
Nominal pressure (bar) 1400
Test pressure (bar) 1500
Thread size A (mm) M56x4
Outside diameter B (mm) 192
Height C (mm) 97

Technical data
2010-01-07

Designation Information
Tool No. 009.062
effective piston area (cm²) 130,18
Effective stroke (mm) 8

6644 009.13-01 EN 1 (6)

009.13 MAN Diesel & Turbo

Designation Information
Hydraulic tensioners/High-pressure pump

Nominal pressure (bar) 1200

Test pressure (bar) 1250
Thread size A (mm) M56x4
Outside diameter B (mm) 200
Height C (mm) 97

Technical data
Designation Information
Tool No. 009.063
effective piston area (cm²) 122,52
Effective stroke (mm) 8
Nominal pressure (bar) 1500
Test pressure (bar) 1600
Thread size A (mm) M64x4
Outside diameter B (mm) 200
Height C (mm) 97

Technical data
Designation Information
Tool No. 009.079
effective piston area (cm²) 226,78
Effective stroke (mm) 12
Nominal pressure (bar) 1400
Test pressure (bar) 1500
Thread size A (mm) M90x4
Outside diameter B (mm) 285
Height C (mm) 145
48/60;48/60B;48/60CR;L40/54;51/60DF

Preliminary remark
Work Cards, Classified by Subjects

The bolt is extended with respect to the component to be fixed using the
piston and casing of the hydraulic tensioner, supplemented by a thrust
piece. This is carried out by pressing slushing oil behind the piston using
the high-pressure pump. When the pressure is high enough, the bolt nut is
accessible and can be releaseed or adjusted according to specifications.
Hydraulic tensioners, like high-pressure hoses, must be completely filled
with slushing oil before use. They must be bled if necessary. A leak test
should be carried out occasionally (see Work Card 009.14).
2010-01-07

Work sequence 1 - Releasing a bolt

Starting position The screw thread is cleaned.

Work steps 1. Place pressure piece (3) over nut (4).

2 (6) 6644 009.13-01 EN

 MAN Diesel & Turbo 009.13

2. Screw the hydraulic tensioning tool (1) onto the screw (5), ensuring that

Hydraulic tensioners/High-pressure pump

the pressure pad (3) is centred by the hydraulic tensioning tool.
3. Turn the hydraulic tensioning tool (1) back by the reset angle (see Work
Card 000.30). See Figs. 1 and 2.
4. Connect high pressure hose (009.306) to hydraulic tensioner (1) and
high-pressure pump (009.342).
5. Set high-pressure pump in operation (see Work Card 009.03) and close
the gap (A) created by turning back.

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

6. Pump the hydraulic tensioning tool (1) until the nut (4) can be released.

Pressure/tensioning pressure
In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

Do not damage the hydraulic tensioning tool!

Observe the stroke monitors (6) on the hydraulic tensioner whilst
pumping! The hydraulic tensioner may be pumped up only until markings
(M) on the stroke controls reach the top edge of the thread stop ring (7)!
Otherwise the hydraulic tensioner will be damaged! See Fig. 3.

7. Using a tommy bar (2), turn back the nut (4) through the cut-out in the
pressure piece (3) (turn-back angle see Work Card 000.30).
8. Release the pressure, uncouple the high pressure hose from hydraulic
tensioner (1) and high pressure pump.
48/60;48/60B;48/60CR;L40/54;51/60DF
The hydraulic tensioner returns to the zero position automatically by the
compression springs (resetting duration about 2 to 3 minutes). However, Work Cards, Classified by Subjects
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

9. Remove tensioner.

Work sequence 2 - Tightening a bolt

Starting position Nut is screwed on and tightened hand-tight. The screw thread is cleaned.

Correct tightening of a bolted connection!

2010-01-07

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Place pressure piece (3) over nut (4).

6644 009.13-01 EN 3 (6)

009.13 MAN Diesel & Turbo

2. Screw the hydraulic tensioning tool (1) onto the screw (5), ensuring that
Hydraulic tensioners/High-pressure pump

the pressure pad (3) is centred by the hydraulic tensioning tool. See Fig.
4.
3. Connect high pressure hose (009.306) to hydraulic tensioner (1) and
high-pressure pump (009.342).
4. Set high pressure pump in operation (see Work Card 009.03) and ten-
sion the screw (5) with specified tensioning pressure (see Work Card
000.30).

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

Do not damage the hydraulic tensioning tool!

Observe the stroke monitors (6) on the hydraulic tensioner whilst
pumping! The hydraulic tensioner may be pumped up only until markings
(M) on the stroke controls reach the top edge of the thread stop ring (7)!
Otherwise the hydraulic tensioner will be damaged! See Fig. 3.

5. Using a tommy bar (2) tighten the nut (4) hand-tight through the cut-out
in the pressure piece (3).
6. Release the pressure, uncouple the high pressure hose from hydraulic
tensioner (1) and high pressure pump.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

7. Remove tensioner.
48/60;48/60B;48/60CR;L40/54;51/60DF
Work Cards, Classified by Subjects

2010-01-07

4 (6) 6644 009.13-01 EN

 MAN Diesel & Turbo 009.13

Hydraulic tensioners/High-pressure pump

1 Hydraulic tensioning tool 6 Stroke monitor
2 Tommy bar 7 Thread stop ring
3 Thrust piece A Gap
4 Nut M Marking on stroke monitor
5 Bolt
Figure 1: Releasing the screw with tensioner attached

48/60;48/60B;48/60CR;L40/54;51/60DF
Work Cards, Classified by Subjects

3 Thrust piece A Gap

Figure 2: Release screw with attached tensioner (position of the gap (A) for horizontal or suspended tensioner)
2010-01-07

6644 009.13-01 EN 5 (6)

009.13 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump

6 Stroke monitor
7 Thread stop ring
M Marking on stroke monitor

Figure 3: Position of the mark on the stroke monitor at max. stroke of the
hydraulic tensioner
48/60;48/60B;48/60CR;L40/54;51/60DF

1 Hydraulic tensioning tool 5 Bolt

2 Tommy bar 6 Stroke monitor
Work Cards, Classified by Subjects

3 Thrust piece 7 Thread stop ring

4 Nut M Marking on stroke monitor
Figure 4: Tensioning of screw with tensioner attached
2010-01-07

6 (6) 6644 009.13-01 EN

 MAN Diesel & Turbo 009.14

Hydraulic tensioner (single-)

Hydraulic tensioners/High-pressure pump

dismantling and assembling

Summary
Impart necessary knowledge, ensure correct execution of work. Hydraulic
tensioner must be filled completely with hydraulic fluid when in use. They
must be bled, if necessary, and checked for leakage occasionally. If they
leak, the sealing rings must be replaced.
The work/work steps include: Venting, Checking for leakages, Dismantling
and assembly, and renewing sealing rings/seal elements.
Tools/aids required
Quantity Designation Number Status
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Set of tools 009.134 Standard
1 Insert 22x12.5 009.134-3 Standard
1 Insert 19x12.5 009.134-4 Standard
1 Side cutter 009.134-10 Standard
1 Screwdriver 1x6.5 009.134-12 Standard
1 Screwdriver 1.2x8 009.134-13 Standard
1 Scriber 009.134-16 Standard
1 Hammer (wood/plastic-) 009.134-18 Standard
1 Mandrel 009.134-25 Standard
1 Extractor 009.134-26 Standard
1 Strip (Nylon) 009.134-27 Standard
1 Opener 009.026 Standard
1 Extension piece 12.5x125 001.911 Option
48/60;48/60B;48/60CR;L40/54;51/60DF
1 Cross handle 001.891 Standard
Work Cards, Classified by Subjects
1 Felt-tip pen/marker pen - Inventory
1 Screwdriver (Set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Belzona Antiseize (anti-seize agent) - Inventory
1 Slushing oil - Inventory

Corresponding Work Cards

Work card Work card Work card
2010-01-07

000.30 000.33 009.03

009.05 009.13

6644 009.14-01 EN 1 (8)

009.14 MAN Diesel & Turbo

Tool No./Spare Part No.

Hydraulic tensioners/High-pressure pump

No. Designation Tool No. Tool No. Tool No. Tool No.
– Hydraulic tensioner, complete 009,053 009,062 009,063 009,079
1* Quick-fitting coupling half 009053-3 009062-3 009063-3 009079-7
2* Double nipple 009053-12 009062-12 009063-12 009079-8
3 Piston 009053-2 009062-2 009063-2 009079-2
4 Stroke control 009053-16 009062-16 009063-16 009079-6
5 Threaded stop ring 009053-13 009062-13 009063-13 009079-3
6* O-ring seal 009053-7 009062-7 009063-7 009079-12
7* TURCON-Ring 009053-6 009062-6 009063-6 009079-11
8* O-ring seal 009053-5 009062-5 009063-5 009079-10
9* Valve ring 009053-4 009062-4 009063-4 009079-9
10 Casing 009053-1 009062-1 009063-1 009079-1
11 sealing screw on distribution block 009053-15 009062-15 009063-15 009079-17
12* Compression spring 009053-14 009062-14 009063-14 009079-16
13 Set screw 009053-18 009062-18 009063-18 009079-19
14 Lock screw, for measuring gauge 009053-17 009062-17 009063-17 009079-18
connection
– Lifting eye bolt M12 — —— — — —— — — —— — 009079-22
– Protection cap 009053-19 009062-19 009063-19 009079-23
– Set of spare parts 009,099 009,101 009,101 009,136
* together with spare parts packet

Preliminary remark
Hydraulic tensioners, like high-pressure hoses, must be completely filled
with slushing oil before use. They must be bled if necessary. Check for
leakage occasionally.
The hydraulic tensioner must be completely dismantled if their TURCON
48/60;48/60B;48/60CR;L40/54;51/60DF

ring /valve rings/ O-ring seals need to be renewed and if there is damage.
Work Cards, Classified by Subjects

In the event of a strip-down, the TURCON ring/ valve rings/ O-ring seals
must be renewed as appropriate. Due to the high working pressures and
the critical Clearances and surfaces, additional repair measures and inter-
ventions are not recommended. We recommend that you have the fixture
overhauled, if necessary, by MAN Diesel & Turbo SE, or one of the author-
ised Service establishments.
Work Sequence 1 - Dismantling the Hydraulic tensioner
Work steps 1. Mark position of casing/threaded stop ring/piston (10, 5 and 3).
2010-01-07

2. Unscrew locking bolts (11) and remove compression springs (12).

3. Remove stroke controls (4) using the extractor (009.134-26). See Fig. 2.
4. Remove protection cap from quick-fitting coupling half (1).

2 (8) 6644 009.14-01 EN

 MAN Diesel & Turbo 009.14

5. Clamp hydraulic tensioner in a vice (23), using protection jaws (22) and

Hydraulic tensioners/High-pressure pump

mandrel (009.134-25). See Fig. 3.
6. Unscrew quick-fitting coupling half (1), unscrew double nipple (2).
7. Remove hydraulic tensioner from vice.
8. Unscrew set screw (13).
9. Unscrew threaded stop ring (5) by hand, turn it back a little to prevent
jamming.

If there is resistance, stop turning the threaded stop ring, release by

means of light hammering with plastic hammer (009.134-18)!

10. Knock out piston (3) from the casing (10) using a plastic hammer.
11. Cut off and remove valve rings (9) and TURCON ring (7) using a side
cutter (009.134-10).
12. Remove O-ring seals (6 and 8) by using scriber (009.134-16).
13. Clean all individual parts and check for damage and replace if neces-
sary.

Work sequence 2 - Assembling the hydraulic tensioner

Starting position All individual parts cleaned and checked for damage or renewed.

Work steps 1. Check new O-rings (6 and 8) for integrity.

2. Apply anti-corrosion oil to the running surface on piston (3) and O-ring
(6).
3. Place O-ring (6) in the relevant groove, making sure that it is uniformly
clamped around the entire periphery and is not twisted.
4. Press O-rings (8) to a kidney shape and place in the appropriate groove,
ensuring that they are not twisted. See Fig. 4.
5. Put new valve rings (9) in boiling water for five minutes, remove them,
dry them, press them into kidney shape and insert into appropriate
48/60;48/60B;48/60CR;L40/54;51/60DF
groove. Work Cards, Classified by Subjects
Danger of scalding by boiling water!
Do not use your bare hands to place valve rings into boiling water or to
take them out! Danger of scalding!

Observe installation position!

Ensure the correct assembly position when assembling the valve rings,
groove on pressure side. See figure 1 / Detail X.
2010-01-07

6. Clamp piston (3) in vice (23), use protection jaws (22) for this purpose.
7. Put new TURCON Ring (7) in boiling water for five minutes, take it out
and dry it off. Insert TURCON-Ring on one side of the piston (3) in the
appropriate groove as far as possible, place strips (009.134-27) at a

6644 009.14-01 EN 3 (8)

009.14 MAN Diesel & Turbo

spacing of about 120° around the TURCON Ring. Pull the TURCON Ring
Hydraulic tensioners/High-pressure pump

over the piston edge into the groove carefully using the strip. Remove
strip. See Fig. 5.

Danger of scalding by boiling water!

Do not use your bare hands to place TURCON ring in boiling water or to
take them out! Danger of scalding!

8. Compress TURCON-Ring (7) back into original shape.

Returning TURCON ring to original shape

The TURCON ring is stretched during assembly. To bring the TURCON
ring back to its original shape, press it into the groove using a round
wooden rod or hammer shank. See Fig. 6.

9. Apply anti-seize agent Belzona Antiseize to the running face of piston

(3) and housing (10).
10. Place piston (3) on housing (10), check the alignment of the marking
piston/housing (work sequence 1, Point 1) and press piston into housing
or drive it in using a soft-faced hammer (009.134-18).
11. Screw the thread stop ring (5) into housing (10), until the top of the thread
stop ring is flush with the top of the housing, turn back a little to prevent
tilting.

Resistance during turning

If there is resistance, stop turning, release by means of light hammering
with soft-faced hammer (009.134-18)!

12. Screw threaded pin (13) in.

13. Check alignment of the holes for stroke monitors (4) between housing
(10) and thread stop ring (5).
14. Drive in stroke controls (4) until top of the stroke control is flush with the
top of the thread stop ring (5). See figure 1 / Detail Y.
48/60;48/60B;48/60CR;L40/54;51/60DF

15. Insert compression springs (12) into the holes, screw in locking screws
(11), until top of the locking screw is flush with top of the thread stop
Work Cards, Classified by Subjects

ring (5). Refer to figure 1/section K-K.

16. Clamp hydraulic tensioner in a vice (23), using protective jaws (22) and
mandrel (009.134-25). See figure 3. See Fig. 3.
17. Thread in double nipple (2) into piston (3) and tighten.
18. Screw on quick acting coupling half (1) on double nipple (2) and tighten.
19. Remove hydraulic tensioner from vice (23).
20. Mount hydraulic tensioning tool on a suitable bolt (see relevant Work
2010-01-07

Card) in such a way that the quick-fit coupling half (1) points upwards.
21. Connect high pressure hose (009.306) to hydraulic tensioner and high
pressure pump (009.342).
22. Put high pressure pump in operation (see Work Card 009.03) and pump
the hydraulic tensioner.

4 (8) 6644 009.14-01 EN

 MAN Diesel & Turbo 009.14

Danger area in axial direction!

Hydraulic tensioners/High-pressure pump

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

Tensioning pressure
Make sure that the specified tensioning pressure of the selected bolt is
not exceeded (see Work Card 000.30)!

23. Release the pressure.

Automatic reset of piston of hydraulic tensioning tool

The hydraulic tensioner returns to the zero position automatically by the
compression springs (resetting duration about 2 to 3 minutes). However,
the high pressure pump must be connected, and its release valve must
be open (see Work Card 009.03).

24. Disconnect high pressure hose. Vent high pressure hose with clamping
fixture (009.026) (see Work Card 009.05).
25. Connect high pressure hose again.
26. Pump hydraulic tensioner up to the tensioning pressure specified for this
bolt (see Work Card 000.30). Hold pressure for five minutes.

Check for leaks

After pumping up the hydraulic tensioning tool, no visible leaks should
arise within this period.

27. Release pressure, uncouple high pressure hose from hydraulic ten-
sioner and high pressure pump.
28. Remove tensioner.
48/60;48/60B;48/60CR;L40/54;51/60DF
29. Fit protective cap on quick-fit coupling half (1).
Work Cards, Classified by Subjects
2010-01-07

6644 009.14-01 EN 5 (8)

009.14 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump

1 Quick-fit coupling half 10 Housing

2 Double nipple 11 Screw plug
3 Piston 12 Pressure spring
4 Stroke monitor 13 Set screw
5 Thread stop ring 14 Screw plug
6 O-ring A Thread size
48/60;48/60B;48/60CR;L40/54;51/60DF

7 TURCON ring B Outside diameter

8 O-ring C Height
Work Cards, Classified by Subjects

9 Valve ring M Marking on stroke monitor

Figure 1: Hydraulic tensioning tool
2010-01-07

6 (8) 6644 009.14-01 EN

 MAN Diesel & Turbo 009.14

Hydraulic tensioners/High-pressure pump

Figure 2: Dismantling the stroke monitor

48/60;48/60B;48/60CR;L40/54;51/60DF
Work Cards, Classified by Subjects
2010-01-07

21 Hydraulic tensioning tool

22 Protective jaws
23 Vice
Figure 3: Clamping the hydraulic tensioner in the vice

6644 009.14-01 EN 7 (8)

009.14 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump

Figure 4: Kidney-shaped compression of a ring

3 Piston
7 TURCON ring
20 Strip

Figure 5: Installing the TURCON ring on the piston

3 Piston
6 O-ring
7 TURCON ring
Round wooden rod or hammer
24
shank
48/60;48/60B;48/60CR;L40/54;51/60DF
Work Cards, Classified by Subjects

Figure 6: Pressing TURCON ring in the end position (left before pressing in,
right after pressing in)
2010-01-07

8 (8) 6644 009.14-01 EN

 MAN Diesel & Turbo 009.15

Measuring gauge (measuring device)

Hydraulic tensioners/High-pressure pump

checking the screw elongation

Summary
Clamping and releasing important threaded connections to the correct val-
ues, ensure correct execution of work. The measuring device is used to
determine the screw elongation compared with a reference value. This
should ensure that particularly important screws are tightened correctly by
using hydraulic tensioners.
The work/work steps include: Correct use/application and measuring the
elongation.
Tools/aids required
Quantity Designation Number Status
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic tensioner 009.079 Standard
1 Hydraulic tensioner 009.063 Standard
1 Hydraulic tensioner 009.062 Standard
1 Hydraulic tensioner 009.053 Standard
1 Measuring device 009.052 Standard
1 Measuring gauge (measuring device) 009.052-1 Standard
1 Extension 009.052-2 Standard
1 Extension 009.052-3 Standard
1 Threaded piece 009.052-4 Standard
1 Screwdriver (Set) - Inventory
1 Hexagon screwdriver (set) - Inventory

Corresponding Work Cards 48/60;48/60B;48/60CR;L40/54;51/60DF

Work card Work card Work card Work Cards, Classified by Subjects
000.30 000.33 009.03
009.05 009.13

Preliminary remark
In case of threaded connections, which are clamped hydraulically, meas-
urement of the screw elongation against a reference value is particularly
important. This is to ensure that the necessary pretension actually exists in
the form of elongation of the screw and compression of the engine parts to
2010-01-07

be clamped. This is not guaranteed if the tensioner is blocked or the tension

pressure is partly or fully dissipated by friction.
Work sequence - Measuring the bolt elongation Δl
Starting position Nut is screwed on and tightened hand-tight. The screw thread is cleaned.

6644 009.15-01 EN 1 (4)

009.15 MAN Diesel & Turbo

Prerequisite for correct tightening of a bolted connection is a pressure

Hydraulic tensioners/High-pressure pump

gauge with an accurate read-out! If in doubt, test the pressure gauge

with a comparative pressure gauge!

Work steps 1. Unscrew locking screw (1) on hydraulic tensioner (3), screw the threaded
insert (009.052-4) into the thread stop ring (2). See Figs. 1 and 2.
2. Mount tensioner on bolt (see Work Card 009.13 or Work Card for the
individual bolt).
3. Screw the extension required (009.052-2 or -3) onto measuring gauge
(009.052-1).
4. Insert measuring gauge into threaded insert and fasten with set screw
(4).

Ensure that measuring pin of the measuring gauge rests on piston of the
hydraulic tensioner!

5. Connect high pressure hose (009.306) to hydraulic tensioner (3) and

high-pressure pump (009.342).
6. Set high pressure pump in operation (see Work Card 009.03) and ten-
sion screw with specified pre-stressing pressure (see Work Card
000.30).

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

7. Reset measuring gauge to "zero".

8. Tension the bolt to the specified final clamping pressure (see Work Card
48/60;48/60B;48/60CR;L40/54;51/60DF

000.30).
9. Tighten nut with tommy bar, hand-tight.
Work Cards, Classified by Subjects

10. Release the pressure.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

11. Tighten undercut bolt again with specified pretension pressure. Read
off screw elongation Δl on dial gauge, note and compare with required
2010-01-07

value (see Work Card 000.30).

Tighten undercut bolt with the specified tensioning pressure, not

according to the screw elongation Δl! The measurement of the screw
elongation Δl is only for checking!

2 (4) 6644 009.15-01 EN

 MAN Diesel & Turbo 009.15

If the deviations from the required value are high, repeat the clamping

Hydraulic tensioners/High-pressure pump

sequence and if necessary check hydraulic tensioner, threaded
connection and pressure gauge.

12. Release pressure, uncouple high-pressure hose from hydraulic ten-

sioner and high-pressure pump.
13. Dismantle dial gauge, remove tensioner.
14. Unscrew threaded insert and close off the threaded hole with a screw
plug (1).

48/60;48/60B;48/60CR;L40/54;51/60DF
Work Cards, Classified by Subjects

1 Screw plug
2 Thread stop ring
3 Hydraulic tensioning tool
2010-01-07

Figure 1: Hydraulic tensioning tool

6644 009.15-01 EN 3 (4)

009.15 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump

2 Thread stop ring

3 Hydraulic tensioning tool
4 Set screw M5x12
Figure 2: Hydraulic tensioning tool with measuring device attached
48/60;48/60B;48/60CR;L40/54;51/60DF
Work Cards, Classified by Subjects

2010-01-07

4 (4) 6644 009.15-01 EN

 MAN Diesel & Turbo 009.16

Hydraulic tensioner

Hydraulic tensioners/High-pressure pump

use

Summary
Impart the necessary knowledge, ensure adequate application. Hydraulic
tensioners are used for undercut bolts with respect to the components to
be connected. In this condition, nuts can be tightened or loosened without
applying force. The piston is pressed back into the initial position by the cup
springs.
The work/work steps include: Releasing and tensioning.
Tools/aids required
Quantity Designation Number Status
1 High-pressure pump 009.342 Standard
1 High-pressure pump 009.338 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic tensioner 009.056 Standard
1 Tommy bar, 12 000.264 Standard
1 Tommy bar, 10 000.263 Standard

Corresponding Work Cards

Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.17

Technical data
Designation Information
Tool No. 009.056
effective piston area (cm²) 97,2 + 120,8 = 218
Effective stroke (mm) 10
Work Cards, Classified by Subjects
Nominal pressure (bar) 1000
Test pressure (bar) 1100
Thread size A (mm) M80x4
Outside diameter B (mm) 172
Height C (mm) 396
L51/60DF;L48/60CR

Preliminary remark
2007-11-07

The screw is elongated with respect to the components to be connected by

using pistons and casing of the hydraulic tensioner, supplemented with the
thrust piece and tension nut. This is carried out by pressing slushing oil
behind the piston using the high-pressure pump. When the pressure is high
enough, the bolt nut is accessible and can be releaseed or adjusted accord-
ing to specifications.

6644 009.16-01 EN 1 (4)

009.16 MAN Diesel & Turbo

Hydraulic tensioners, like high-pressure hoses, must be completely filled

Hydraulic tensioners/High-pressure pump

with slushing oil before use. They must be bled if necessary. A leak test
should be carried out occasionally (see Work Card 009.17).
Work sequence 1 - Releasing a bolt
Starting position The screw thread is cleaned.

Work steps 1. Place pressure pad (4) over the nut (7).

2. Check with tommy bar (000.263) whether tension nut (3) is screwed
tightly on the hydraulic tensioner (1).
3. Screw the hydraulic tensioner (1) onto bolt (5), ensuring that thrust piece
(4) is centred. See Fig. 1.

Insert tommy bar (6) in hole (B) or use socket spanner to screw on the
hydraulic tensioner.

4. After screwing-on, turn back the hydraulic tensioner (1) including ten-
sioning nut by the unscrewing angle valid for each of the threaded con-
nections (see Work Card 000.30). See Fig. 1.
5. Connect high-pressure hose (009.306) to hydraulic tensioner and high-
pressure pump (009.338).
6. Set high-pressure pump in operation (see Work Card 009.03) and close
the gap (A) that resulted from the turning back.

When releasing, ensure that no one is in the extended axis of the bolt to
be released!

7. Pump the hydraulic tensioner (1) until the nut (7) can be released.

The pressure must be max. 7% below or 5% above the clamping

pressure (see Work Card 000.30)!
Work Cards, Classified by Subjects

8. Using a tommy bar (6), turn back the nut (7) through the cut-out in the
thrust piece (4) (turn-back angle see Work Card 000.30).
9. Release the pressure, uncouple the high-pressure hose from hydraulic
tensioner (1) and high-pressure pump.
L51/60DF;L48/60CR

The hydraulic tensioner returns to the zero position automatically by a

set of cup springs (2) (reset duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
2007-11-07

open (see Work Card 009.03).

10. Remove tensioner.

2 (4) 6644 009.16-01 EN

 MAN Diesel & Turbo 009.16

Work sequence 2 - Tightening a bolt

Hydraulic tensioners/High-pressure pump

Starting position Nut is screwed on and tightened hand-tight. The screw thread is cleaned.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Place pressure pad (4) over the nut (7).

2. Check with tommy bar (000.263) whether tension nut (3) is screwed
tightly on the hydraulic tensioner (1).
3. Screw the hydraulic tensioner (1) onto bolt (5), ensuring that thrust piece
(4) is centred. See Fig. 1.

Insert tommy bar (6) in hole (B) or use socket spanner to screw on the
hydraulic tensioner.

4. Connect high-pressure hose (009.306) to hydraulic tensioner and high-

pressure pump (009.338).
5. Set high-pressure pump in operation (see Work Card 009.03) and ten-
sion the screw (5) with specified clamping pressure (see Work Card
000.30).

When tightening, ensure that no one is in the extended axis of the bolt
to be tightened!

6. Using a tommy bar (6) tighten the nut (7) hand-tight through the cut-out
in the thrust piece (4).
7. Release the pressure, uncouple the high-pressure hose from hydraulic
tensioner (1) and high-pressure pump.

The hydraulic tensioner returns to the zero position automatically by a

Work Cards, Classified by Subjects
set of cup springs (2) (reset duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

8. Remove tensioner.
L51/60DF;L48/60CR
2007-11-07

6644 009.16-01 EN 3 (4)

009.16 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump
Work Cards, Classified by Subjects

1 Hydraulic tensioner 5 Bolt A Gap

2 Cup spring 6 Tommy bar B Hole for tommy bar ∅ 12
3 Tension nut 7 Nut C Hole for tommy bar ∅ 10
4 Thrust piece 8 Cylinder crankcase
Figure 1: Screw with attached tensioner (illustration left: Release / Illustration right: Tension)
L51/60DF;L48/60CR

2007-11-07

4 (4) 6644 009.16-01 EN

 MAN Diesel & Turbo 009.17

Hydraulic tensioner

Hydraulic tensioners/High-pressure pump

dismantling and assembling

Summary
Impart necessary knowledge, ensure correct execution of work. Hydraulic
tensioner must be filled completely with hydraulic fluid when in use. They
must be bled, if necessary, and checked for leakage occasionally. If they
leak, the sealing rings must be replaced.
The work/work steps include: Venting, Checking for leakages, Dismantling
and assembly, and renewing sealing rings/seal elements.
Tools/aids required
Quantity Designation Number Status
1 High-pressure pump 009.342 Standard
1 High-pressure pump 009.338 Standard
1 High-pressure hose 009.306 Standard
1 Blanking washer 009.104 Standard
1 Hydraulic tensioner 009.056 Standard
1 Opener 009.026 Standard
1 Hexagon screw driver 19 000.302 Standard
1 Tommy bar, 12 000.264 Standard
1 Tommy bar, 10 000.263 Standard
1 Screwdriver (Set) - Inventory
2 Strip (Nylon) - Inventory
1 Hammer (wood/plastic-) - Inventory
1 Combination pliers - Inventory
1 Slushing oil - Inventory
1 Molecular gold grease (anti-seize agent) - Inventory

Corresponding Work Cards Work Cards, Classified by Subjects

Work card Work card Work card
000.30 000.33 009.03
009.05 009.16

Technical data
L51/60DF;L48/60CR

Designation Information
Tool No. 009.056
2007-11-07

effective piston area (cm²) 97,2 + 120,8 = 218

Effective stroke (mm) 10
Nominal pressure (bar) 1000
Test pressure (bar) 1100
Thread size (mm) M80x4

6644 009.17-01 EN 1 (8)

009.17 MAN Diesel & Turbo

Designation Information
Hydraulic tensioners/High-pressure pump

Outside diameter (mm) 172

Height (mm) 396

Tool No./Spare Part No.

No. Designation Tool No.
– Hydraulic tensioner, complete 009,056
1 Hydraulic nipple 009056-8
2 Sealing ring 009056-7
3 Piston 009056-3
4 Threaded piece 009056-6
5 Nut 009056-5
6 O-ring seal 009056-15
7* Set of seals 009056-14
8 Casing 009056-4
9 O-ring seal 009056-17
10 Set of seals 009056-16
11 O-ring seal 009056-19
12 Set of seals 009056-18
13 Casing 009056-2
14 Dowel pin 009056-21
15 Cup spring 009056-20
16 Piston 009056-1

Preliminary remark
Hydraulic tensioners, like high-pressure hoses, must be completely filled
with slushing oil before use. They must be bled if necessary. Check for
leakage occasionally.
The hydraulic tensioner must be completely dismantled if set of seals / O-
ring seals must be replaced and if there is damage. In case of a strip-down,
Work Cards, Classified by Subjects

all set of seals /O-ring seals must be renewed. Due to the high working
pressures and the critical Clearances and surfaces, additional repair meas-
ures and interventions are not recommended. We recommend that you have
the device overhauled, if required, by MAN Diesel & Turbo SE or an author-
ised service facility.
Work Sequence 1 - Dismantling the Hydraulic tensioner
L51/60DF;L48/60CR

Starting position Hexagon screwdriver clamped in the vice.

2007-11-07

Work steps 1. Place the piston (16) on clamped hexagon screwdriver (000.302).

2. Loosen and unscrew the tension nut (17) by using tommy bar (000.263).
3. Remove dowel pin (15) and remove cup springs (14).
4. Connect high-pressure hose (009.306) to hydraulic tensioner.

2 (8) 6644 009.17-01 EN

 MAN Diesel & Turbo 009.17

5. Open non-return valve on high-pressure hose with push-on fixture

Hydraulic tensioners/High-pressure pump

(009.026) (see Work Card 009.05).

If non-return valves are not open, the casing (13) cannot be extracted.

6. Remove casing (13).

7. Uncouple hydraulic hose from hydraulic nipple (1).
8. Fit piston (16) on clamped hexagon screwdriver.
9. Release nut (5) and plug plate (009.104) by light tapping with a hammer,
and unscrew.

Screwed connection of nut and piston has a left-hand thread!

10. Pull out piston (3) and casing (8).

11. Remove set of seals (7, 10 and 12) and O-ring seals (6, 9 and 11).
12. Clean all individual parts and check for damage and replace if neces-
sary.
13. Blow oil bores in the piston (16) out with compressed air.

Work sequence 2 - Assembling the hydraulic tensioner

Starting position All individual parts are cleaned and checked for damage or renewed if nec-
essary. Hexagon screwdriver clamped in a vice.
Work steps 1. Check new set of seals (7, 10 and 12) and O-ring seals (6, 9 and 11) for
integrity.
2. Apply slushing oil to O-ring seal (6) and place it in the corresponding
groove, making sure that it is clamped uniformly around the entire
periphery and is not twisted.
3. Press O-ring seals (9 and 11) into a kidney shape and place in the Work Cards, Classified by Subjects
appropriate groove, ensuring that they are not twisted. See Fig. 3.
4. Put new set of seals (10 and 12) in boiling water for five minutes, remove
them, dry them, press them into a kidney shape and insert into the
appropriate groove.

Do not use your bare hands to place set of seals in boiling water or to
take them out! Danger of scalding!
L51/60DF;L48/60CR
2007-11-07

5. Put new set of seals (7) in boiling water for five minutes, take them out
and dry them.

6644 009.17-01 EN 3 (8)

009.17 MAN Diesel & Turbo

Do not use your bare hands to place set of seals in boiling water or to
Hydraulic tensioners/High-pressure pump

take them out! Danger of scalding!

6. Insert set of seals (7) on one side of the piston (3 or 16) in the respective
groove as far as possible, place strips (20) at a spacing of about 120°
around the set of seals. Pull the set of seals over the piston edge into
the groove carefully using the strip. Remove strip. See Fig. 4.
7. Press back set of seals (7) in initial shape.

The set of seals is stretched due to fitting. To bring the set of seals into
its original shape, press it into the groove using a round wooden bar or
hammer shaft.

8. Apply a thin coat of Molecular Gold-Grease anti-seize agent to the run-

ning surface of piston (3 and 16) and casing (8 and 13).

Set of seals and grooves must remain free!

9. Press piston (3) into casing (8).

10. Set casing (8) and piston (3) together on the piston (16) and push them
on.
11. Place the piston (16) on clamped hexagon screwdriver (000.302).
12. Thread on the nut (5) on piston up to the stop and tighten with plug plate
(009.104). See Fig. 1.

Screwed connection of nut and piston has a left-hand thread!

13. Connect high-pressure hose (009.306) to hydraulic nipple (1).

Work Cards, Classified by Subjects

14. Open non-return valve on high-pressure hose with push-on fixture

(009.026) (see Work Card 009.05).

If non-return valves are not open, the casing (13) cannot be fitted.
L51/60DF;L48/60CR

15. Fit the casing (13) up to the stop on piston (16). See Fig. 1.
2007-11-07

16. Disconnect high-pressure hose from the hydraulic tensioner.

17. Assemble cup springs (15), ensuring the correct sequence. See Fig. 1.
18. Insert dowel pin (14) in casing thus securing the position of the cup
springs (15).
19. Screw tension nut (17) onto piston (16) and tighten it by hand.

4 (8) 6644 009.17-01 EN

 MAN Diesel & Turbo 009.17

20. Fit piston (16) onto clamped hexagon screwdriver and screw tension nut

Hydraulic tensioners/High-pressure pump

on using tommy bar (000.263) until it sits in position. See Fig. 2.

cup springs must be compressed a little.

21. Attach hydraulic tensioner to a suitable bolt (see corresponding Work

Card) such that hydraulic nipple (1) points upwards.
22. Connect high-pressure hose to hydraulic tensioner and high-pressure
pump (009.338).
23. Put high-pressure pump in operation (see Work Card 009.03) and pump
the hydraulic tensioner.

Make sure that the specified clamping pressure of the selected bolt is
not exceeded (see Work Card 000.30)!

24. Release the pressure.

The hydraulic tensioner returns to the zero position automatically by the set
of cup springs (resetting duration about 2 to 3 minutes). However, the high-
pressure pump must be connected, and its relief valve must be open (see
Work Card 009.03).
When resetting the piston by the cup springs, existing air escapes through
the high-pressure hose.

The hydraulic tensioner returns to the zero position automatically by the

set of cup springs (resetting duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).
When resetting the piston by the cup springs, existing air escapes
through the high-pressure hose.

1. Disconnect high-pressure hose.

2. Vent high-pressure hose with push-on fixture (see Work Card 009.05). Work Cards, Classified by Subjects
3. Connect high-pressure hose again.
4. Pump hydraulic tensioner up to the tensioning pressure specified for this
bolt (see Work Card 000.30). Hold pressure for five minutes.

After pumping up the hydraulic tensioner, no visible leakage should arise

within this period.
L51/60DF;L48/60CR
2007-11-07

5. Release pressure, uncouple high-pressure hose from hydraulic ten-

sioner and high-pressure pump.
6. Remove tensioner.

6644 009.17-01 EN 5 (8)

009.17 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump
Work Cards, Classified by Subjects

1 Hydraulic nipple 7 Set of seals 13 Casing

2 Sealing ring 8 Casing 14 Dowel pin
3 Piston 9 O-ring seal 15 Cup spring
4 Threaded piece 10 Set of seals 16 Piston
5 Nut 11 O-ring seal
6 O-ring seal 12 Set of seals
L51/60DF;L48/60CR

Figure 1: Hydraulic tensioner

2007-11-07

6 (8) 6644 009.17-01 EN

 MAN Diesel & Turbo 009.17

Hydraulic tensioners/High-pressure pump

13 Casing 17 Tension nut
15 Cup spring C Hole for tommy bar Ø10
16 Piston
Figure 2: Hydraulic tensioner with tension nut screwed on

Work Cards, Classified by Subjects

L51/60DF;L48/60CR

Figure 3: Kidney-shaped compression of a ring

2007-11-07

6644 009.17-01 EN 7 (8)

009.17 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump

3 Piston
7 Set of seals
20 Strip

Figure 4: Pulling the set of seals onto the piston

Work Cards, Classified by Subjects
L51/60DF;L48/60CR

2007-11-07

8 (8) 6644 009.17-01 EN

 MAN Diesel & Turbo 009.18

Measuring gauge (measuring device)

Hydraulic tensioners/High-pressure pump

checking the screw elongation

Summary
Clamping and releasing important threaded connections to the correct val-
ues, ensure correct execution of work. The measuring device is used to
determine the screw elongation compared with a reference value. This is to
ensure that bolts of particular significance are tightened correctly by means
of the hydraulic tensioner.
The work/work steps include: Correct use/application and measuring the
elongation.
Tools/aids required
Quantity Designation Number Status
1 Extension 009.450 Standard
1 Extension 009.449 Standard
1 High-pressure pump 009.342 Standard
1 High-pressure pump 009.338 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic tensioner 009.056 Standard
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 Measuring gauge (measuring device) 009.051-14 Standard
1 Extension 009.051-15 Standard
1 Extension 009.051-16 Standard
1 Screwdriver (Set) - Inventory

Corresponding Work Cards Work Cards, Classified by Subjects

Work card Work card Work card
000.30 000.33 009.03
009.05 009.16

Preliminary remark
L51/60DF;L48/60CR

In case of threaded connections, which are clamped hydraulically, meas-

urement of the screw elongation against a reference value is particularly
important. This is to ensure that the necessary pretension actually exists in
2007-11-07

the form of elongation of the screw and compression of the engine parts to
be clamped. This is not guaranteed if the tensioner is blocked or the tension
pressure is partly or fully dissipated by friction.

6644 009.18-01 EN 1 (5)

009.18 MAN Diesel & Turbo

Work sequence - Measuring the bolt elongation Δl

Hydraulic tensioners/High-pressure pump

Starting position Nut is screwed on and tightened hand-tight. The screw thread is cleaned.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Mount tensioner on bolt (see Work Card 009.16 or Work Card for the
individual bolt).
2. Connect high-pressure hose (009.306) to hydraulic tensioner (4) and
high-pressure pump (009.338).
3. Set high-pressure pump in operation (see Work Card 009.03) and
tighten bolt with specified clamping pressure (see Work Card 000.30).

When tightening, ensure that no one is in the extended axis of the bolt
to be tightened!

4. Set measuring device (009.051) on casing of the hydraulic tensioner.

Ensure that measuring pin of the measuring gauge rests on piston of the
hydraulic tensioner!

The position of the measuring gauge and feeler pin can be adjusted to
the situation by using various assemblies, and by using the extensions
(009.051-15 or 009.051-16). See Fig. 2.
In tight situations (e.g. crankshafts bearing bolt on the exhaust side) the
view of the dial gauge can be improved by the additional use of
extensions (009.449 and 009.450). See Fig. 3.

5. Reset measuring gauge to "zero".

6. Tension the bolt to the specified final clamping pressure (see Work Card
Work Cards, Classified by Subjects

000.30).
7. Tighten nut with tommy bar, hand-tight.
8. Release the pressure.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
L51/60DF;L48/60CR

the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).
2007-11-07

9. Tighten undercut bolt again with specified pretension pressure.

10. Read off screw elongation Δl on dial gauge, note and compare with
required value (see Work Card 000.30).

2 (5) 6644 009.18-01 EN

 MAN Diesel & Turbo 009.18

Tighten undercut bolt with the specified tensioning pressure, not

Hydraulic tensioners/High-pressure pump

according to the screw elongation Δl! The measurement of the screw
elongation Δl is only for checking!

If the deviations from the required value are high, repeat the clamping
sequence and if necessary check hydraulic tensioner, threaded
connection and pressure gauge.

11. Release pressure, uncouple high-pressure hose from hydraulic ten-

sioner and high-pressure pump.
12. Disassemble measuring device.
13. Remove tensioner.

Work Cards, Classified by Subjects

1 Cylinder screw M5x12 3 Stud M6x50 4 Hydraulic tensioner

L51/60DF;L48/60CR

2 Knurled nut M6
Figure 1: Measuring device, placed on hydraulic tensioner
2007-11-07

6644 009.18-01 EN 3 (5)

009.18 MAN Diesel & Turbo
Hydraulic tensioners/High-pressure pump

Figure 2: Measuring device (assembly variants)

Work Cards, Classified by Subjects
L51/60DF;L48/60CR

2007-11-07

4 (5) 6644 009.18-01 EN

 MAN Diesel & Turbo 009.18

Hydraulic tensioners/High-pressure pump

Work Cards, Classified by Subjects
L51/60DF;L48/60CR

2 Knurled nut M6 4 Hydraulic tensioner

3 Stud M6x50 5 Cylinder screw M4x8
2007-11-07

Figure 3: Measuring device, set on hydraulic tensioner (for tight spaces)

6644 009.18-01 EN 5 (5)

MAN Diesel & Turbo 005

Operating values/Operating results

001 Operating media systems/Pipes
002 Operating media/Auxiliary agents
003 Machine Elements
004 Hydraulic tensioners/High-pressure pump
005 Operating values/Operating results

6704 2.5-1 EN 1 (1)

 MAN Diesel & Turbo 000.25

Ignition and compression pressures

Operating values/Operating results

determining

Summary
Collate and assess operational data, detect problems on (influencing) sub-
assemblies /systems.
Ignition and compression pressures are important measures for the
mechanical loading of the engine. They are closely connected to important
operating data and allow conclusions as to the condition of components
and systems to be drawn.
The work/work steps include:
Recording pressures,
Collating operational data and
Assessing results.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Ignition measuring instrument by Baewert, Type 419.019 Option
250E
1 Protective gloves - Inventory

Preliminary remarks
Ignition pressures are an important benchmark for the mechanical loading
of the engine. They are closely connected to important operating data and
allow conclusions as to the condition of components and systems to be
drawn. They must be determined with an indicator (pressure gauge) at reg-
ular intervals, in accordance with the maintenance schedule. When evalu-
ating, both the absolute values and the differences from cylinder to cylinder
are important.
Work Cards, Classified by Subjects
The calibration interval for the ignition pressure measuring device should be
one year.
Work sequence 1 - Recording pressures
Starting position Engine at desired performance level in stable operation. Steady state con-
dition of operational values is reached.
Work steps 1. Before indicating, open the indicator valve and keep it open for 2-3 igni-
tion strokes to remove carbon or combustion residues which have built
2010-03-24

up in the indicator pipe.

Do not step in front of the fire jet!

General

6682 000.25-03 EN 1 (3)

000.25 MAN Diesel & Turbo

2. Close the indicator valve.

Operating values/Operating results

3. Screw pressure sensor of the measuring device onto the indicator valve.
4. Record the ignition pressures according to the Operating Instructions
for the ignition pressure meter Type 250E (419.019).

The compression pressures can be recorded in a similar way to the

ignition pressures, if, during that procedure, the control rod of the
associated injection pump is set to zero against the force of the buckling
lever spring.

Measurement of the compression pressure is only allowed up to a load

where the remaining cylinders still operating can take the load of the
cylinder which is switched off.
Work Cards, Classified by Subjects

Figure 1: Baewert Ignition pressure meter Type 250E

Work sequence 2 - Evaluation/Assessment

The following limit values/requirements must be observed:
▪ measured ignition pressures at nominal output ≤ maximum value,
2010-03-24

▪ Deviations between cylinders ≤ average tolerance

(for corresponding limit values, refer to 010.005 Engine - Operating
Instructions, Chapter 2.5.2),
General

▪ same regulating rod position with all fuel-injection pumps.

2 (3) 6682 000.25-03 EN

 MAN Diesel & Turbo 000.25

For practical reasons, the diagrams/results should be compared with those

Operating values/Operating results

in the test run report, or those obtained during earlier measurements. If the
ignition pressures are too high, this is because fuel is being injected too early
or not enough fuel is being injected. If the ignition pressures at the individual
cylinders are too low, this may be due to one of the following malfunctions:
▪ fuel-injection nozzle is dripping or not injecting properly,
▪ damaged/worn fuel-injection pump and
▪ leaking gas exchange valves.

Type and source of danger

You can analyse measured data graphically and/or arithmetically using
the PC software supplied.

Work Cards, Classified by Subjects

2010-03-24

General

6682 000.25-03 EN 3 (3)

 MAN Diesel & Turbo 000.40

Charge air cooler/crankcase

Operating values/Operating results

Measuring the differential pressure

Summary
Collecting operating data, ensuring/restoring operating safety, enabling/
supporting economic operation. Differential pressure measurements sup-
port, in addition to the details in the maintenance schedule, the determina-
tion of the most suitable cleaning intervals of charge air coolers and they
enable the assessment of operating data.
The work includes: Measurement by means of a digital pressure gauge, and
measurement by means of a U-tube pressure gauge.
Tools/aids required
Quantity Designation Number Status
1 Digital pressure gauge "Digima-Premo" 009.090 Option
1 Storage bag 009.090-1 Option
1 9V battery 009.090-2 Option
1 Plug-in charger 009.090-3 Option
1 PVC hose 009.090-4 Option
4 Quick-fitting coupling 009.090-5 Option
2 Hose plug-in nipple 009.090-6 Option
2 Filter 009.090-7 Option
1 U-tube pressure gauge/ water-filled PVC hose - Inventory
1 Measuring tape - Inventory

Preliminary remarks
Contamination of the charge air cooler reduces the cooling effect and has
a negative effect on the operating values of the engine. In addition to the
recommended cleaning intervals in the maintenance schedule, the meas-
urement of differential pressure helps to determine the most suitable time
for cleaning and to evaluate the operating data. The measurement can be Work Cards, Classified by Subjects
done with a digital differential pressure gauge or a U-tube pressure gauge.
2007-11-15

General

6682 000.40-01 EN 1 (5)

000.40 MAN Diesel & Turbo

Measuring set-up/measuring devices

Operating values/Operating results

1 Casing before charge air cooler 4 Measuring connection

2 Charge air cooler 5 Measuring device
3 Charge air pipe
Figure 1: Measuring points/measuring set-up (figure shows engine L 40/54 with
single-stage charge air cooler)
Work Cards, Classified by Subjects

2007-11-15
General

2 (5) 6682 000.40-01 EN

 MAN Diesel & Turbo 000.40

Operating values/Operating results

1a "On" push-button 4 "Attenuation" push-button 7 Indication of
measured value
1b "Off" push-button 5a Pressure connection p1 8 Battery tray
2a "●" push-button (measur- 5b Pressure connection p2 9 Indication "lo bat"
ing range 0-2 bar) (battery status)
2b "●" push-button (measur- 6a Zero-point setting for measuring range 0-2 10a Output for record-
ing range 0-10 bar) bar ing instrument (+)
3 Information area (indica- 6b Zero-point setting for measuring range 10b Output for printer
tion of measuring range/ 0-10 bar (-)
attenuation)
Figure 2: Measuring device "Digima-Premo" made by SI, special instruments

Safety Instructions
Maximum pressure on the device 14 bar.
Only dry gases are allowed to be admitted at connection p1 and only gases
and fluids which do not attack polyester, silicone and silicon are allowed on
connection p2. On connection p1 you may only use a measuring hose with
a water repellent filter.
Work Cards, Classified by Subjects
Differential pressure measurements normally p2 > p1. If p2 < p1 the sign of
the measured value is negative. With relative pressure measurements p1=
ambient pressure, p2 = measuring pressure.
The hose couplings on the engine and on the hoses in front of the measuring
device are self-blocking.
Measurement with digital pressure gauge
One-off preparations Fit hose plug-in nipple and quick-fit coupling on both ends of the PVC hoses.
Cut the hose approx. 30 cm before the coupling and connect both ends to
2007-11-15

the connections on the water repellent filter. Also use this hose for connec-
tion p1!
Work steps 1. Blow by the measuring connections. In order to do so, connect hose
General

plug-in nipple with nom. Ø 8 mm temporarily to the coupling at the

engine side.

6682 000.40-01 EN 3 (5)

000.40 MAN Diesel & Turbo

2. Connect PVC hoses with filter to measuring points A and B. The locking
Operating values/Operating results

rings of the hose couplings must engage.

3. Connect measuring device and press push-button "w" for measurement
of the 0 - 2 bar range. Indication at "w" will be visible in area 3.
4. Press "On" push-button. Read off the measured value of the display.
5. Pulsating pressures lead to unstable indications. In this case press the
push-button "attenuation". Indication at "D" will be visible in area 3.
6. Turn off measuring device. Remove measuring hoses from the meas-
uring points (lift locking ring to do so).
7. Compare measured value with reference value and evaluate. The dif-
ferential pressure in the as-new condition can be taken from the engine
acceptance test record. The charge air cooler is, at the latest, to be
cleaned when the differential pressure has reached the maximum value
(see manual section 2.5).
Additional information If the battery or accumulator voltage is too low a pre-warning "lo bat" will
appear in the indication field 9. The device can be used until the indication
starts to flash. From this point onwards incorrect measured values can
occur.
The recording instrument outputs 10a/10b provide a DC voltage of 1 mV/
digit (maximum 2 V) which is proportional to the measured value.
The zero-point setting can be carried out with the potentiometer 6a/6b when
the device is unloaded.
Measurement with U-tube pressure gauge
Work steps 1. Blow by the measuring connections as described above.

2. Fit hose nipples, which are mounted on the measuring connections on

the engine, to both ends of the PVC hose having 8 mm inner diameter.
3. Fill hose with water until the water column is approx. 300 mm high on
both sides.
4. Grasp hose ends and connect to the couplings of the measuring points
at the same time.
5. Measure water level h and evaluate the result as described above.
Work Cards, Classified by Subjects

100 mm WG = 10 mbar differ-

Δh
ential pressure
Connection before charge air
2
cooler
Connection after charge air
3
cooler
2007-11-15
General

Figure 3: Differential pressure measurement with U-tube pressure gauge

4 (5) 6682 000.40-01 EN

 MAN Diesel & Turbo 000.40

Checking the crankcase pressure

Operating values/Operating results

A measuring connection is also located on the crankcase (approx. in the
middle of engine on the exhaust side). The crankcase pressure can be
measured here on connection p2, relative to the atmosphere. When evalu-
ating the measured values, the following must be considered: the wear
condition of the piston, piston rings and cylinder liners, a potential sealing
air transition from the bearings of the turbocharger to the running gear area,
the function of the crankcase air bleed valve and other factors.

Figure 4: Measuring point on crankcase (engine L 40/54)

Work Cards, Classified by Subjects

2007-11-15

General

6682 000.40-01 EN 5 (5)

MAN Diesel & Turbo

Work Cards, classified into sub-assemblies

1 Introduction
2 Work Cards, Classified by Subjects
3 Work Cards, classified into sub-assemblies
4 Appendix

6704 3-1 EN 1 (1)

MAN Diesel & Turbo 000

Sub-assembly overview
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.1-1 EN 1 (2)

 MAN Diesel & Turbo
Sub-assembly overview

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.1-1 EN

 MAN Diesel & Turbo 3.1

Sub-assembly overview

Sub-assembly overview
Sub-assembly overview - longitudinal and cross-section of the engine

Work Cards, classified into sub-assemblies

2007-11-16

L48/60B

Figure 1: Cross-section of the engine

6704 3.1-01 EN 1 (4)

3.1 MAN Diesel & Turbo
Sub-assembly overview
Work Cards, classified into sub-assemblies

2007-11-16
L48/60B

Figure 2: Longitudinal section of engine

2 (4) 6704 3.1-01 EN

 MAN Diesel & Turbo 3.1

Overview of components - Designation

Sub-assembly overview
Sub-assem-
Designation
bly
0112) Oil sump
012 Cylinder crankcase
020 Crankshaft
021 Crankshaft bearing
023 2)
Crankshaft extension
027a Torsional vibration damper
027b 2)
Torsional vibration damper of camshaft
030 Connecting rod
034 Piston
050 Cylinder liner
055 Cylinder head
057 Safety valve
071 Casing on coupling side
071 1)
Dead centre indicator
072 Covering at free engine end
073 Casings, crankcase casings with pressure-relief valve / splash oil
077 Casing of camshaft
100 Control device operating mechanism
102 Camshaft bearing
102 1)
Camshaft thrust bearing
111 Control lever with bearing
112a Push rod with covering
112b Inlet and exhaust rocker arm with bearing

Work Cards, classified into sub-assemblies

113 Inlet valve
114 Exhaust valve
1251) Operating device
1401) Speed controller
160 Starting air pilot valve
1611) Starting valve
1621) Main starting valve
200 Fuel injection pump
201 Fuel injection pump drive
2021)2) Fuel injection timer
2007-11-16

203 Governor control linkage

203 1)
Fuel index transmitter
L48/60B

209 Camshaft
221 Fuel injection oil
280 Charge air pipe

6704 3.1-01 EN 3 (4)

3.1 MAN Diesel & Turbo

Sub-assem-
Designation
Sub-assembly overview

bly
2801)2) Air bypass pipe
280 1)
Pressure measuring transducer
286 Built-on components for turbocharger
289 Exhaust pipe
289 Exhaust pipe
300 2)
Lubricating oil pump
302 1)
Lubricating oil pump for cylinder lubrication
302 1)2)
Lubricating oil pump for valve seat lubrication
311 1)
Crankcase ventilation
322 Charge air cooler
350 2)
Cooling water pump
400 1)2)
Impulse transmitter
400 1)2)
Pulse pick-up
408 1)
Fitting parts for transmission cover for splash oil
408 1)2)
Crankshaft bearing temperature monitoring
409 1)
Exhaust gas temperature monitoring
413 1)
Cabling on engine for splash-oil temperature monitoring
413 1)2)
Oil mist detector
419 1)
Indicating device
432 Starting air pipe
432 1)
Control air line
434a Fuel injection pipe
434b Fuel pipe
440 Lube oil pipe
441 1)
Pressure gauge pipe
Work Cards, classified into sub-assemblies

442 1)
Condensate drain
443 1)
Cylinder lubrication
443 1)2)
Valve seat lubrication
444 1)
Pipes to lubricant module
446 1)
Pipes to the turbocharger
447 Cooling water line
Table 1: Sub-assembly designation
1)
These sub-assemblies cannot be seen in the pictures
2)
if fitted
2007-11-16
L48/60B

4 (4) 6704 3.1-01 EN

MAN Diesel & Turbo 009

Foundations/Bearings
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.2-1 EN 1 (2)

 MAN Diesel & Turbo
Foundations/Bearings

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.2-1 EN

 MAN Diesel & Turbo 000.09

Position of crankshaft flange in relation to driven flange

Foundations/Bearings
determining/checking

Summary
Checking alignment, detecting problems on (influencing) sub-assemblies/
systems, ensuring/restoring operational safety.
The crankshaft flange/the engine must have specific offsets to the flange/
unit to be driven in the cold state. The alignment must be measured upon
installation and must be checked regularly.
This includes:
Checking the alignment,
recording measured values and
evaluating results.
Tools/aids required
Quantity Designation Number Status
2 Dial gauge - Inventory
1 Inside micrometer - Inventory
1 External micrometer - Inventory

Corresponding Work Cards

Work card Work card Work card
000.10 012.01

Preliminary remarks
The flange of the crankshaft, i.e. ultimately the engine, must show certain
axial offsets in the cold state, with respect to the driven flange so that influ-
encing factors are compensated for under operating conditions. Such fac-

Work Cards, classified into sub-assemblies

tors are:
▪ thermal expansion of the foundations,
▪ thermal expansion of the engine, generator or the gear,
▪ thermal expansion of the rubber elements in the case of resilient mount-
ing,
▪ the settling behaviour of the resilient mounting and
▪ shaft disalignment under pressure.
The position of both flanges is to be measured on the original equipment
and checked subsequently at regular intervals in accordance with the main-
tenance schedule.
2007-07-23

If required, a special manual can be prepared for certain propulsion

systems, in which the necessary alignment measurements are given.
These can vary from those in the flywheel alignment diagram.
General

6682 000.09-01 EN 1 (3)

000.09 MAN Diesel & Turbo
Foundations/Bearings

1 Driven shaft flange C Reference mounting dimension, coupling G Shaft axis

2 Engine main flange D Spacing
A Radial offset E Spacing ΔA Difference, radial offset
B Axial offset F Engine crankshaft axle ST Control side
Figure 1: Alignment of the crankshaft flange with respect to the driven flange - measurements and terms

Work sequence 1 - Measuring the flange alignment

Starting position The crank web deflection complies with the regulations (see Work Card
000.10).
Prerequisites/measuring pro- In order to ascertain the exact alignment during assembly, it is necessary to
cedure make a measuring bracket with two dial gauges to be fastened to the fly-
wheel. One measuring gauge records the radial axle misalignment (A) for
the vertical and horizontal deviations, the other gauge measures the plane
parallelism or the flange divergence (B). The measuring bracket can be used
for subsequent checks, as required in resiliently mounted engines in par-
ticular.
Work Cards, classified into sub-assemblies

The axial distance (E) is measured using a micrometer from the flange of the
crankshaft to the flange of the driven shaft, the reference dimension is
measured (C) from the flywheel to the flange of the driven shaft. The distance
between the engine and the driven flange and the fitting dimension (C) of
the flexible coupling is adjusted / checked with the pretension possibly
required.

The engine bearings must, if required, be equipped with emergency

lubrication during rotation of the crankshaft for alignment.

The measured values are to be noted and recorded on a printed form (see
2007-07-23

suggestion on the following page). The original measured values are to be

compared with the calculated given values, or with empirical values. If nec-
essary, the alignment must be corrected again. Later comparison of the
General

values allows conclusions to be drawn concerning time sequencing, the

scope and possible causes for changes.

2 (3) 6682 000.09-01 EN

 MAN Diesel & Turbo 000.09

Alignment protocol Date:

Engine Factory Ref. No.: Time:

Foundations/Bearings
1 - Driven shaft flange 2 - Engine main flange
* Enter values in the table
** Enter values in the figure

The actual radial offset amounts to only half of the calculated difference
from the dial gauge indications (ΔA).

1. Measurement 2. Measurement 3. Measurement 4. Measure-

ment
Radial offset (A), dial gauge indication
Axial offset (B), dial gauge indication
horizontal vertical

Work Cards, classified into sub-assemblies

Difference in measurement (ΔA)
Actual radial offset (ΔA/2)
Reference mounting dimension (C), coupling
Spacing (D)
Spacing (E)
Distance between the main flange and engine crankcase
Distance between flange and bearing of the driven shaft
Engine coupled uncoupled
Engine condition cold hot [°C]
Engine room temperature [°C]
2007-07-23

Remarks:
General

Signature:

6682 000.09-01 EN 3 (3)

 MAN Diesel & Turbo 012.01

Foundation bolts and foundations

Foundations/Bearings
inspecting

Summary
Execute the work in time according to the maintenance schedule, ensure
the correct execution of work, ensure / restore operational safety. Inspect/
test foundation bolts and foundations at regular intervals.
The work/work steps include: Determine and assess release pressure,
clamp connection at required pressure, inspection of parts/components.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Thrust piece 055.125 Standard
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic tensioner 009.062 Standard
1 Torque wrench 008.016 Standard
1 Socket spanner insert 41x20 001.772 Standard
1 Tommy bar, 8 000.262 Standard
1 Combination spanner (set) - Inventory
1 Hammer (wood/plastic-) - Inventory
1 Grease (acid-free) - Inventory

Work Cards, classified into sub-assemblies

Corresponding Work Cards
Work card Work card Work card
000.09 000.10 000.30
000.32 000.33 009.03
009.05 009.13

Preliminary remark
The work specified in the service schedule includes the inspection of the
hydraulically tensioned foundation bolts for correct pretensioning, the check
that the foundation bolts tightened by torque for correct tightening, the
2008-10-22

checking of the stopper and wedges for firm seating as well as the synthetic
resin chocking for resilience, dangerous cracks and breakaways.
L48/60B

Another point in the service schedule is the inspection of the crank web
deflection (see Work Card 000.10). If an unacceptably high value (especially
on cylinder 1) is detected during this inspection, and this cannot be elimi-
nated by aligning the gearbox connecting shaft, the engine must be real-

6704 012.01-01 EN 1 (6)

012.01 MAN Diesel & Turbo

igned. It is advisable to have the new alignment carried out by a MAN Diesel
Foundations/Bearings

& Turbo personnel or at a MAN Diesel & Turbo support location.

After a period of bad weather, after a collision or grounding, check the

precise position of the engine and re-tighten all the foundation bolts! The
foundation bolts on the coupling side and the free engine end are the
most at danger!

Work sequence 1 - Checks on the cylinder crankcase

Type and source of danger

Danger of death! During all work in the cylinder crankcase, close the
starter air cylinder, vent the starter pipe and engage the turning gear, to
prevent starting of the engine and rotation of the running gear! For
additional safety regulations, refer to Volume 010.005 in the Engine -
Operating Instructions.

Work steps 1. Carefully clean cylinder crankcase and oil sump when overhauling and
at every oil change.
2. Examine cylinder crankcase from inside and outside for cracks.

Work sequence 2 - Checking the foundations

Checking the foundation bolts starts on the coupling side.

Work steps 1. Remove protection caps (1).

2. Clean the threads of the foundation bolts (3 and 11).

Work Cards, classified into sub-assemblies

3. Place the thrust piece (055.125) over the nut (2).

4. Screw hydraulic tensioner (009.062) onto foundation bolt (3 or 11),
ensuring that thrust piece is centred by the hydraulic tensioner. See
Figs. 3 and 4.
5. Turn back the hydraulic tensioner by the turn-back angle (see Work Card
000.30).
6. Connect high-pressure hose (009.306) to hydraulic tensioner and high-
pressure pump (009.338).
7. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

Ensure that no is present in the extension of the axis of the foundation

2008-10-22

bolt!
L48/60B

8. Pump the hydraulic tensioner until the nut (2) can be loosened.

2 (6) 6704 012.01-01 EN

 MAN Diesel & Turbo 012.01

In the process, the pressure must not be more than max. 7 % below or

Foundations/Bearings
max. 5 % above the tensioning pressure (see Work Card 000.30)!

Observe the stroke controls (19) on the hydraulic tensioner whilst

pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke controls reach the top edge of the threaded
stop ring (20)! Otherwise the hydraulic tensioner will be damaged! See
Fig. 4.

9. Make a note of the release pressure and compare it to the clamping

pressure.
10. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
11. Tighten nut (2) manually through cut-out in the thrust piece using a
tommy bar (000.262).
12. Release the pressure, uncouple the high-pressure hose from the
hydraulic tensioner.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

13. Remove tensioner.

14. Fit the tensioner onto next foundation bolt (3 or 11) and repeat the proc-
ess until all foundation bolts are inspected. See Point 3 and Point 12.
15. Uncouple the high-pressure hose from the high-pressure pump after
concluding the inspection work.
16. Preserve the thread ends of the foundation bolts (3 and 11) with non-

Work Cards, classified into sub-assemblies

acidic grease and fit protection caps (1).
17. Check hexagon nuts (16) of the foundation bolts (17 and 18) with speci-
fied torque (see Work Card 000.30) and re-tighten hexagon nuts if nec-
essary. See Fig. 2.
18. Check hexagon bolts (12) of the guide rails (6) for firm seating and re-
tighten hexagon bolts if necessary. See Fig. 1.
19. Check firm seating of taper (5) and stopper (15) by using a wooden or
plastic hammer. See Figs. 1 and 2.
20. Examine synthetic resin chocking (8) for resilience, dangerous cracks
and spallings. See Figs. 1 and 2.
2008-10-22

L48/60B

6704 012.01-01 EN 3 (6)

012.01 MAN Diesel & Turbo
Foundations/Bearings
Work Cards, classified into sub-assemblies

1 Protection cap 5 Taper 9 Foundation

2 Nut 6 Guide rail 10 Nut
3 Foundation bolt (fitting bolt) 7 Steel spring plate 11 Foundation bolt
4 Cylinder crankcase 8 Synthetic resin chocking 12 Hexagon bolt
Figure 1: Semi-resilient support
2008-10-22
L48/60B

4 (6) 6704 012.01-01 EN

 MAN Diesel & Turbo 012.01

Foundations/Bearings
4 Cylinder crankcase 14 Washer
7 Steel spring plate 15 Stopper
8 Synthetic resin chocking 16 Hexagon nut
9 Foundation 17 Foundation bolt (fitting bolt)
13 Hexagon nut 18 Foundation bolt
Figure 2: Semi-resilient support

Work Cards, classified into sub-assemblies

2008-10-22

L48/60B

6704 012.01-01 EN 5 (6)

012.01 MAN Diesel & Turbo
Foundations/Bearings

3 Foundation bolt (fitting bolt) 4 Cylinder crankcase 11 Foundation bolt

Figure 3: Foundation bolts with attached tensioner
Work Cards, classified into sub-assemblies

2 Nut 19 Stroke control

3 Foundation bolt (fitting bolt) 20 Threaded stop ring
4 Cylinder crankcase M Marking on the stroke control
2008-10-22

11 Foundation bolt
Figure 4: Foundation bolt with attached tensioner
L48/60B

6 (6) 6704 012.01-01 EN

MAN Diesel & Turbo 012

Cylinder crankcase/tie rod

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.3-1 EN 1 (2)

 MAN Diesel & Turbo
Cylinder crankcase/tie rod

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.3-1 EN

 MAN Diesel & Turbo 012.02

Crankshaft bearing bolts and cross tie rods

Cylinder crankcase/tie rod

inspection, loosening and tightening

Summary
Tension and release important threaded connections with the correct val-
ues, ensure correct execution of work.
crankshaft bearing bolts and cross tie rods should be inspected at regular
intervals by means of hydraulic tensioners.
The work/work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 055.100 Standard
1 Suspension device 021.150 Standard
2 Thrust piece 021.149 Standard
2 Tension nut 021.148 Standard
1 Extension 009.450 Standard
1 Extension 009.449 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard

Work Cards, classified into sub-assemblies

1 Claw wrench 009.070 Standard
1 Box spanner 009.067 Standard
2 Hydraulic tensioner 009.063 Standard
2 Hydraulic tensioner 009.056 Standard
2 Measuring device 009.051 Standard
L48/60B;L51/60DF;L48/60CR

2 Magnetic prism with support 009.051-1 Standard

2 Clamping piece 009.051-5 Standard
2 Sleeve 009.051-6 Standard
2 Measuring gauge (measuring device) 009.051-14 Standard
2 Extension 009.051-15 Standard
2008-01-29

2 Extension 009.051-16 Standard

1 Suspension device 009.050 Standard
1 Shackle A1.0 002.453 Standard
1 Ratchet tool 001.521 Standard
1 Thickness gauges 0.05-1 000.451 Option

6704 012.02-02 EN 1 (15)

012.02 MAN Diesel & Turbo

Quantity Designation Number Status

Cylinder crankcase/tie rod

1 Tommy bar, 12 000.264 Standard

1 Tommy bar, 10 000.263 Standard
1 Tommy bar, 8 000.262 Standard
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Lifting tackle with rope - Inventory
1 Sliding calliper Form C - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.13
009.16 009.18

Technical data
Designation Information
Hydraulic tensioner 66 kg
Thrust piece 13,5 kg
Bolt projection (A) 190 mm

Work sequence 1 - Checking the cross tie rods

Work steps 1. Remove protection caps (14).

2. Clean threads of the cross tie rods (11).

3. Place thrust pieces (055.100) over nuts (10).
4. Screw hydraulic tensioner (009.063) onto cross tie rod (11), ensuring that
Work Cards, classified into sub-assemblies

thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
5. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
6. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338 or 009.342).
7. Set the high-pressure pump in operation (see Work Card 009.03) and
L48/60B;L51/60DF;L48/60CR

close the gap that resulted from the turning back.

When releasing, ensure that no is present in the extended axis of the

cross tie rod!
2008-01-29

8. Pump the hydraulic tensioners until the nuts (10) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

2 (15) 6704 012.02-02 EN

 MAN Diesel & Turbo 012.02

Observe the stroke monitors (17) on the hydraulic tensioner whilst

Cylinder crankcase/tie rod

pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke monitors reach the top edge of the thread
stop ring (16)! Otherwise the hydraulic tensioner will be damaged! See
Image 3.

9. Make a note of the release pressure and compare it to the clamping

pressure.
10. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
11. Hand-tighten both nuts (10) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
12. Release pressure, uncouple high-pressure hoses from hydraulic ten-
sioners and high-pressure pump.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

13. Detach the tensioners.

14. Fit protection caps (14) on threads of the cross tie rods (11).

Work sequence 2 - Checking the crankshaft bearing bolts

Starting position Cooling water for fuel injection pump cooling system is drained completely.

Work steps 1. Open cylinder head cover and cylinder head cover of the adjacent cyl-
inder.
2. Remove all obstructing pipes (e.g. lube oil pipe for cam follower lubri-
cation, air pipe for starting valve etc.).
3. Remove protection caps (3).

Work Cards, classified into sub-assemblies

4. Clean the thread of the crankshaft bearing bolts (5).
5. Fasten suspension device (021.150) onto thrust piece (021.149), fasten
cable (18) with shackle (002.453) to suspension device and hook into
lifting tackle. See Fig. 4.
6. Push the thrust piece over main bearing bolt (5) and place over nut (4).
L48/60B;L51/60DF;L48/60CR

Remove the suspension device.

7. Place second thrust piece over second nut (4) in the same manner. See
Point 5 and Point 6.
8. Check with tommy bar (000.263) whether tension nuts (021.148) are
tightly screwed to the hydraulic tensioners (009.056).
9. Screw suspension device (009.050) into hydraulic tensioner, fasten
2008-01-29

cable (18) with shackle (002.453) to suspension device and hook into
lifting tackle. See Fig. 5.
10. Push hydraulic tensioner over main bearing bolt (5), locate in this posi-
tion and tighten by a few revolutions. Remove the suspension device.

6704 012.02-02 EN 3 (15)

012.02 MAN Diesel & Turbo

11. Fit socket wrench (009.067) on hydraulic tensioner, fit ratchet (001.521)
Cylinder crankcase/tie rod

and screw hydraulic tensioner completely onto crankshaft bearing bolt

(5). Detach the tool. See Fig. 6.
12. Attach the second hydraulic tensioner to the second crankshaft bearing
bolt (5) in the same manner. See point 9 to 11.
13. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
14. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338 or 009.342).
15. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

Ensure that no one is in the extended axis of the main bearing bolt!

16. Pump the hydraulic tensioners until the nuts (4) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

17. Make a note of the release pressure and compare it to the clamping
pressure.
18. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
19. Hand-tighten both nuts (4) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
20. Release pressure, uncouple high-pressure hoses from hydraulic ten-
sioners and high-pressure pump.
Work Cards, classified into sub-assemblies

The hydraulic tensioners return to the zero position automatically by the

cup springs (resetting duration about 2 to 3 minutes). However, the high-
pressure pump must be connected, and its relief valve must be open (see
Work Card 009.03).

21. Unscrew hydraulic tensioner using socket wrench (009.067) and remove
L48/60B;L51/60DF;L48/60CR

with suspension device (009.050).

22. Remove thrust pieces with suspension fixture (021.150).
23. Fasten protection caps (3) on crankshaft bearing bolts (5).
24. Replace pipes that have been removed.
25. Close cylinder head cover.
2008-01-29

Work sequence 3 - Unloading the cross tie rods

Work steps 1. Remove protection caps (14).

2. Clean threads of the cross tie rods (11).

4 (15) 6704 012.02-02 EN

 MAN Diesel & Turbo 012.02

3. Place thrust pieces (055.100) over nuts (10).

Cylinder crankcase/tie rod

4. Screw hydraulic tensioner (009.063) onto cross tie rod (11), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
5. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
6. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338 or 009.342).
7. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

When releasing, take care that no one is present in the extended axis of
the cross tie rod to be released!

8. Pump the hydraulic tensioners until the nuts (10) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

Observe the stroke controls (17) on the hydraulic tensioner whilst

pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke controls reach the top edge of the threaded
stop ring (16)! Otherwise the hydraulic tensioner will be damaged! See
Fig. 3.

9. Make a note of the release pressure and compare it to the clamping

pressure.
10. Turn back both nuts (10) using tommy bar (000.264) through the cut-out
in the thrust pieces (for turn-back angle see Work Card 000.30).

Work Cards, classified into sub-assemblies

11. Release pressure, uncouple high-pressure hoses from hydraulic ten-
sioners and high-pressure pump.

The hydraulic tensioners return to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
L48/60B;L51/60DF;L48/60CR

open (see Work Card 009.03).

12. Detach the tensioners.

Work sequence 4 - Releasing the crankshaft bearing bolts

Starting position Cooling water for fuel injection pump cooling system is drained completely.
Cross tie rods are unloaded.
2008-01-29

Before releasing main bearing bolts, cross tie rods must be unloaded
(see work sequence 3)!

6704 012.02-02 EN 5 (15)

012.02 MAN Diesel & Turbo

Work steps 1. Open cylinder head cover and cylinder head cover of the adjacent cyl-
Cylinder crankcase/tie rod

inder.
2. Remove all obstructing pipes (e.g. lube oil pipe for cam follower lubri-
cation, air pipe for starting valve etc.).
3. Remove protection caps (3).
4. Clean the thread of the crankshaft bearing bolts (5).
5. Fasten suspension device (021.150) onto thrust piece (021.149), fasten
cable (18) with shackle (002.453) to suspension device and hook into
lifting tackle. See Fig. 4.
6. Push the thrust piece over main bearing bolt (5) and place over nut (4).
Remove the suspension device.
7. Place second thrust piece over second nut (4) in the same manner. See
Point 5 and Point 6.
8. Check with tommy bar (000.263) whether tension nuts (021.148) are
tightly screwed to the hydraulic tensioners (009.056).
9. Screw suspension device (009.050) into hydraulic tensioner, fasten
cable (18) with shackle (002.453) to suspension device and hook into
lifting tackle. See Fig. 5.
10. Push hydraulic tensioner over main bearing bolt (5), locate in this posi-
tion and tighten by a few revolutions. Remove the suspension device.
11. Fit socket wrench (009.067) on hydraulic tensioner, fit ratchet (001.521)
and screw hydraulic tensioner completely onto crankshaft bearing bolt
(5). Detach the tool. See Fig. 6.
12. Attach the second hydraulic tensioner to the second crankshaft bearing
bolt (5) in the same manner. See point 9 to 11.
13. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
14. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338 or 009.342).
Work Cards, classified into sub-assemblies

15. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

When releasing, ensure that no one is in the extended axis of the main
bearing bolts to be released!
L48/60B;L51/60DF;L48/60CR

16. Pump the hydraulic tensioners until the nuts (4) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!
2008-01-29

17. Make a note of the release pressure and compare it to the clamping
pressure.
18. Turn back both nuts (4) using tommy bar (000.264) through the cut-out
in the thrust pieces (for turn-back angle see Work Card 000.30).

6 (15) 6704 012.02-02 EN

 MAN Diesel & Turbo 012.02

19. Release pressure, uncouple high pressure hoses from hydraulic ten-

Cylinder crankcase/tie rod

sioners and high pressure pump.

The hydraulic tensioners return to the zero position automatically by the

cup springs (resetting duration about 2 to 3 minutes). However, the high-
pressure pump must be connected, and its relief valve must be open (see
Work Card 009.03).

20. Unscrew hydraulic tensioner using socket wrench (009.067) and remove
with suspension device (009.050).
21. Remove thrust pieces with suspension fixture (021.150).

Work sequence 5 - Tensioning the main bearing bolts and the cross tie rods
Starting position Cylinder head cover and cylinder head cover of the adjacent cylinder is
opened. Main bearing cap is lifted until it rests on the cylinder crankcase,
all nuts (4 and 6) are screwed on and tightened hand-tight. Threads of the
crankshaft bearing bolts and of the cross tie rod are cleaned.

Carry out tensioning of the main bearing bolts and of the cross tie rod in
several steps! Ensure correct order of tightening!
Prerequisite for correct tightening of a bolted connection is a pressure
gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Check length of projection of thread (A) of the crankshaft bearing bolt
(5). See Figs. 1 and 7.
2. Check that gap in the parting line between crankshaft bearing cover (8)
and cylinder crankcase (9) is equal on both sides.
3. Place thrust pieces (055.100) over nuts (10).
4. Screw hydraulic tensioner (009.063) onto cross tie rod (11), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
5. Fasten suspension device (021.150) onto thrust piece (021.149), fasten

Work Cards, classified into sub-assemblies

cable (18) with shackle (002.453) to suspension device and hook into
lifting tackle. See Fig. 4.
6. Push the thrust piece over main bearing bolt (5) and place over nut (4).
Remove the suspension device.
7. Place second thrust piece over second nut (4) in the same manner. See
L48/60B;L51/60DF;L48/60CR

Point 5 and Point 6.

8. Check with tommy bar (000.263) whether tension nuts (021.148) are
tightly screwed to the hydraulic tensioners (009.056).
9. Screw suspension device (009.050) into hydraulic tensioner, fasten
cable (18) with shackle (002.453) to suspension device and hook into
lifting tackle. See Fig. 5.
2008-01-29

10. Push hydraulic tensioner over main bearing bolt (5), locate in this posi-
tion and tighten by a few revolutions. Remove the suspension device.
11. Fit socket wrench (009.067) on hydraulic tensioner, fit ratchet (001.521)
and screw hydraulic tensioner completely onto crankshaft bearing bolt
(5). Detach the tool. See Fig. 6.

6704 012.02-02 EN 7 (15)

012.02 MAN Diesel & Turbo

12. Attach the second hydraulic tensioner to the second crankshaft bearing
Cylinder crankcase/tie rod

bolt (5) in the same manner. See point 9 to 11.

13. Connect high-pressure hoses (009.306) to hydraulic tensioner of the
cross tie rods (11) and to high-pressure pump (009.338 or 009.342).
14. Set high-pressure pump in operation (see Work Card 009.03) and
tighten cross tie rod (11) with a pre-tension pressure of 300 bar.

When tightening, ensure that no one is in the extended axis of the cross
stay or main bearing bolts to be tightened!

Observe the stroke controls (17) on the hydraulic tensioner whilst

pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke controls reach the top edge of the threaded
stop ring (16)! Otherwise the hydraulic tensioner will be damaged! See
Fig. 3.

15. Hand-tighten both nuts (10) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
16. Release pressure and uncouple high-pressure hoses from hydraulic
tensioners and high-pressure pump.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

17. Connect high-pressure hoses to hydraulic tensioners of the main bear-

ing bolts (5).
18. Set high-pressure pump in operation (see Work Card 009.03) and
tighten main bearing bolts (5) with pre-tension pressure 300 bar.
Work Cards, classified into sub-assemblies

19. Hand-tighten both nuts (4) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
20. Release pressure and uncouple high-pressure hoses from hydraulic
tensioners and high-pressure pump.

The hydraulic tensioners return to the zero position automatically by the

L48/60B;L51/60DF;L48/60CR

cup springs (resetting duration about 2 to 3 minutes). However, the high-

pressure pump must be connected, and its relief valve must be open (see
Work Card 009.03).

21. Connect high-pressure hoses again to hydraulic tensioners of the cross

tie rods (11).
2008-01-29

22. Set high-pressure pump in operation (see Work Card 009.03) and
tighten cross tie rod (11) with specified clamping pressure (see Work
Card 000.30).
23. Hand-tighten both nuts (10) through the cut-out in the thrust pieces
using a tommy bar.

8 (15) 6704 012.02-02 EN

 MAN Diesel & Turbo 012.02

24. Release pressure and uncouple high-pressure hoses from hydraulic

Cylinder crankcase/tie rod

tensioners and high-pressure pump.
25. Connect high-pressure hoses to hydraulic tensioners of the main bear-
ing bolts (5).
26. Set high-pressure pump in operation (see Work Card 009.03) and
tighten main bearing bolts (5) with a pre-tension pressure of 300 bar.
27. Place measuring devices (009.051) onto casing of the hydraulic ten-
sioners. See Fig. 9.

Ensure that feeler pin of the measuring gauges rests on piston of the
hydraulic tensioners!

The positions of dial gauge and sensor pin can be adjusted to the
situation by various assembly variants and by using the extensions (see
Work Card 009.18).
In addition, use the extensions (009.449 and 009.450) for a better view of
the measuring gauge for the crankshaft bearing bolt on exhaust side.

28. Set measuring gauges to "Zero".

29. Tension crankshaft bearing bolts (5) with specified tensioning pressure
(see Work Card 000.30).
30. Hand-tighten both nuts (4) through the cut-out in the thrust pieces using
a tommy bar.
31. Release the pressure.
32. Tension crankshaft bearing bolts (5) again with pretensioning pressure 300
bar.
33. Read off bolt elongation Δl on measurement gauges, note and compare
with required value (see Work Card 000.30).

Work Cards, classified into sub-assemblies

Tension main bearing bolts with the specified tensioning pressure, not
according to the bolt elongation Δl! The measurement of the screw
elongation Δl is only for checking!

In the event of larger deviations from the nominal value, repeat the
L48/60B;L51/60DF;L48/60CR

tensioning process, if needed, check the hydraulic tensioners, the bolt

connections and pressure gauges.

34. Release pressure, uncouple high-pressure hoses from hydraulic ten-

sioners and high-pressure pump.
35. Detach measuring device.
2008-01-29

36. Unscrew hydraulic tensioner using socket wrench (009.067) and remove
with suspension device (009.050).
37. Remove thrust pieces with suspension fixture (021.150).
38. Fasten protection caps (3) on crankshaft bearing bolts (5).

6704 012.02-02 EN 9 (15)

012.02 MAN Diesel & Turbo

39. Refit the pipes that have been removed (e.g. lube oil pipe for control
Cylinder crankcase/tie rod

lever lubrication, air pipe for starting valve etc.).

40. Detach tensioners from cross tie rods (11).
41. Fit protection caps (14) on threads of the cross tie rods (11).
42. Close cylinder head cover.

Work sequence 6 - Tightening the cross tie rods

Remarks Work sequence 6 describes tightening the cross tie rods of the neighbouring
main bearing after the installation of main bearing shells (see Work Card
021.01 and 021.02).
Starting position Nuts are tightened hand-tight, cross tie rod threads are cleaned.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Place thrust pieces (055.100) over nuts (10).

2. Screw hydraulic tensioner (009.063) onto cross tie rod (11), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
3. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338 or 009.342).
4. Set high-pressure pump in operation (see Work Card 009.03) and
tighten cross tie rod (11) with specified clamping pressure (see Work
Card 000.30).

While tensioning, take care that no one is present in the extended axis
of the cross tie-rod to be tensioned!
Work Cards, classified into sub-assemblies

Observe the stroke controls (17) on the hydraulic tensioner whilst

pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke controls reach the top edge of the threaded
stop ring (16)! Otherwise the hydraulic tensioner will be damaged! See
Fig. 3.
L48/60B;L51/60DF;L48/60CR

5. Hand-tighten both nuts (10) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
6. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

The hydraulic tensioner returns to the zero position automatically by the

2008-01-29

compression springs (resetting duration about 2 to 3 minutes). However,

the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

7. Detach the tensioners.

10 (15) 6704 012.02-02 EN

 MAN Diesel & Turbo 012.02

8. Fit protection caps (14) on threads of the cross tie rods (11).

Cylinder crankcase/tie rod

Work Cards, classified into sub-assemblies
1 Hexagon bolt 10 Nut
2 Washer 11 Cross tie rod
3 Protection cap 12 Ring
4 Nut 14 Protection cap
5 Crankshaft bearing bolt 15 Nut
8 Main bearing cap A Bolt projection
L48/60B;L51/60DF;L48/60CR

9 Cylinder crankcase
Figure 1: Crankshaft bearing bolt and cross tie rod
2008-01-29

6704 012.02-02 EN 11 (15)

012.02 MAN Diesel & Turbo
Cylinder crankcase/tie rod
Work Cards, classified into sub-assemblies

5 Crankshaft bearing bolt 11 Cross tie rod

9 Cylinder crankcase 12 Ring
L48/60B;L51/60DF;L48/60CR

Figure 2: Crankshaft bearing bolt and cross tie rod with attached tensioners
2008-01-29

12 (15) 6704 012.02-02 EN

 MAN Diesel & Turbo 012.02

Cylinder crankcase/tie rod

9 Cylinder crankcase 13 O-ring seal
10 Nut 16 Threaded stop ring
11 Cross tie rod 17 Stroke control
12 Ring M Marking on the stroke control
Figure 3: Cross tie rod with attached tensioner

4 Nut Work Cards, classified into sub-assemblies

5 Crankshaft bearing bolt
9 Cylinder crankcase
18 Rope
L48/60B;L51/60DF;L48/60CR

19 Hexagon bolt M6x16

2008-01-29

Figure 4: Suspending the thrust piece

6704 012.02-02 EN 13 (15)

012.02 MAN Diesel & Turbo
Cylinder crankcase/tie rod

18 Rope

Figure 5: Suspending the hydraulic tensioner

Work Cards, classified into sub-assemblies

Figure 6: Screwing on/off the hydraulic tensioner

L48/60B;L51/60DF;L48/60CR

2008-01-29

14 (15) 6704 012.02-02 EN

 MAN Diesel & Turbo 012.02

Cylinder crankcase/tie rod

4 Nut
5 Crankshaft bearing bolt
9 Cylinder crankcase
A Bolt projection

Figure 7: Crankshaft bearing bolt with attached tensioner

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF;L48/60CR
2008-01-29

Figure 8: Hydraulic tensioner with attached measuring device (left illustration for main bearing bolt on control
side - right illustration for main bearing bolt on exhaust side)

6704 012.02-02 EN 15 (15)

 MAN Diesel & Turbo 012.03

Crankshaft bearing bolt (external bearing) and cross tie rod

Cylinder crankcase/tie rod

inspection, loosening and tightening

Summary
Tension and release important threaded connections with the correct val-
ues, ensure correct execution of work.
crankshaft bearing bolts and cross tie rods should be inspected at regular
intervals by means of hydraulic tensioners.
The work/work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 055.125 Standard
2 Thrust piece 055.100 Standard
1 Foot board (for oil sump) 011.007 Standard
1 Foot board (for oil sump) 011.003 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
2 Hydraulic tensioner 009.063 Standard
2 Hydraulic tensioner 009.062 Standard
1 Thickness gauges 0.05-1 000.451 Option

Work Cards, classified into sub-assemblies

1 Tommy bar, 12 000.264 Standard
1 Tommy bar, 8 000.262 Standard
L48/60;L48/60B;L51/60DF;L48/60CR
1 Combination spanner (set) - Inventory
1 Securing compound, Loctite 243 - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.13

Work sequence 1 - Checking the cross tie rods

2007-07-30

Work steps 1. Remove protection caps (4).

2. Clean threads of the cross tie rods (5).

3. Place thrust pieces (055.100) over nuts (3).

6644 012.03-01 EN 1 (10)

012.03 MAN Diesel & Turbo

4. Screw hydraulic tensioner (009.063) onto cross tie rod (5), ensuring that
Cylinder crankcase/tie rod

thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
5. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
6. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
7. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

When releasing, ensure that no is present in the extended axis of the

cross tie rod!

8. Pump the hydraulic tensioners until the nuts (3) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

Observe the stroke controls (10) on the hydraulic tensioner whilst

pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke controls reach the top edge of the threaded
stop ring (11)! Otherwise the hydraulic tensioner will be damaged! See
Fig. 3.

9. Make a note of the release pressure and compare it to the clamping

pressure.
10. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
11. Hand-tighten both nuts (3) through the cut-out in the thrust pieces by
Work Cards, classified into sub-assemblies

using a tommy bar (000.264).

12. Release pressure, uncouple high-pressure hoses from hydraulic ten-
sioners and high-pressure pump.
L48/60;L48/60B;L51/60DF;L48/60CR

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

13. Detach the tensioners.

14. Fit protection caps (4) on threads of the cross tie rods (5).

Work sequence 2 - Checking the crankshaft bearing bolts

2007-07-30

Starting position Casing covers on the camshaft drive are removed.

Work steps 1. Insert foot board (011.007 for normal oil sump or 011.003 for V oil sump)
into oil sump.

2 (10) 6644 012.03-01 EN

 MAN Diesel & Turbo 012.03

2. Remove temperature sensor from crankshaft bearing cover (9) and

Cylinder crankcase/tie rod

place it safely outside the camshaft drive.

It may be necessary to remove a few clamps used for fastening the

temperature sensor line.

3. Clean the thread of the crankshaft bearing bolts (8).

4. Place thrust pieces (055.125) over nuts (7).
5. Screw hydraulic tensioner (009.062) onto crankshaft bearing bolts (8),
ensuring that thrust pieces are centred by the hydraulic tensioner. See
Figs. 2 and 4.
6. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
7. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338).
8. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

Ensure that no one is in the extended axis of the main bearing bolt!

9. Pump the hydraulic tensioners until the nuts (7) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

Work Cards, classified into sub-assemblies

Observe the stroke controls (10) on the hydraulic tensioner whilst
pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke controls reach the top edge of the threaded
stop ring (11)! Otherwise the hydraulic tensioner will be damaged! See
L48/60;L48/60B;L51/60DF;L48/60CR

Fig. 4.

10. Make a note of the release pressure and compare it to the clamping
pressure.
11. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
12. Insert a tommy bar (000.262) through the cut-out in the thrust pieces
and tighten both nuts (7) hand-tight.
13. Release pressure, uncouple high pressure hoses from hydraulic ten-
2007-07-30

sioners and high pressure pump.

6644 012.03-01 EN 3 (10)

012.03 MAN Diesel & Turbo

The hydraulic tensioner returns to the zero position automatically by the

Cylinder crankcase/tie rod

compression springs (resetting duration about 2 to 3 minutes). However,

the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

14. Detach the tensioners.

15. Install the temperature sensor in the main bearing cap (9).

If the clamps which are used for fastening the temperature sensor line
have been removed, their hexagon bolts must be locked with securing
compound Loctite 243 when re-fitting them.

16. Remove foot board from the oil sump.

Work sequence 3 - Unloading the cross tie rods

Work steps 1. Remove protection caps (4).

2. Clean threads of the cross tie rods (5).

3. Place thrust pieces (055.100) over nuts (3).
4. Screw hydraulic tensioner (009.063) onto cross tie rod (5), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
5. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338).
6. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

When releasing, take care that no one is present in the extended axis of
the cross tie rod to be released!
Work Cards, classified into sub-assemblies

7. Pump the hydraulic tensioners until the nuts (3) can be released.

In the process, the pressure must not be more than max. 7 % below or
L48/60;L48/60B;L51/60DF;L48/60CR

max. 5 % above the tensioning pressure (see Work Card 000.30)!

Observe the stroke controls (10) on the hydraulic tensioner whilst

pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke controls reach the top edge of the threaded
stop ring (11)! Otherwise the hydraulic tensioner will be damaged! See
Fig. 4.
2007-07-30

8. Make a note of the release pressure and compare it to the clamping

pressure.
9. Turn back both nuts (3) using tommy bar (000.264) through the cut-out
in the thrust pieces (for turn-back angle see Work Card 000.30).

4 (10) 6644 012.03-01 EN

 MAN Diesel & Turbo 012.03

10. Release pressure, uncouple high pressure hoses from hydraulic ten-

Cylinder crankcase/tie rod

sioners and high pressure pump.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

11. Detach the tensioners.

Work sequence 4 - Releasing the crankshaft bearing bolts

Starting position Casing covers on the camshaft drive are removed.

Before releasing main bearing bolts, cross tie rods must be unloaded
(see work sequence 3)!

Work steps 1. Insert foot board (011.007 for normal oil sump or 011.003 for V oil sump)
into oil sump.
2. Remove temperature sensor from crankshaft bearing cover (9) and
place it safely outside the camshaft drive.

It may be necessary to remove a few clamps used for fastening the

temperature sensor line.

3. Clean the thread of the crankshaft bearing bolts (8).

4. Place thrust pieces (055.125) over nuts (7).
5. Screw hydraulic tensioner (009.062) onto crankshaft bearing bolts (8),
ensuring that thrust pieces are centred by the hydraulic tensioner. See
Figs. 2 and 3.

Work Cards, classified into sub-assemblies

6. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
L48/60;L48/60B;L51/60DF;L48/60CR
7. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338).
8. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

When releasing, ensure that no one is in the extended axis of the main
bearing bolts to be released!
2007-07-30

9. Pump the hydraulic tensioners until the nuts (7) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

6644 012.03-01 EN 5 (10)

012.03 MAN Diesel & Turbo

Observe the stroke controls (10) on the hydraulic tensioner whilst

Cylinder crankcase/tie rod

pumping! The hydraulic tensioner may be pumped up only until the

markings (M) on the stroke controls reach the top edge of the threaded
stop ring (11)! Otherwise the hydraulic tensioner will be damaged! See
Fig. 4.

10. Make a note of the release pressure and compare it to the clamping
pressure.
11. Turn back both nuts (7) by inserting tommy bar (000.262) through the
cut-out in the thrust pieces (for turn-back angle see Work Card 000.30).
12. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

13. Detach the tensioners.

Work sequence 5 - Tensioning the main bearing bolts and the cross tie rods
Starting position Foot board is inserted in the oil sump. Temperature sensor is placed aside
safely outside the camshaft drive. Crankshaft bearing cap is lifted until it
rests on the cylinder crankcase, all nuts (3 and 7) are screwed on and tight-
ened hand-tight. Threads of the crankshaft bearing bolts and of the cross
tie rod are cleaned.

Carry out tensioning of the main bearing bolts and of the cross tie rod in
several steps! Ensure correct order of tightening!
Prerequisite for correct tightening of a bolted connection is a pressure
gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!
Work Cards, classified into sub-assemblies

Work steps 1. Check that gap in the parting line between crankshaft bearing cover (9)
and cylinder crankcase (6) is equal on both sides.
L48/60;L48/60B;L51/60DF;L48/60CR

2. Place thrust pieces (055.100) over nuts (3).

3. Screw hydraulic tensioner (009.063) onto cross tie rod (5), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
4. Place thrust pieces (055.125) over nuts (7).
5. Screw hydraulic tensioner (009.062) onto crankshaft bearing bolts (8),
ensuring that thrust pieces are centred by the hydraulic tensioner. See
Figs. 2 and 4.
6. Connect high-pressure hoses (009.306) to hydraulic tensioner of the
cross tie rods (5) and to high-pressure pump (009.338).
2007-07-30

7. Put high pressure pump in operation (see Work Card 009.03) and ten-
sion cross tie rod (5) with pre-tensioning pressure 300 bar.

6 (10) 6644 012.03-01 EN

 MAN Diesel & Turbo 012.03

When tightening, ensure that no one is in the extended axis of the cross

Cylinder crankcase/tie rod

stay or main bearing bolts to be tightened!

Observe the stroke controls (10) on the hydraulic tensioner whilst

pumping! The hydraulic tensioner may be pumped up only until the
markings (M) on the stroke controls reach the top edge of the threaded
stop ring (11)! Otherwise the hydraulic tensioner will be damaged! See
Figs. 3 and 4.

8. Hand-tighten both nuts (3) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
9. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

10. Connect high-pressure hoses to hydraulic tensioners of the main bear-

ing bolts (8).
11. Set high-pressure pump in operation (see Work Card 009.03) and
tighten main bearing bolts (8) with specified clamping pressure (see
Work Card 000.30).
12. Insert a tommy bar (000.262) through the cut-out in the thrust pieces
and tighten both nuts (7) hand-tight.
13. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.
14. Connect high-pressure hoses again to hydraulic tensioners of the cross

Work Cards, classified into sub-assemblies

tie rods (5).
15. Set high-pressure pump in operation (see Work Card 009.03) and
tighten cross tie rod (5) with specified clamping pressure (see Work Card
L48/60;L48/60B;L51/60DF;L48/60CR
000.30).
16. Hand-tighten both nuts (3) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
17. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.
18. Detach tensioners from main bearing bolts (8) and cross tie rods (5).
19. Install the temperature sensor in the main bearing cap (9).
2007-07-30

If the clamps which are used for fastening the temperature sensor line
have been removed, their hexagon bolts must be locked with securing
compound Loctite 243 when re-fitting them.

20. Remove foot board from the oil sump.

6644 012.03-01 EN 7 (10)

012.03 MAN Diesel & Turbo

21. Fit protection caps (4) on threads of the cross tie rods (5).
Cylinder crankcase/tie rod

1 Ring 6 Cylinder crankcase

2 O-ring seal 7 Nut
3 Nut 8 Crankshaft bearing bolt
4 Protection cap 9 Main bearing cap
5 Cross tie rod
Figure 1: Crankshaft bearing (external bearing)
Work Cards, classified into sub-assemblies
L48/60;L48/60B;L51/60DF;L48/60CR

2007-07-30

8 (10) 6644 012.03-01 EN

 MAN Diesel & Turbo 012.03

Cylinder crankcase/tie rod

1 Ring 9 Main bearing cap
Figure 2: Crankshaft bearing bolt and cross tie rod with attached tensioners

Work Cards, classified into sub-assemblies

L48/60;L48/60B;L51/60DF;L48/60CR

1 Ring 9 Cylinder crankcase

2 O-ring seal 10 Stroke control
3 Nut 11 Threaded stop ring
5 Cross tie rod M Marking on the stroke control
2007-07-30

Figure 3: Cross tie rod with attached tensioner

6644 012.03-01 EN 9 (10)

012.03 MAN Diesel & Turbo
Cylinder crankcase/tie rod

7 Nut 10 Stroke control

8 Crankshaft bearing bolt 11 Threaded stop ring
9 Main bearing cap M Marking on the stroke control
Figure 4: Crankshaft bearing bolt with attached tensioner
Work Cards, classified into sub-assemblies
L48/60;L48/60B;L51/60DF;L48/60CR

2007-07-30

10 (10) 6644 012.03-01 EN

 MAN Diesel & Turbo 012.04

Cylinder head bolts

Cylinder crankcase/tie rod

removal and installation

Summary
Insert/ replace components, ensure proper application. Cylinder head bolts
should be removed, if their O-rings are damaged. Cylinder head bolts should
also be removed, if cylinder liners need to be removed in tight fitting height
locations.
The work/work steps include: Dismantling of components, Installation of
components.
Tools/aids required
Quantity Designation Number Status
1 Bolt extractor 014.015 Standard
1 Tommy bar, 16 000.266 Standard
1 Combination spanner (set) - Inventory
1 Lifting tackle with rope - Inventory
1 Side cutter - Inventory
1 Sliding calliper Form C - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
034.01 050.01 055.01
055.02

Technical data

Work Cards, classified into sub-assemblies

Designation Information
Cylinder head bolt - L 48/60 B 33,5 kg
Cylinder head bolt - L 48/60 B 29,5 kg
Projection (A) 50 mm

Preliminary remark
48/60B;48/60CR;51/60DF

The Work sequences 1 and 2 describe the normal installation and removal
of the cylinder head bolts.
The Work sequences 3 and 4 describe the installation and removal of the
cylinder head bolts in tight space conditions (e. g low construction height
for removal of the cylinder liner).
2007-12-06

Work sequence 1 - Removing the cylinder head bolts

Starting position Cylinder liner with backing ring is removed.

Work steps 1. Check that hexagon nuts (7) on bolt extractors (014.015) are released.

6707 012.04-01 EN 1 (9)

012.04 MAN Diesel & Turbo

2. Screw bolt extractor onto cylinder head bolt (1).

Cylinder crankcase/tie rod

Pay attention to projection (A) between bolt extractor and cylinder head
bolt. See Fig. 2.

3. Tighten hexagon nuts (7).

4. Insert tommy bar (000.266) into bolt extractor. See Fig. 2.
5. Release and unscrew cylinder head bolt (1).
6. Loop cable around tommy bar and bolt extractor and suspend from lift-
ing tackle.
7. Remove cylinder head bolt (1) and place carefully on a clean surface.
8. Remove cable, pull out tommy bar, release hexagon nuts (7) and
unscrew bolt extractor.
9. Remove the remaining cylinder head bolts (1) in the same manner. See
point 2 to 8.
10. Remove O-rings (3 and 6) and ring (4) from cylinder head bolts (1).
11. Clean cylinder head bolts (1).

Work sequence 2 - Installing the cylinder head bolts

Starting position Cylinder head bolts are cleaned.

Work steps 1. Clean holes and threads in the cylinder crankcase (5) carefully.

2. Lightly oil shank of the cylinder head bolt (1) with clean lubricating oil.
3. Slide new O-rings (3) and new ring (4) over threads on shank of the cyl-
inder head bolt (1).

When sliding the O-ring seals over, make sure that they are not damaged
in the process!
Work Cards, classified into sub-assemblies

4. Slide new O-ring seal (6) over threads and insert in ring groove, ensuring
that this is tensioned equally around the entire periphery and is not
twisted. Oil the O-ring seal with clean lubricating oil.

When sliding the O-ring seals over, make sure that they are not damaged
48/60B;48/60CR;51/60DF

in the process!

5. Check that hexagon nuts (7) on bolt extractors (014.015) are released.
2007-12-06

6. Screw bolt extractor onto cylinder head bolt (1).

Pay attention to projection (A) between bolt extractor and cylinder head
bolt. See Fig. 2.

2 (9) 6707 012.04-01 EN

 MAN Diesel & Turbo 012.04

7. Tighten hexagon nuts (7).

Cylinder crankcase/tie rod

8. Insert tommy bar (000.266) into bolt extractor. See Fig. 2.
9. Loop cable around tommy bar and bolt extractor and suspend from lift-
ing tackle. Lift cylinder head bolt (1) carefully.
10. Insert cylinder head bolt (1) in hole.
11. Remove rope.
12. Screw cylinder head bolt (1) in, and tighten it hand-tight.
13. Pull out tommy bar, release hexagon nuts (7) and unscrew bolt extractor.
14. Oil locating bore in the cylinder crankcase (5) as well as O-rings (3) and
ring (4) with clean lubricating oil.
15. Slide O-rings (3) and ring (4) individually into the locating hole, ensuring
that O-rings are not twisted. See Fig. 1.
16. Install the remaining cylinder head bolts (1) in the same manner. See
point 2 to 15.
17. Fit cylinder liner (with backing ring), piston, top land ring and cylinder
head (see Work Cards 050.01, 034.01 and 055.02).
18. Tighten cylinder head bolts (see Work Card 055.01).

Before clamping the cylinder head bolts, make sure that the cylinder
crankcase and the cylinder head bolts are at the same temperature!
This is particularly important for the replacement of cylinder head bolts
in an engine at a hot operating temperature!

Work sequence 3 - Removal of the cylinder head bolts (for low dismantling height for
cylinder liner)
Starting position Cylinder head removed.

Work Cards, classified into sub-assemblies

Work steps 1. Check that hexagon nuts (7) on bolt extractors (014.015) are released.

2. Screw bolt extractor onto cylinder head bolt (1).

Pay attention to projection (A) between bolt extractor and cylinder head
bolt. See Fig. 2.
48/60B;48/60CR;51/60DF

3. Tighten hexagon nuts (7).

4. Insert tommy bar (000.266) into bolt extractor. See Fig. 2.
5. Release and unscrew cylinder head bolt (1). See Fig. 3/I.
6. Loop cable around tommy bar and bolt extractor and suspend from lift-
2007-12-06

ing tackle.
7. Lift cylinder head bolt (1) until O-rings (3) and ring (4) are exposed. See
Fig. 3/II.
8. Cut through O-rings (3) using side cutters and remove.

6707 012.04-01 EN 3 (9)

012.04 MAN Diesel & Turbo

9. Remove cylinder head bolt (1) slowly, the ring (4) always having to be
Cylinder crankcase/tie rod

displaced during the dismantling.

It is necessary to displace the ring during dismantling because the

diameter of the hole in the thrust ring (2) is smaller than the outside
diameter of the ring.

10. Remove the O-ring seal (6) and ring (4) before finally removing the cyl-
inder head bolt (1). See Fig. 3/III.
11. Remove cylinder head bolt (1) completely and place carefully on a clean
surface.
12. Remove cable, pull out tommy bar, release hexagon nuts (7) and
unscrew bolt extractor.
13. Remove the remaining cylinder head bolts (1) in the same manner. See
point 2 to 12.
14. Clean cylinder head bolts (1).

Work sequence 4 - Installation of the cylinder head bolts (with low dismantling height for
cylinder liner)
Starting position Cylinder head bolts are cleaned, backing ring and cylinder liner are installed.

Work steps 1. Clean holes and threads in the cylinder crankcase (5) carefully.

2. Check that hexagon nuts (7) on bolt extractors (014.015) are released.
3. Screw bolt extractor onto cylinder head bolt (1).

Pay attention to projection (A) between bolt extractor and cylinder head
bolt. See Fig. 2.

4. Tighten hexagon nuts (7).

Work Cards, classified into sub-assemblies

5. Insert tommy bar (000.266) into bolt extractor. See Fig. 2.

6. Loop cable around tommy bar and bolt extractor and suspend from lift-
ing tackle. Lift cylinder head bolt (1) carefully.
7. Lightly oil shank of the cylinder head bolt (1) with clean lubricating oil.
8. Insert cylinder head bolt (1) through hole in the backing ring (2). See Fig.
4/I.
48/60B;48/60CR;51/60DF

9. Slide new O-rings (3 and 6) and new ring (4) over threads on shank of
the cylinder head bolt (1). See Fig. 4/I.

Ensure correct sequential order!

When sliding the O-rings over, make sure that they are not damaged in
2007-12-06

the process!

10. Lower cylinder head bolt (1) slightly and Insert new O-ring seal (6) in ring
groove, ensuring that this is tensioned equally around the entire periph-

4 (9) 6707 012.04-01 EN

 MAN Diesel & Turbo 012.04

ery and is not twisted. Oil the O-ring seal with clean lubricating oil. See

Cylinder crankcase/tie rod

Fig. 4/II.
11. Push O-rings (3) and ring (4) until they rests on backing ring (2). See Fig.
4/II.
12. Again lower the cylinder head bolt (1) slightly and move O-rings (3) and
ring (4) again until they rest on backing ring (2).
13. Keep repeating point 12 until cylinder head bolt (1) is completely inserted
in cylinder crankcase (5).
14. Remove rope.
15. Screw cylinder head bolt (1) in, and tighten it hand-tight. See Fig. 4/III.
16. Pull out tommy bar, release hexagon nuts (7) and unscrew bolt extractor.
17. Oil locating bore in the cylinder crankcase (5) as well as O-rings (3) and
ring (4) with clean lubricating oil.
18. Slide O-rings (3) and ring (4) individually into the locating hole, ensuring
that O-rings are not twisted. See Fig. 1.
19. Install the remaining cylinder head bolts (1) in the same manner. See
point 3 to 18.
20. Attach piston, top land ring and cylinder head (see Work Cards 034.01
and 055.02).
21. Tighten cylinder head bolts (see Work Card 055.01).

Before clamping the cylinder head bolts, make sure that the cylinder
crankcase and the cylinder head bolts are at the same temperature!
This is particularly important for the replacement of cylinder head bolts
in an engine at a hot operating temperature!

Work Cards, classified into sub-assemblies

48/60B;48/60CR;51/60DF
2007-12-06

6707 012.04-01 EN 5 (9)

012.04 MAN Diesel & Turbo
Cylinder crankcase/tie rod
Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

1 Cylinder head bolt 4 Ring

2007-12-06

2 Backing ring 5 Cylinder crankcase

3 O-ring seal 6 O-ring seal
Figure 1: Cylinder head bolt

6 (9) 6707 012.04-01 EN

 MAN Diesel & Turbo 012.04

Cylinder crankcase/tie rod

1 Cylinder head bolt
7 Hexagon nut M10
Projection
A (bolt extractor - cylinder head
bolt)

Figure 2: Attaching the bolt extractor to the cylinder head bolt

Work Cards, classified into sub-assemblies

48/60B;48/60CR;51/60DF
2007-12-06

6707 012.04-01 EN 7 (9)

012.04 MAN Diesel & Turbo
Cylinder crankcase/tie rod
Work Cards, classified into sub-assemblies

1 Cylinder head bolt 4 Ring I-III Work steps

2 Backing ring 5 Cylinder crankcase
3 O-ring seal 6 O-ring seal
Figure 3: Dismantling of a cylinder head bolt (low dismantling height for cylinder liner - Work sequence 3)
48/60B;48/60CR;51/60DF

2007-12-06

8 (9) 6707 012.04-01 EN

 MAN Diesel & Turbo 012.04

1 Cylinder head bolt 4 Ring I-III Work steps

Cylinder crankcase/tie rod
Work Cards, classified into sub-assemblies
2 Backing ring 5 Cylinder crankcase
3 O-ring seal 6 O-ring seal
Figure 4: Installation of a cylinder head bolt (low dismantling height for cylinder liner - Work sequence 4)
48/60B;48/60CR;51/60DF
2007-12-06

6707 012.04-01 EN 9 (9)

MAN Diesel & Turbo 020

Crankshaft/Coupling bolts
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.4-1 EN 1 (2)

 MAN Diesel & Turbo
Crankshaft/Coupling bolts

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.4-1 EN

 MAN Diesel & Turbo 000.10

Crankshaft

Crankshaft/Coupling bolts
Measuring crankshaft deflection

Summary
Check alignment, detect problems (having an influence) on components/
systems, ensure/restore operational safety.
The web deflection indicates the alignment of the crankshaft bearing and
the bearing/alignment of the driven shaft. Web deflection must be checked
in regular intervals.
The work includes:
checking the alignment,
recording measured values and
evaluation of results.
Safety requirements
- Engine secured against starting
- Engine shut down
Personnel and time required
Number Qualification Duration in h

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;51/60DF;V28/33D
1 Technician 0,15
1 Assistant 0,15

Tools/aids required
Quantity Designation Number Status
1 Guide tube 021.032 Standard
1 Tools, Basic Scope 009.229 Option
1 Web deflection measurement unit (mechanical) 008.171 Option

Work Cards, classified into sub-assemblies

1 Thickness gauges 0.05-1 000.454 Standard
1 Felt-tip pen/marker pen - Inventory

Corresponding Work Cards

Work card Work card Work card
000.09

Preliminary remark
The crank web deflection is the difference in the measured values between
two crank web positions offset by 180º. The crank web deflection indicates
the alignment of the main bearings and the bearing of the driven shaft. If the
2010-03-24

measured values (table 2 and 3) exceed the maximum values (table 4)

allowed, the cause should be eliminated and the crankshaft realigned. Pos-
sible causes are:
▪ Unequal wear on crankshaft bearing,
▪ Changes of the position of the driven shaft or

6682 000.10-05 EN 1 (6)

000.10 MAN Diesel & Turbo

▪ Changes in the fixing of the engine on the foundations or of the foun-

Crankshaft/Coupling bolts

dation.
The results of the measurement of the crank web deflection are correlated
with the check of the alignment of the crankshaft flange to the driven shaft.
Work sequence 1 - Measuring the crank web deflection
The measuring gauge is to be read at the RBDC and LBDC points when the
connecting rod is installed. If the connecting rod is installed, then it is to be
read in the BDC position.
The position of the crankshaft pin, not that of the measurement unit, is
decisive for the designation.
The designation of the crankshaft's sides and sense of rotation must be
made when looking at the crankshaft from the coupling flange (coupling
side).
For the subsequent work steps, the measurement must be made with the
connecting rods installed (normal case).
Work steps 1. Dismantle the covers on the running gear apertures.

2. Turn crankshaft cylinder 1 to the starting position, depending on the

normal rotation direction of the engine, either in the LBDC or RBDC
position.
32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;51/60DF;V28/33D

Initial position
The initial position for the measurement of each crank is a position that
is closest possible to the left or right of the BDC and that allows the
measurement unit to be located.

3. Check whether the crankshaft is lying on the lower bearing shells using
the feeler gauges (000.454).

Incorrect values due to not fully supported crankshaft

If the crankshaft ist not fully supported, the values of the web deflection
Work Cards, classified into sub-assemblies

measurement will be incorrect.

4. Select suitable extension rods and mount them on measurement unit.

5. Locate the measurement unit in the measuring points (2).

Measuring points
The measuring points for the measurement with fitted running gears are
in the balance weights! Exception: Engine 58/64, the measuring points
are in the crank webs!

Measurement when engine is hot

If the engine is measured when it is hot, the measurement unit should be
2010-03-24

placed in the crankcase approx. 15 minutes before measuring for

temperature adjustment.

6. Set the dial gauge approximately at the centre of the measuring range
to "0" as initial value.

2 (6) 6682 000.10-05 EN

 MAN Diesel & Turbo 000.10

7. Turn crankshaft in the normal rotation direction to the intended meas-

Crankshaft/Coupling bolts
uring positions (from RBDC to RTDC - TDC - LTDC - LBDC for engine
with left-hand rotation, from LBDC to LTDC - RTDC - RBDC). At the
positions stated, read the value and direction of the dial gauge indication
against the initial value and enter the figures into a table (see table 1).
Values are positive (+) if the measured distance is larger, values are
negative (-) if the measured distance is smaller than the initial value of
"0" (fig. 2, 3 and 4 / table 1).

Turning the crankshaft

Take care not to damage the measurement unit with the big-end bearing
bolts when turning the crankshaft!
When turning over a V-engine, ensure that the measurement unit is not
damaged by the slave connecting rod!

8. Measure the other crankshaft webs in the same way.

9. After measuring all webs, disassemble the measurement unit, clean it
and store it in the wooden case.

Work sequence 2 - Recording measured values

The measurement report must include the following information:
▪ Measurement value and direction of deviation (fig. 3, table 1),

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;51/60DF;V28/33D
▪ Assembly condition (e.g. piston/connecting rod installed/removed),
▪ Coupling type (rigid, resilient),
▪ Engine mounting (rigid, resilient, semi-resilient),
▪ Other relevant conditions (e.g. ship in dock or floating)
▪ Oil and coolant temperatures if the measurements are taken at engine
operating temperature, and
▪ Engine's main direction of rotation.

Work sequence 3 - Evaluation/Assessment

Work Cards, classified into sub-assemblies

Crank position Crank number
1 2 3 4 5 6 ...
Crank at RBDC 1)
0 0 0 0 0 0 ...
Crank at RTDC -2 +1 0 +2 +1 -1 ...
Crank at TDC -5 +3 +5 +6 +1 -3 ...
Crank at LTDC +1 +2 +4 +3 -3 -2 ...
Crank at LBDC 1)
+2 0 +2 0 -1 -1 ...
Table 1: Recording of measurement values (example) - measurement values in
1/100 mm
2010-03-24

1)
Measurement with connecting rod removed = BDC

Crank web deflection Crank number

1 2 3 4 5 6 ...
vertical av -6 +3 +4 +6 +1,5 -2,5 ... av = TDC - 1/2 (LBDC+RBDC)

6682 000.10-05 EN 3 (6)

000.10 MAN Diesel & Turbo

horizontal ah -3 -1 -4 -1 +4 +1 ... ah = RTDC - LTDC

Crankshaft/Coupling bolts

Table 2: Recording of measurement values (example) - web deflections in 1/100 mm

For comparison with the maximum permissible web deflection values, the
values of table 1 must be evaluated as stated in table 2. The vertical and
horizontal web deflection is determined (av and ah).
To obtain a value corresponding to the BDC position, a mean value of LBDC
and RBDC is calculated.
Example:
vertical av crank no. 6: av = (-3) - 0.5 ((-1) + 0) = -2.5
horizontal ah crank no. 6: ah = (-1) - (-2) = +1

Web deflection, with the corresponding algebraic sign, must not exceed the
maximum permissible value.

Crank number
1 to 2 2 to 3 3 to 4 4 to 5 5 to 6 6 to ... ...
Difference 8 2 1 5 4 ... ...
Table 3: Evaluation of TDC measurement values of adjacent cylinders (example) - absolute differential values
in 1/100 mm
32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;51/60DF;V28/33D

The absolute difference between the TDC values of adjacent cranks (cal-
culated in table 3) must not exceed the absolute values of the permissible web
deflection.
Example:
TDC measurement value between crank 5 +1 - (-3) = 4
and 6:
TDC measurement value between crank 2 +3 - (+5) = -2, absolute difference = 2
and 3:

Engine type 28/33 D 32/40 L 32/44 CR V 32/44 CR 40/54 L 48/60 V 48/60 58/64
Work Cards, classified into sub-assemblies

L 48/60 B V 48/60 B
L 48/60 CR V 48/60 CR
L 51/60 DF V 51/60 DF
Crank web with cold ±15 ±142) ±182) ±182) ±18 ±23 ±26 ±23
deflection engine
with warm ±15 +14 +18 +18 ±18 ±23 ±26 ±23
engine -20 -25 -25
Measuring 320 460 540 550 505 580 580 560
point dis-
tance (A)
Table 4: Maximum permissible web deflection (differential values) with the running gear installed and
corresponding measuring point distances. Applies to all cranks of rigidly or resiliently mounted engines,
except engine type 32/40 and 32/44 CR.1)2)
2010-03-24

Web deflection in 1/100 mm, measuring point distances in mm

1)
The values specified are guide values only. The measured values must be tested and approved by MAN Diesel
& Turbo SE individually for new construction or for maintenance checking purposes. Attention: Different values with
tighter limits apply to newly installed engines!
For crank no. 1 (on coupling side) for engines with resilient couplings of the type 32/40 the maximum values of
2)

+14/-20 apply, for type 32/44 CR the maximum values of +18/-25 apply.

4 (6) 6682 000.10-05 EN

 MAN Diesel & Turbo 000.10

Crankshaft/Coupling bolts
1 Crank web
2 Measuring point (centre punch)
3 Crank pin
A Measuring point distance

Figure 1: Measuring the crank web deflection

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;51/60DF;V28/33D
Work Cards, classified into sub-assemblies

1 Crank web 5 Counterweight LTDC Left Top Dead Centre

2 Measuring point LL Sense of engine rotation left RTDC Right Top Dead Centre
3 Crank pin RL Sense of engine rotation right LBDC Left Bottom Dead Centre
4 Connecting rod TDC Top Dead Centre RBDC Right Bottom Dead Centre
Figure 2: Web deflection measurement (with connecting rod) - seen from the coupling side - in-line engine
48/60 B shown
2010-03-24

6682 000.10-05 EN 5 (6)

000.10 MAN Diesel & Turbo
Crankshaft/Coupling bolts

1 Crank web
3 Crank pin

Figure 3: Direction of deviation - measuring point distance relative to initial value

"0" in BDC or LBDC or RBDC (+ = increase, – = decrease)

TDC Top Dead Centre

LTDC Left Top Dead Centre
RTDC Right Top Dead Centre
BDC Bottom Dead Centre
LBDC Left Bottom Dead Centre
RBDC Right Bottom Dead Centre

Figure 4: Designation of crank positions - seen from the coupling side

32/40;32/44CR;48/60B;48/60CR;L40/54;L58/64CD;51/60DF;V28/33D
Work Cards, classified into sub-assemblies

2010-03-24

6 (6) 6682 000.10-05 EN

 MAN Diesel & Turbo 020.01

Balance weight bolts

Crankshaft/Coupling bolts
inspection, loosening and tightening

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the correct execution of the work/restore operational safety.
Bolted connections which are tightened with hydraulic tensioners must be
checked according to the maintenance schedule for correct tensioning.
The work/work steps include:
determining pressure release and evaluating
tightening connection with target pressure.
Safety requirements
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 055.125 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
2 Hydraulic tensioner 009.062 Standard
2 Measuring device 009.052 Standard
2 Measuring gauge (measuring device) 009.052-1 Standard
2 Extension 009.052-2 Standard
2 Extension 009.052-3 Standard
2 Threaded piece 009.052-4 Standard

Work Cards, classified into sub-assemblies

1 Thickness gauges 0.05-1 000.451 Option
1 Tommy bar, 8 000.262 Standard
1 Screwdriver (Set) - Inventory
L48/60;L48/60B;L51/60DF;L48/60CR

Corresponding Work Cards

Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.13
009.15 020.02 020.03
027.01

Preliminary remark
2007-07-30

Check all bolted connections of torsional vibration damper, flywheel, crank-

shaft gearwheel and balance weights in the case of assembly work.

6644 020.01-01 EN 1 (8)

020.01 MAN Diesel & Turbo

Work sequence 1 - Checking the balance weight bolts

Crankshaft/Coupling bolts

Starting position Crankcase is opened, running gear turned over such that balance weight
bolts are easily accessible (balance weight points towards crankcase aper-
ture). See Fig. 1.

If the tensioners are attached to the balance weight bolts, the crankshaft
must not be turned over!

Work steps 1. Clean threads of the balance weight bolts (1).

2. Place thrust pieces (055.125) over nuts (2).

3. Screw hydraulic tensioner (009.062) onto balance weight bolts (1),
ensuring that thrust pieces are centred by the hydraulic tensioner. See
Figs. 2 and 3.
4. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
5. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338).
6. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

Ensure that nobody is present in the extension of the axis of the balance
weight bolts!

7. Pump the hydraulic tensioners until the nuts (2) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!
Work Cards, classified into sub-assemblies

While pumping up, watch the stroke controls (6) of the hydraulic
L48/60;L48/60B;L51/60DF;L48/60CR

tensioners! The hydraulic tensioners must only be pumped up to the

point where the markings (M) on the lift monitors reach the upper edge
of the threaded stop ring (7)! Otherwise the hydraulic tensioners will be
damaged!

8. Make a note of the release pressure and compare it to the clamping

pressure.
9. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
2007-07-30

10. Insert a tommy bar (000.262) through the cut-out in the thrust pieces
and tighten both nuts (2) hand-tight.
11. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

2 (8) 6644 020.01-01 EN

 MAN Diesel & Turbo 020.01

The hydraulic tensioner returns to the zero position automatically by the

Crankshaft/Coupling bolts
compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

12. Detach the tensioners.

Work sequence 2 - Detensioning the balance weight bolts

Starting position Crankcase is opened, running gear turned over such that balance weight
bolts are easily accessible (balance weight points towards crankcase aper-
ture). See Fig. 1.

If the tensioners are attached to the balance weight bolts, the crankshaft
must not be turned over!

Work steps 1. Clean threads of the balance weight bolts (1).

2. Place thrust pieces (055.125) over nuts (2).

3. Screw hydraulic tensioner (009.062) onto balance weight bolts (2),
ensuring that thrust pieces are centred by the hydraulic tensioner. See
Figs. 2 and 3.
4. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
5. Connect high-pressure hoses (009.306) to hydraulic tensioners and
high-pressure pump (009.338).
6. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

While releasing, take care that no one is present in the extended axis of
the balance weight bolts to be released!

7. Pump the hydraulic tensioners until the nuts (2) can be released. Work Cards, classified into sub-assemblies
L48/60;L48/60B;L51/60DF;L48/60CR

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

While pumping up, watch the stroke controls (6) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the lift monitors reach the upper edge
of the threaded stop ring (7)! Otherwise the hydraulic tensioners will be
2007-07-30

damaged!

8. Make a note of the release pressure and compare it to the clamping

pressure.

6644 020.01-01 EN 3 (8)

020.01 MAN Diesel & Turbo

9. Turn back both nuts (2) by inserting tommy bar (000.262) through the
Crankshaft/Coupling bolts

cut-out in the thrust pieces (for turn-back angle see Work Card 000.30).
10. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

The hydraulic tensioners return to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

11. Detach the tensioners.

Work sequence 3 -Tensioning of balance weight bolts

Starting position Nuts are screwed on and tightened by hand. Threads of the balance weight
bolts are cleaned.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Check that gap in the parting line between balance weight (3) and
crankshaft (4) is equal on both sides.
2. Unscrew locking bolt on hydraulic tensioners (009.062) (see Work Card
009.15). Screw the threaded piece (009.052-4) into threaded stop ring
(7). See Fig. 4.
3. Place thrust pieces (055.125) over nuts (2).
4. Screw hydraulic tensioners onto balance weight bolts (1), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
5. Screw the requisite extensions (009.052-2 or -3) onto measurement
gauges (009.052-1).
6. Insert measuring gauges into threaded pieces and fasten with cylinder
Work Cards, classified into sub-assemblies

bolts (8). See Fig. 4.

Ensure that feeler pin of the measuring gauges rests on piston of the
L48/60;L48/60B;L51/60DF;L48/60CR

hydraulic tensioners!

7. Connect high-pressure hoses (009.306) to hydraulic tensioners and to

high-pressure pump (009.338).
8. Put high pressure pump in operation (see Work Card 009.03) and ten-
sion balance weight bolts (1) with pre-tensioning pressure 50 bar.

While tensioning, take care that no one is present in the extended axis
2007-07-30

of the balance weight bolts to be tensioned!

4 (8) 6644 020.01-01 EN

 MAN Diesel & Turbo 020.01

While pumping up, watch the stroke controls (6) of the hydraulic

Crankshaft/Coupling bolts
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the lift monitors reach the upper edge
of the threaded stop ring (7)! Otherwise the hydraulic tensioners will be
damaged!

9. Set measuring gauges to "Zero".

10. Tension balance weight bolts (1) with specified tensioning pressure (see
Work Card 000.30).
11. Insert a tommy bar (000.262) through the cut-out in the thrust pieces
and tighten both nuts (2) hand-tight.
12. Release the pressure.
13. Tension balance weight bolts (1) again with pre-tensioning pressure 50
bar.
14. Read off bolt elongation Δl on measurement gauges, note and compare
with required value (see Work Card 000.30).

Tension balance weight bolts with the specified tensioning pressure, not
according to the screw elongation Δl! The measurement of the screw
elongation Δl is only for checking!

In the event of larger deviations from the nominal value, repeat the
tensioning process, if needed, check the hydraulic tensioners, the bolt
connections and pressure gauges.

15. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

The hydraulic tensioners return to the zero position automatically by the

Work Cards, classified into sub-assemblies

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03). L48/60;L48/60B;L51/60DF;L48/60CR
16. Remove measurement gauges.
17. Detach the tensioners.
18. Unscrew threaded piece from threaded stop rings (7) and close off tap-
ped holes with locking bolts (see Work Card 009.15).
2007-07-30

6644 020.01-01 EN 5 (8)

020.01 MAN Diesel & Turbo
Crankshaft/Coupling bolts

1 Balance weight bolts 3 Balance weight

2 Nut 4 Crankshaft
Work Cards, classified into sub-assemblies

Figure 1: Balance weight

L48/60;L48/60B;L51/60DF;L48/60CR

2007-07-30

6 (8) 6644 020.01-01 EN

 MAN Diesel & Turbo 020.01

Crankshaft/Coupling bolts
1 Balance weight bolts 3 Balance weight

Work Cards, classified into sub-assemblies

Figure 2: Balance weight bolts with attached tensioners
L48/60;L48/60B;L51/60DF;L48/60CR
2007-07-30

6644 020.01-01 EN 7 (8)

020.01 MAN Diesel & Turbo
Crankshaft/Coupling bolts

1 Balance weight bolts 6 Stroke control

2 Nut 7 Threaded stop ring
3 Balance weight M Marking on the stroke control
Figure 3: Balance weight bolt with attached tensioner

7 Threaded stop ring

8 Cylinder screw M5x12
Work Cards, classified into sub-assemblies
L48/60;L48/60B;L51/60DF;L48/60CR

Figure 4: Hydraulic tensioner with attached measuring device 2007-07-30

8 (8) 6644 020.01-01 EN

 MAN Diesel & Turbo 020.02

Coupling bolts

Crankshaft/Coupling bolts
inspection, loosening and tightening

Summary
Carry out the work in due time according to the maintenance schedule,
ensure the operational safety of the screwed connections.
The coupling bolts must be checked at regular intervals.
The work/work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 055.100 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
1 Combination spanner (set) 009.231 Option
2 Hydraulic tensioner 009.063 Standard
1 Torque wrench 750-2,000 Nm 008.005 Standard
1 Tommy bar, 12 000.264 Option
1 Felt-tip pen/marker pen - Inventory
1 Lifting tackle - Inventory

Work Cards, classified into sub-assemblies

1 Sliding calliper Form C - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Rope - Inventory
1 Socket spanner insert 50x25 - Inventory
48/60;48/60B;48/60CR;51/60DF

1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.13
071.01
2010-01-07

Technical data
Designation Information
Bolt projection (A) 150 mm

6644 020.02-02 EN 1 (8)

020.02 MAN Diesel & Turbo

Work sequence 1 -Checking the coupling bolts

Crankshaft/Coupling bolts

Starting position Coupling bolts are accessible.

Work steps 1. Remove oil tube (20) and casing (18) (see Work Card 071.01).

2. Clean threads of the coupling bolts (10 and 11).

3. Fit pressure pieces (055.100) on two opposing nuts (17).
4. Screw hydraulic tensioners (009.063) onto both coupling bolts (10 or
11), ensuring that pressure pieces are centred by the hydraulic ten-
sioner. See figs. 2 and 3.
5. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
6. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
7. Set the high pressure pump in operation (see Work Card 009.03) and
close the gap resulting from unscrewing.

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

8. Pump the hydraulic tensioners until the nuts (17) can be released.

Release pressure
The pressure must be max. 7 % under or max. 5 % above the clamping
pressure (see Work Card 000.30)!
Work Cards, classified into sub-assemblies

Do not damage hydraulic tensioners!

While pumping up, watch the lift checks (23) of the hydraulic tensioners.
The hydraulic tensioners must only be pumped up to the point where the
markings (M) on the lift checks reach the upper edge of the thread stop
ring (24). Otherwise the hydraulic tensioners will be damaged.
48/60;48/60B;48/60CR;51/60DF

9. Make a note of the release pressure and compare it to the clamping

pressure.
10. Adjust the high-pressure pump until the specified clamping pressure is
reached (see Work Card 000.30).
11. Tighten both nuts (17) fingertight through the cut-out in the pressure
pieces using a tommy bar (000.264).
2010-01-07

12. Release the pressure, uncouple the high pressure hoses from the
hydraulic tensioners.

2 (8) 6644 020.02-02 EN

 MAN Diesel & Turbo 020.02

Resetting the hydraulic tensioners

Crankshaft/Coupling bolts
The hydraulic tensioners return to the zero position automatically by the
compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its pressure-relief valve
must be open (see Work Card 009.03).

13. Detach the tensioners.

14. Re-position tensioners on next bolt pair and repeat the procedure until
all coupling bolts (10 or 11) have been checked. See points 3 to 13.
15. Uncouple high-pressure hoses from high-pressure pump once inspec-
tion is complete.
16. Fit casing (18) and oil tube (20) (see Work Card 071.01).
17. Check hexagon head screws (13) by applying specified torque (see
drawing of flywheel arrangement or coupling assembly drawing of the
specific unit in Volume 000 Systems Information - Drawings), re-tighten
hexagon head screws if necessary.

Work sequence 2 - Releasing the coupling bolts

Starting position Coupling removed (see documentation by the coupling manufacturer in
Volume 020.010 Coupling arrangement), Coupling bolts are accessible, fly-
wheel fastened to crankshaft by four hexagon socket bolts (22).
Work steps 1. Remove oil tube (20) and casing (18) (see Work Card 071.01).

2. Clean threads of the coupling bolts (10 and 11).

3. Fit pressure pieces (055.100) on two opposing nuts (17).
4. Screw hydraulic tensioners (009.063) onto both coupling bolts (10 or
11), ensuring that pressure pieces are centred by the hydraulic ten-
sioner. See figs. 2 and 3.
5. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).

Work Cards, classified into sub-assemblies

6. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
7. Set the high pressure pump in operation (see Work Card 009.03) and
close the gap resulting from unscrewing.
48/60;48/60B;48/60CR;51/60DF

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

8. Pump the hydraulic tensioners until the nuts (17) can be released.
2010-01-07

Release pressure
The pressure must be max. 7 % under or max. 5 % above the clamping
pressure (see Work Card 000.30)!

6644 020.02-02 EN 3 (8)

020.02 MAN Diesel & Turbo

Do not damage hydraulic tensioners!

Crankshaft/Coupling bolts

While pumping up, watch the lift checks (23) of the hydraulic tensioners.
The hydraulic tensioners must only be pumped up to the point where the
markings (M) on the lift checks reach the upper edge of the thread stop
ring (24). Otherwise the hydraulic tensioners will be damaged.

9. Make a note of the release pressure and compare it to the clamping

pressure.
10. Turn back both nuts (17) using tommy bar (000.264) through the cut-out
in the pressure pieces (for turn-back angle see Work Card 000.30).
11. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

Resetting the hydraulic tensioners

The hydraulic tensioners return to the zero position automatically by the
compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its pressure-relief valve
must be open (see Work Card 009.03).

12. Detach the tensioners.

13. Move tensioners to next bolt pair and repeat the sequence until all cou-
pling bolts (10 or 11) are released. See points 3 to 12.
14. Once all coupling bolts are released, uncouple high pressure hoses from
the high pressure pump.

Removing the flywheel

Before removing flywheel, check whether position of flywheel in relation
to the crankshaft flange is marked, if not, mark it.

Work sequence 3 - Tightening the coupling bolts

Work Cards, classified into sub-assemblies

Starting position The flywheel is fastened to the crankshaft with four hexagonal socket
screws (22), the plant no. and marks on the engine or crankshaft flange and
flywheel correspond. Coupling bolts have been cleaned and inserted in
holes.

Installation of coupling bolts

48/60;48/60B;48/60CR;51/60DF

Ensure correct installation of the coupling bolts (number of coupling

bolts, position of the fitting bolts (10), bolt protrusion (A) of coupling
bolts). See flywheel arrangement drawing of the unit concerned in
Volume 000 Systems Information - Drawings.

All nuts are screwed on and tightened fingertight.

Tightening the coupling bolts

2010-01-07

Tighten one pair of screws (two opposing coupling bolts) at a time.

4 (8) 6644 020.02-02 EN

 MAN Diesel & Turbo 020.02

Prerequisite for correct tightening of a bolted connection

Crankshaft/Coupling bolts
Prerequisite for correct tightening of a bolted connection is a pressure
gauge with an accurate read-out! If in doubt, test the pressure gauge
with an equivalent pressure gauge!

Work steps 1. Check bolt protrusion (A) of the coupling bolts (10 and 11).

2. Fit pressure pieces (055.100) on two opposing nuts (17).

3. Screw hydraulic tensioners (009.063) onto both coupling bolts (10 or
11), ensuring that pressure pieces are centred by the hydraulic ten-
sioner. See figs. 2 and 3.
4. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
5. Start high-pressure pump (see Work Card 009.03) and tension coupling
bolts (10 or 11) to specified clamping pressure (see Work Card 000.30).

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

Do not damage hydraulic tensioners!

While pumping up, watch the lift checks (23) of the hydraulic tensioners.
The hydraulic tensioners must only be pumped up to the point where the
markings (M) on the lift checks reach the upper edge of the thread stop
ring (24). Otherwise the hydraulic tensioners will be damaged.

6. Tighten both nuts (17) fingertight through the cut-out in the pressure
pieces using a tommy bar (000.264).
7. Release the pressure, uncouple the high-pressure hoses from the

Work Cards, classified into sub-assemblies

hydraulic tensioners.

Resetting the hydraulic tensioners

The hydraulic tensioners return to the zero position automatically by the
compression springs (resetting duration about 2 to 3 minutes). However,
48/60;48/60B;48/60CR;51/60DF

the high-pressure pump must be connected, and its pressure-relief valve

must be open (see Work Card 009.03).

8. Detach the tensioners.

9. Move tensioners to next bolt pair and repeat the sequence until all cou-
pling bolts (10 or 11) are clamped. See points 2 to 8.
10. Once all coupling bolts (10 or 11) are tensioned, uncouple high pressure
2010-01-07

hoses from the high pressure pump.

11. Fit casing (18) and oil tube (20) (see Work Card 071.01).
12. Attach coupling (see documentation of the coupling manufacturer in
Volume 020.010 Coupling arrangement), ensuring that threads and head
contact of the hexagon head screws (13) are lubricated with clean lubri-

6644 020.02-02 EN 5 (8)

020.02 MAN Diesel & Turbo

cating oil, screwed on by hand and tightened to specified torque (see

Crankshaft/Coupling bolts

flywheel arrangement drawing or coupling assembly drawing of the rel-

evant unit in Volume 020.010 Systems Information - Drawings).
Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

2010-01-07

10 Coupling bolt (fitting bolt) *15 Flywheel 20 Oil tube

11 Coupling bolt 16 Nut 21 Casing
*12 Coupling 17 Nut 22 Hexagonal socket screw
13 Hexagon head screw 18 Casing A Bolt protrusion
14 Washer 19 Crankshaft
Figure 1: Connection between crankshaft, flywheel and coupling

6 (8) 6644 020.02-02 EN

 MAN Diesel & Turbo 020.02

10 Coupling bolt (fitting bolt) 16 Nut

Crankshaft/Coupling bolts
Work Cards, classified into sub-assemblies
11 Coupling bolt 19 Crankshaft
48/60;48/60B;48/60CR;51/60DF

*15 Flywheel
Figure 2: Coupling bolts with attached tensioners
2010-01-07

6644 020.02-02 EN 7 (8)

020.02 MAN Diesel & Turbo
Crankshaft/Coupling bolts

10 Coupling bolt (fitting bolt) 23 Lift check

11 Coupling bolt 24 Threaded stop ring
17 Nut M Marking on the lift check
19 Crankshaft
Figure 3: Coupling bolt with attached tensioner

* Shape and size of the coupling and of the flywheel can differ from those shown
in the illustrations.
Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

2010-01-07

8 (8) 6644 020.02-02 EN

 MAN Diesel & Turbo 020.03

Bolts of the crankshaft gearwheel

Crankshaft/Coupling bolts
inspection, loosening and tightening

Summary
Clamping and releasing important threaded connections to the correct val-
ues, ensure correct execution of work.
Check crankshaft gearwheel bolts at regular intervals.
The work/work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Tension screw 020.047 Standard
2 Thrust piece 020.046 Standard
1 Foot board (for oil sump) 011.010 Standard
1 Foot board (for oil sump) 011.009 Standard
1 Foot board (for oil sump) 011.007 Standard
1 Foot board (for oil sump) 011.003 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
2 Hydraulic tensioner 009.062 Standard

Work Cards, classified into sub-assemblies

1 Tommy bar, 10 000.263 Standard
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Sliding calliper - Inventory
48/60;48/60B;48/60CR;51/60DF

Corresponding Work Cards

Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.13

Preliminary remark
2008-10-09

It is advisable to have overhaul work on the camshaft drive carried out at a

service location or by a MAN Diesel & Turbo staff.

6647 020.03-01 EN 1 (10)

020.03 MAN Diesel & Turbo

Work sequence 1 - Checking crankshaft gearwheel bolts

Crankshaft/Coupling bolts

Starting position Casing cover on the camshaft drive is removed. Running gear is turned such
that tensioners can be mounted on crankshaft gearwheel bolts.
Work steps Normal oil sump V oil sump
L 48/60 B and L 48/60 CR 011007 011003
V 48/60 and V 48/60 B 011009 011010
1. Place foot board (tool number given above) in oil sump.
2. Clean threads of the crankshaft gearwheel bolts (8).
3. Screw tension screws (020.047) in until they fit on crankshaft gearwheel
bolts (bolts 1 and 2). See Figs. 2 and 4.
4. Place the thrust pieces (020.046) over the tension screws and nuts (6).
5. Screw hydraulic tensioners (009.062) onto tension screws. See Fig. 4.
6. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
7. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
8. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

Ensure that no one is in the extended axis of the crankshaft gearwheel

bolts!

9. Pump the hydraulic tensioners until the nuts (6) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!
Work Cards, classified into sub-assemblies

While pumping up, watch the stroke controls (10) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (9)! Otherwise the hydraulic tensioners will be
48/60;48/60B;48/60CR;51/60DF

damaged! See Fig. 4.

10. Make a note of the release pressure and compare it to the clamping
pressure.
11. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
12. Insert tommy bar (000.263) through cut-out in the thrust pieces and
2008-10-09

tighten both nuts (6) hand-tight.

13. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

2 (10) 6647 020.03-01 EN

 MAN Diesel & Turbo 020.03

The hydraulic tensioner returns to the zero position automatically by the

Crankshaft/Coupling bolts
compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

14. Detach the tensioners.

15. Re-position tensioners on the crankshaft gearwheel bolts (bolt 3 and 4) and
check them in the same way. See points 3 to 12 - see figures 3 and 4.
16. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.
17. Detach the tensioners.
18. Remove foot board from the oil sump.

Work sequence 2 - Releasing crankshaft gearwheel bolts

Starting position Casing cover on the camshaft drive is removed. Running gear is turned such
that tensioners can be mounted on crankshaft gearwheel bolts.
Work steps Normal oil sump V oil sump
L 48/60 B and L 48/60 CR 011007 011003
V 48/60 and V 48/60 B 011009 011010
1. Place foot board (tool number given above) in oil sump.
2. Clean threads of the crankshaft gearwheel bolts (8).
3. Screw tension screws (020.047) in until they fit on crankshaft gearwheel
bolts (bolts 1 and 2). See Figs. 2 and 4.
4. Place the thrust pieces (020.046) over the tension screws and nuts (6).
5. Screw hydraulic tensioners (009.062) onto tension screws. See Fig. 4.
6. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
7. Connect high-pressure hoses (009.306) to the hydraulic tensioners and

Work Cards, classified into sub-assemblies

connect the high-pressure pump (009.342).
8. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

When releasing, ensure that no one is in the extended axis of the

48/60;48/60B;48/60CR;51/60DF

crankshaft gearwheel bolts to be released!

9. Pump the hydraulic tensioners until the nuts (6) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!
2008-10-09

6647 020.03-01 EN 3 (10)

020.03 MAN Diesel & Turbo

While pumping up, watch the stroke controls (10) of the hydraulic
Crankshaft/Coupling bolts

tensioners! The hydraulic tensioners must only be pumped up to the

point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (9)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 4.

10. Make a note of the release pressure and compare it to the clamping
pressure.
11. Turn back both nuts (6) using tommy bar (000.264) through the cut-out
in the thrust pieces (for turn-back angle see Work Card 000.30).
12. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

13. Detach the tensioners.

14. Re-position tensioners on the crankshaft gearwheel bolts (bolt 3 and 4) and
check them in the same way. See points 3 to 11 - see figures 3 and 4.
15. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.
16. Detach the tensioners.

Work sequence 3 - Clamping crankshaft gearwheel bolts

Starting position Nuts are screwed on and tightened by hand. Threads of the crankshaft
gearwheel bolts are cleaned. Foot board is inserted in the oil sump.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
Work Cards, classified into sub-assemblies

with a comparative pressure gauge!

Work steps 1. Measure length of the crankshaft gearwheel bolts (8) and note it.
48/60;48/60B;48/60CR;51/60DF

It is advisable to prepare a separate measurement log for the tensioning

of the crankshaft gearwheel bolts.

2. Screw tension screws (020.047) in until they fit on crankshaft gearwheel

bolts (bolts 1 and 2). See Figs. 2 and 4.
3. Place the thrust pieces (020.046) over the tension screws and nuts (6).
2008-10-09

4. Screw hydraulic tensioners (009.062) onto tension screws. See Fig. 4.

5. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
6. Set high-pressure pump in operation (see Work Card 009.03) and
tighten crankshaft gearwheel bolts with a pre-tension pressure of 400 bar.

4 (10) 6647 020.03-01 EN

 MAN Diesel & Turbo 020.03

When tensioning, ensure that no one is in the extended axis of the

Crankshaft/Coupling bolts
crankshaft gearwheel bolts to be tensioned!

While pumping up, watch the stroke controls (10) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (9)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 4.

7. Insert tommy bar (000.263) through cut-out in the thrust pieces and
tighten both nuts (6) hand-tight.
8. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

9. Detach the tensioners.

10. Re-position tensioners on the crankshaft gearwheel bolts (bolt 3 and 4). See
points 2 to 4 / see figures 3 and 4.
11. Connect high-pressure hoses to hydraulic tensioners.
12. Set high-pressure pump in operation (see Work Card 009.03) and
tighten crankshaft gearwheel bolts with specified clamping pressure
(see Work Card 000.30).
13. Hand-tighten both nuts (6) through the cut-out in the thrust pieces using
a tommy bar.
14. Release the pressure, uncouple the high-pressure hoses from the

Work Cards, classified into sub-assemblies

hydraulic tensioners.
15. Detach the tensioners.
16. Re-position tensioners on the crankshaft gearwheel bolts (bolts 1 and 2).
See points 2 to 4 / see figures 2 and 4.
48/60;48/60B;48/60CR;51/60DF

17. Connect high-pressure hoses to hydraulic tensioners.

18. Set high-pressure pump in operation (see Work Card 009.03) and
tighten crankshaft gearwheel bolts with specified clamping pressure
(see Work Card 000.30).
19. Hand-tighten both nuts (6) through the cut-out in the thrust pieces using
a tommy bar.
20. Release pressure, uncouple high pressure hoses from hydraulic ten-
2008-10-09

sioners and high pressure pump.

21. Detach the tensioners.
22. Measure length of the crankshaft gearwheel bolts (8) and note it.
23. Determine difference from measured values from point 1 and point 22.

6647 020.03-01 EN 5 (10)

020.03 MAN Diesel & Turbo

Differences are elongation values of the individual crankshaft gearwheel

Crankshaft/Coupling bolts

bolts.

24. Compare bolt elongation Δl of the individual crankshaft gearwheel bolts

with the required value (see Work Card 000.30).

Tension crankshaft gearwheel bolts with the specified clamping

pressure, not according to the screw elongation Δl! The measurement of
the screw elongation Δl is only for checking!

In the event of larger deviations from the nominal value, repeat the
tensioning process, if needed, check the hydraulic tensioners, the bolted
connections and pressure gauges.

25. Remove foot board from the oil sump.

Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

2008-10-09

6 (10) 6647 020.03-01 EN

 MAN Diesel & Turbo 020.03

1-4 Bolt number/ 6 Nut 8 Crankshaft gearwheel bolt

Crankshaft/Coupling bolts
Work Cards, classified into sub-assemblies
Tightening order
48/60;48/60B;48/60CR;51/60DF

5 Crankshaft gearwheel 7 Crankshaft

Figure 1: Crankshaft gearwheel (illustration shows V-engine 48/60)
2008-10-09

6647 020.03-01 EN 7 (10)

020.03 MAN Diesel & Turbo
Crankshaft/Coupling bolts
Work Cards, classified into sub-assemblies

1-4 Bolt number/ 5 Crankshaft gearwheel 8 Crankshaft gearwheel bolt

Tightening order
48/60;48/60B;48/60CR;51/60DF

Figure 2: Crankshaft gearwheel bolts with attached tensioners - Tightening order 1 – 2 (Illustration shows V-
engine 48/60)
2008-10-09

8 (10) 6647 020.03-01 EN

 MAN Diesel & Turbo 020.03

1-4 Bolt number/ 5 Crankshaft gearwheel 8 Crankshaft gearwheel bolt

Crankshaft/Coupling bolts
Work Cards, classified into sub-assemblies
Tightening order
48/60;48/60B;48/60CR;51/60DF

Figure 3: Crankshaft gearwheel bolts with attached tensioners - Tightening order 3 – 4 (Illustration shows V-
engine 48/60)
2008-10-09

6647 020.03-01 EN 9 (10)

020.03 MAN Diesel & Turbo
Crankshaft/Coupling bolts

5 Crankshaft gearwheel 9 Threaded stop ring

6 Nut 10 Stroke control
8 Crankshaft gearwheel bolt M Marking on the stroke control
Figure 4: Crankshaft gearwheel bolt with attached tensioner
Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

2008-10-09

10 (10) 6647 020.03-01 EN

 MAN Diesel & Turbo 020.04

Crankshaft oil bore

Crankshaft/Coupling bolts
closing

Summary
Ensure correct execution of work, allow emergency operation.
Ensure correct execution of work, enable emergency operation. If the engine
must continue to be run despite an disassembled running gear (piston with
connecting rod), the oil bores of the respective crank pin are to be closed.
The work/work steps include:
Proper assembly and, if necessary, removal.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Locking device 020.045 Standard
1 Threaded rod 020.045-1 Standard
2 Sealing plug 020.045-2 Standard
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card

Work Cards, classified into sub-assemblies

030.05 034.01 055.02
112.01 200.02

Work sequence 1 - Blocking the oil bore (emergency operation)

Starting position Piston and connecting rod of a cylinder are dismantled, engine must con-
48/60;48/60B;48/60CR;51/60DF

tinue to be run.

Type and source of danger

The engine should continue to be operated with running gear detached
only in emergency and in that case at reduced power and speed (observe
instructions in Volume 010.005 Engine - Operating Instructions)!
Consequences
In case of engines with flexible mounting, emergency operation with detached run-
2008-10-22

ning gear is not possible!

Work steps 1. Check O-rings (5) in the sealing plugs (020.045-2) for damage, install
new O-rings in grooves if necessary.

6644 020.04-01 EN 1 (3)

020.04 MAN Diesel & Turbo

Type and source of danger

Crankshaft/Coupling bolts

Oil new O-ring seals with clean lubricating oil and install in the ring
grooves, ensuring that they are tensioned equally around the entire
periphery and are not twisted.

2. Fit first sealing plugs on threaded rod (020.045-1). See Fig. 1.

3. Insert threaded rod with sealing plugs in oil bore (2).
4. fit second sealing plug on threaded rod, bolt castle nut (3) and secure
with cotter pin (4). See Fig. 1.
5. Attach complete cylinder head (see Work Card 055.02), but do not insert
push rods.
6. Shut down exhaust and inlet cam follower (fix outside of the cam range),
close lubrication holes.
7. Take injection pump of the concerned cylinder out of operation (pull
control rod to zero filling and lock with pipe clamp, see Work Card
200.02).
8. Close oil pipe to the rocker arm lubrication.
9. Block pontrol air pipe to the stopped cylinder.
Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

2008-10-22

2 (3) 6644 020.04-01 EN

 MAN Diesel & Turbo 020.04

Crankshaft/Coupling bolts
Work Cards, classified into sub-assemblies
1 Crankshaft/crank pin 4 Cotter pin
2 Oil bore 5 O-ring seal
3 Castle nut M10
Figure 1: Crankshaft - Block the oil bore (Illustration shows in-line engine L
48/60;48/60B;48/60CR;51/60DF

48/60)
2008-10-22

6644 020.04-01 EN 3 (3)

 MAN Diesel & Turbo 020.05

Balance weight

Crankshaft/Coupling bolts
removal and installation

Summary
Ensure correct execution of work, enable emergency operation.
Dismantling a balance weight is not customary maintenance work. This is
necessary only in special cases, e.g. emergency operation of the engine
with dismantled running gear.
The work/work steps include:
removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Bolt extractor 014.015 Standard
1 Foot board (for oil sump) 011.007 Standard
1 Foot board (for oil sump) 011.003 Standard
1 Torque wrench 750-2,000 Nm 008.005 Standard
2 Shackle A1.0 002.453 Standard
1 Extension piece 25x400 001.916 Standard
1 Tommy bar, 16 000.266 Standard
1 Tommy bar, 8 000.262 Standard
2 Lifting eye bolt M20 000.155 Standard

Work Cards, classified into sub-assemblies

1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Lifting tackle with rope - Inventory
1 Sliding calliper Form C - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory

Corresponding Work Cards

L48/60;L48/60B;L51/60DF

Work card Work card Work card

000.30 000.32 020.01

Technical data
2008-12-02

Designation Information
Balance weight 341 kg
Projection (A) 52 mm

6644 020.05-01 EN 1 (9)

020.05 MAN Diesel & Turbo

Work sequence 1 - Removing the balance weight

Crankshaft/Coupling bolts

Starting position Crankcase is opened, running gear turned over such that balance weight
bolts are easily accessible (balance weight points towards crankcase aper-
ture). See Fig. 1.
Work steps 1. Insert foot board (011.007 for normal oil sump or 111.003 for V oil sump)
in oil sump (8 or 9).
2. Release balance weight bolts (1) of the respective balance weight (3)
(see Work Card 020.01).
3. Unscrew one nut (2) by half a revolution.

Do not remove the nut!

4. Check that hexagon nuts (10) on bolt extractors (014.015) are released.
5. Screw bolt extractors (014.015) onto balance weight bolt (1).

Pay attention to projection (A) between bolt extractor and balance weight
bolt. See Fig. 2.

6. Tighten hexagon nuts (10).

7. Insert tommy bar (000.266) into bolt extractor. Please refer to figure.
8. Release balance weight bolt (1).

Just release the balance weight bolt, do not unscrew!

Work Cards, classified into sub-assemblies

9. Screw the nut (2) on again by hand until it comes to rest, using a tommy
bar (000.262), remove bolt extractor.
10. Release second balance weight bolt (1) in the same manner. See point
3 to 9.
11. Turn the running gear over carefully, until balance weight (3) points
downwards. See Fig. 3.
L48/60;L48/60B;L51/60DF

12. Screw lifting eye bolts (000.155) in the side of the balance weight (3),
fasten cables (5) with shackle (002.453) to lifting eye bolts and suspend
on lifting tackle. Tension rope.
13. Unscrew both nuts (2).
14. Unscrew balance weight bolts (1).
2008-12-02

15. Lower balance weight (3) uniformly, until spring pin (7) and bolt (6)
become free.

2 (9) 6644 020.05-01 EN

 MAN Diesel & Turbo 020.05

Ensure that dowel pin and pin stick in balance weight and do not remain

Crankshaft/Coupling bolts
in the crank web.

16. Pull out balance weight (3) carefully from the crankcase by alternately
releaseing and tightening on the ropes (5). See Fig. 5.

When removing, ensure that no engine parts (big-end bearing bolt, dowel
pin, bolt etc.) get damaged!

17. Place balance weight (3) on a supporting surface and remove tool.
18. Clean individual parts.

Work sequence 2 - Fitting the balance weight

Starting position All individual parts are cleaned, foot board is placed in the oil sump.

Work steps 1. Clean joint face on the crank web deflection.

2. Screw lifting eye bolts (000.155) in the side of the balance weight (3) and
fasten cables (5) with shackle (002.453) to lifting eye bolts.
3. Guide a rope (5) through crankcase. Suspend cable from lifting tackle.

Pay attention to the correct position of the dowel pin (7).

4. Guide balance weight (3) carefully into the crankcase by alternately

releaseing and tightening the cables (5). See Fig. 5.

When fitting, ensure that no engine parts (big-end bearing bolt, dowel

Work Cards, classified into sub-assemblies

pin, bolt etc.) get damaged!

5. Lift balance weight (3) evenly, until balance weight is in contact with
crank web deflection.

See that dowel pin (7) and bolt (6) are flush in holes!
L48/60;L48/60B;L51/60DF

6. Apply MoS2 lubricant to the threads of the balance weight bolts (1) and
screw in by hand until they are in position.
2008-12-02

7. Screw nuts (2) in by hand until they rest on balance weight bolts (1).
8. Remove the tool.
9. Turn running gear over carefully, until balance weight bolts (1) are easily
accessible (balance weight (3) points to crankcase opening). See Fig. 1.

6644 020.05-01 EN 3 (9)

020.05 MAN Diesel & Turbo

10. Unscrew one nut (2) by half a revolution.

Crankshaft/Coupling bolts

Do not remove the nut!

11. Check that hexagon nuts (10) on bolt extractors (014.015) are released.
12. Screw bolt extractors (014.015) onto balance weight bolt (1).

Pay attention to projection (A) between bolt extractor and balance weight
bolt. See Fig. 2.

13. Tighten hexagon nuts (10).

14. Tighten balance weight bolt (1) with specified tightening torque (see
Work Card 000.30).
15. Screw the nut (2) on again all the way finger-tight with the tommy bar
(000.262), then remove bolt extractor.
16. Tighten second balance weight bolt (1) in the same manner. See point
10 to 15.
17. Tension balance weight bolts (1) (see Work Card 020.01).
18. Remove foot board from oil sump (8 or 9).
Work Cards, classified into sub-assemblies
L48/60;L48/60B;L51/60DF

2008-12-02

4 (9) 6644 020.05-01 EN

 MAN Diesel & Turbo 020.05

Crankshaft/Coupling bolts
1 Balance weight bolts 4 Balance weight
2 Nut 5 Crankshaft

Work Cards, classified into sub-assemblies

Figure 1: Balance weight L48/60;L48/60B;L51/60DF
2008-12-02

6644 020.05-01 EN 5 (9)

020.05 MAN Diesel & Turbo
Crankshaft/Coupling bolts

1 Balance weight bolts 10 Hexagon nut M10

2 Nut A Projection
(Bolt extractor - balance weight bolt)
3 Balance weight
Figure 2: Attaching the bolt extractor on the balance weight bolt
Work Cards, classified into sub-assemblies
L48/60;L48/60B;L51/60DF

2008-12-02

6 (9) 6644 020.05-01 EN

 MAN Diesel & Turbo 020.05

Crankshaft/Coupling bolts
1 Balance weight bolts 4 Crankshaft 7 Dowel pin
2 Nut 5 Rope 8 V oil sump
3 Balance weight 6 Pin 9 Normal oil sump
Figure 3: Removal / installation of the balance weight bolt

Work Cards, classified into sub-assemblies

L48/60;L48/60B;L51/60DF
2008-12-02

6644 020.05-01 EN 7 (9)

020.05 MAN Diesel & Turbo
Crankshaft/Coupling bolts

Figure 4: Removal /Installation of the balance weight

Work Cards, classified into sub-assemblies
L48/60;L48/60B;L51/60DF

2008-12-02

8 (9) 6644 020.05-01 EN

 MAN Diesel & Turbo 020.05

Crankshaft/Coupling bolts
Figure 5: Removal /Installation of the balance weight

Work Cards, classified into sub-assemblies

L48/60;L48/60B;L51/60DF
2008-12-02

6644 020.05-01 EN 9 (9)

MAN Diesel & Turbo 021

Crankshaft bearing/main thrust bearing

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.5-1 EN 1 (2)

 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.5-1 EN

 MAN Diesel & Turbo 021.01

Crankshaft bearing shell

Crankshaft bearing/main thrust bearing

inspecting

Summary
Execute work in time according to the maintenance schedule,
Ensure operating safety of bearings.
Bearing shells must be checked at regular intervals. The wear condition and
running profile will give a clue to the load ratios, lubricating oil care etc.
The work/work steps include:
Removal of the cross tie rod,
Lowering bearing cover,
Checking bearing shell and
Restoring the initial state.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Pilot rod 034.006 Standard
2 Support 021.280 Standard
2 Guide pipe 021.279 Standard
1 Cross tie 021.278 Standard
1 Bracket 021.277 Standard
1 Raising and lowering fixture 021.275 Standard

Work Cards, classified into sub-assemblies

4 Tommy bar, 12 021.275-17 Standard
1 Centring template 021.164 Standard
1 Turning block 021.163 Standard
1 Turning block 021.162 Standard
1 Foot board (for oil sump) 011.007 Standard
1 Hydraulic hand pump with hose pipe 009.138 Standard
1 Telescopic cylinder 009.137 Standard
1 Thickness gauges 0.05-1 000.454 Standard
1 Tommy bar, 12 000.264 Standard
1 Eye bolt M6 000.023 Standard
L48/60;L48/60B

1 Combination spanner (set) - Inventory

2008-10-22

1 Lubricant (containing molybdenum disulphide) - Inventory

1 Securing compound, Loctite 243 - Inventory

6644 021.01-01 EN 1 (14)

021.01 MAN Diesel & Turbo

Corresponding Work Cards

Crankshaft bearing/main thrust bearing

Work card Work card Work card

000.10 000.11 000.19
012.02

Work sequence 1 - Dismantle and inspection of the lower bearing shell

It is recommended that the following work be done when the engine is

hot!

Starting position Crankcase is opened, running gear is rotated so that main bearing cap is
easily accessible.
Preliminary remark Read through the manufacturer's operating instructions carefully before commis-
sioning the hydraulic hand pump (009.138) and the telescopic cylinder (009.137)!
Work steps 1. Insert foot board (011.007) in oil sump (8).

2. Dismantle temperature sensor (30) from main bearing cap (7) and place
it safely outside the crankcase.

It may be necessary to remove a few clamps used for fastening the

temperature sensor line.

3. Release main bearing bolts (6) and cross tie rods (3) of the relevant main
bearing (see Work Card 012.02).
4. Unscrew nuts (2) and remove rings (11) including O-rings (12).
5. Remove both cross tie rods (3).
6. De-tension the adjacent main bearing (see Work Card 012.02) and
Work Cards, classified into sub-assemblies

loosen nuts.
7. Place cross tie (021.278) in oil sump (8), place guide tubes (021.279) in
bores in the cross-beam and slide under main bearing cap (7) or main
bearing bolts (6).
8. Screw guide tubes into crankshaft bearing bolts (6) and tighten by hand,
raise cross-beam and fix by inserting one tommy bar (021.275-17) each
into the bottom hole of the guide tubes. See Fig. 2.
9. Fit two braces (021.280) on traverse and clamp in the crankcase by
turning the hexagon nuts (22). The cross tie will be pressed against the
tommy bars by doing this.
10. Place retracted telescope cylinder (009.137) on cross tie and fix in posi-
L48/60;L48/60B

tion.
2008-10-22

Tighten hexagon bolts (23) hand-tight only to the extent that telescope
cylinder still remains movable and can be aligned for further work!

2 (14) 6644 021.01-01 EN

 MAN Diesel & Turbo 021.01

11. Fit holder (021.277) on cylinder crankcase foot and mount on cylinder

Crankshaft bearing/main thrust bearing

crankcase side wall.
12. Slide hydraulic hand pump (009.138) in the guide on holder and secure
in position.
13. Connect hydraulic hoses (13) to telescope cylinder.

Ensure correct connection of the hydraulic hoses to the telescope

cylinder! See Fig. 3.

14. Check oil level in hydraulic hand pump by means of oil dipstick (16).

Hydraulic hand pump must always have sufficient clean slushing oil in it!
Otherwise there is the danger that air could enter the hydraulic system
which would necessitate complete bleeding of the entire hydraulic
system of the raising and lowering device!

15. Set lever (19) on the hydraulic hand pump to up (position "Raise"). See
Fig. 3/Z.
16. Fit pilot rod (034.006) to lever (18). Operate hydraulic hand pump by an
up/down movement of the lever, thereby raising telescope cylinder.
17. Raise telescope cylinder up to contact with the main bearing cap (7).
Move lever (19) into middle setting (rest position). See figure 2 and figure
3/X.
18. Fasten telescope cylinder to main bearing cap (7).
19. Unscrew nuts (5) and place on cross tie.
20. Insert two more tommy bars in the holes in the guide tubes. See Fig. 4.

Before lowering the main bearing cap (inner adjusting bearing) situated
between the camshaft drive and cylinder 1 lock locating bearing ring!

Work Cards, classified into sub-assemblies

Otherwise there is a danger that the locating bearing ring will also be
turned when turning the crankshaft and will fall down!

21. Point lever (19) downwards (position "Lower"). See figure 3/Y.
22. Operate hydraulic hand pump by up/down movement of the lever (18)
thus lowering telescope cylinder. Watch the pressure gauge (17)!

Pressure must not exceed 100 bar during the lowering of the main
bearing cap!
L48/60;L48/60B

A large pressure increase during lowering indicates tilting of the main

2008-10-22

bearing cap! Stop the lowering process!

Continue the lowering process of the main bearing cap only after
correcting the tilt!

23. Lower main bearing cap (7) onto the tommy bars. See Fig. 5.

6644 021.01-01 EN 3 (14)

021.01 MAN Diesel & Turbo

24. Dismantle bearing shell (26).

Crankshaft bearing/main thrust bearing

25. Carefully clean running surface of the bearing shell (26), do not damage
whilst doing so.
26. Check the condition of the running surface, (see Work Card 000.11).

Do not perform any rework on the bearing shell!

Replace bearing shell if damaged or if there is severe scoring caused by

dirt!
If the bearing shell has scoring caused by dirt, the shaft journal must be
checked and, if necessary, repolished (polishing cloth with grain <15 µm)!

Work sequence 2 - Removing and checking the upper bearing shell

Starting position Main bearing cap is lowered, lower bearing shell is removed.

Work steps 1. Insert the turning block (021.162) into the oil hole (9) in the crankshaft,
if needed, turn the crankshaft slightly. See Fig. 6.

Turning block must be completely in contact with the crankshaft!

2. Turn out bearing shell (27) carefully, without damaging it.

3. Pull out turning block with eye bolt (000.023).
4. Carefully clean running surface of the bearing shell (27), do not damage
whilst doing so.
Work Cards, classified into sub-assemblies

5. Check the condition of the running surface, (see Work Card 000.11).

Do not perform any rework on the bearing shell!

Replace bearing shell if damaged or if there is severe scoring caused by

dirt!
If the bearing shell has scoring caused by dirt, the shaft journal must be
checked and, if necessary, repolished (polishing cloth with grain <15 µm)!
L48/60;L48/60B

2008-10-22

4 (14) 6644 021.01-01 EN

 MAN Diesel & Turbo 021.01

Work sequence 3 - Installing the upper bearing shell

Crankshaft bearing/main thrust bearing

New bearing shells are delivered ready for installation and must not be
rescraped or adapted in any way!

Starting position Bearing shell is cleaned.

Work steps 1. Place the centring template (021.164) onto the cylinder crankcase (4).
Insert centring bolt of the centring template in hole for bearing shell fix-
ation (centring template is held magnetically). See Fig. 7.
2. Oil the running surface of the bearing shell (27) liberally (reverse side of
the bearing shell remains dry).
3. Place bearing shell (27) on the centring template and push in as far as
possible by hand.

Note the position of the groove for bearing shell fixation (C), even before
sliding in the bearing shell!

4. Turn the crankshaft (9) until the turning block (021.163) can be inserted
through a hole in the bearing shell (27) into the crankshaft's oil hole.

In order to avoid warping of the thin bearing shell when screwing in, set
turning block as close as possible to the parting line of the main bearing!

5. Turn in bearing shell (27) in several steps (depending on the hole spac-
ing). Pull out the turning block after the first turn, turn crankshaft (9) one
back by on hole and insert turning block again. Repeat process up to
the last hole.

Work Cards, classified into sub-assemblies

6. Pull out turning block, turn back crankshaft (9) until oil hole is free.
7. Insert the turning block (021.162) directly into the oil bore of the crank-
shaft (9) and screw the bearing shell (27) in completely.

Ensure even end position of the joint face of the bearing shells!

8. Remove centring template and pull out turning block with eye bolt
(000.023).

Work sequence 4 - Installing the lower bearing shell

L48/60;L48/60B
2008-10-22

New bearing shells are delivered ready for installation and must not be
rescraped or adapted in any way!

6644 021.01-01 EN 5 (14)

021.01 MAN Diesel & Turbo

Starting position Bearing shell and cross tie rod is/are cleaned.
Crankshaft bearing/main thrust bearing

Preliminary remark Read through the manufacturer's operating instructions carefully before commis-
sioning the hydraulic hand pump (009.138) and the telescopic cylinder (009.137)!
Work steps 1. Oil the running surface of the bearing shell (26) liberally (reverse side of
the bearing shell remains dry).
2. Insert bearing shell (26) in main bearing cap (7).

Pay attention to the position of the groove for bearing shell fixation when
assembling the bearing shell! See Fig. 5.

3. Set lever (19) on the hydraulic hand pump (009.138)upwards (position

"Raise"). See Fig. 3/Z.
4. Fit pilot rod (034.006) to lever (18). Operate hydraulic hand pump by up/
down movement of the lever thus raising telescope cylinder (009.137).
Watch the pressure gauge (17)!

Pressure must not exceed 100 bar when raising the main bearing cap!

Large pressure increase during raising indicates tilting of the main

bearing cap! Stop raising process!
Continue the raising process of main bearing cap only after correcting
the tilt!

5. Raise main bearing cap (7) up to contact with the cylinder crankcase (4).
Move lever (19) into middle setting (rest position). See figure 3/X.
6. Remove upper tommy bars (021.275-17) and screw the nuts (5) onto
crankshaft bearing caps (6) until they rest on crankshaft bearing cap (7)
Work Cards, classified into sub-assemblies

and tighten by hand.

Observe specified projection of the crankshaft bearing bolts (see Work

Card 012.02)!

7. Remove hexagon bolt (24).

8. Point lever (19) downwards (position "Lower"). See figure 3/Y.
9. Operate hydraulic hand pump by up/down movement of the lever (18)
thus lowering telescope cylinder.
L48/60;L48/60B

Operate lever until telescope cylinder is driven completely in.

2008-10-22

10. Uncouple hydraulic hoses (13) from telescope cylinder and remove
complete raising and lowering fixture (021.275).

6 (14) 6644 021.01-01 EN

 MAN Diesel & Turbo 021.01

Remove the securing device for locating bearing ring (crankshaft bearing

Crankshaft bearing/main thrust bearing

between camshaft drive and cylinder 1)!

11. Apply MoS2 lubricant to the screw threads of the cross tie rods (3) and
screw into the crankshaft bearing cap (7) hand-tight until it comes to
rest.
12. Place new O-ring seals (12) and rings (11) over the cross tie rods (3),
screw nuts (2) hand-tight up to the stop.
13. Tighten main bearing bolts (6) and cross tie rods (3) (see Work Card
012.02).
14. Tighten nuts of the cross tie rods of the adjacent crankshaft bearing
hand-tight. Tighten the adjacent crankshaft bearing hand-tight (see
Work Card 012.02).
15. Check crankshaft bearing clearance with thickness gauges (000.454),
by inserting the thickness gauge about 10 mm deep from the coupling
side and from the free engine end.
16. Measure the crank web deflection (see Work Card 000.10) and note in
the operating log sheets.
17. Install temperature sensors (30) in main bearing caps (7).

If the clamps which are used for fastening the temperature sensor line
have been removed, their hexagon bolts must be locked with securing
compound Loctite 243 when re-fitting them.

18. Remove foot boards (011.007) from oil sump (8).

Observe the running-in guidelines

For information about running in new bearing shells refer to the running-
in guidelines in Volume 010.005 Engine - Operating Instructions!

Work Cards, classified into sub-assemblies

L48/60;L48/60B
2008-10-22

6644 021.01-01 EN 7 (14)

021.01 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies

1 Balance weight 6 Crankshaft bearing bolt 11 Ring

2 Nut 7 Main bearing cap 12 O-ring seal
L48/60;L48/60B

3 Cross tie rod 8 Oil sump 30 Temperature sensor

2008-10-22

4 Cylinder crankcase 9 Crankshaft ST Control side

5 Nut 10 Connecting rod
Figure 1: Crankshaft bearing - illustration shows engine L 48/60

8 (14) 6644 021.01-01 EN

 MAN Diesel & Turbo 021.01

Crankshaft bearing/main thrust bearing

Work Cards, classified into sub-assemblies

4 Cylinder crankcase 16 Oil dipstick 22 Hexagon nut M24x2

7 Main bearing cap 17 Pressure gauge 23 Hexagon bolt M12x45
8 Oil sump 18 Lever 24 Hexagon bolt M20x45
L48/60;L48/60B
2008-10-22

13 Hydraulic hose 19 Lever ST Control side

14 Stud 20 Hexagon bolt M10x30
15 Hexagon nut 21 Hexagon nut M10
Figure 2: Crankshaft bearing and attached lifting and lowering device

6644 021.01-01 EN 9 (14)

021.01 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies

13 Hydraulic hose 18 Lever A Connection for hydraulic hose

16 Oil dipstick 19 Lever B Connection for hydraulic hose
L48/60;L48/60B

17 Pressure gauge
2008-10-22

Figure 3: Hydraulic hand pump and telescope cylinder (Illustration "X": Lever (19) in middle position - telescope
cylinder in stop position /Illustration "Y": Lever (19) down - Lower the telescope cylinder /Illustration "Z": Lever
(19) up - Raise telescope cylinder)

10 (14) 6644 021.01-01 EN

 MAN Diesel & Turbo 021.01

Crankshaft bearing/main thrust bearing

5 Nut 7 Main bearing cap ST Control side
6 Crankshaft bearing bolt
Figure 4: Crankshaft bearing and attached lifting and lowering device

Work Cards, classified into sub-assemblies

L48/60;L48/60B
2008-10-22

6644 021.01-01 EN 11 (14)

021.01 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies

4 Cylinder crankcase 18 Lever 26 Fixing piece

7 Main bearing cap 19 Lever ST Control side
L48/60;L48/60B

17 Pressure gauge 25 Bearing shell, lower

2008-10-22

Figure 5: Crankshaft bearing and attached lifting and lowering device

12 (14) 6644 021.01-01 EN

 MAN Diesel & Turbo 021.01

4 Cylinder crankcase 28 O-ring seal

Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies
9 Crankshaft ST Control side
27 Bearing shell, upper I - II Work steps
Figure 6: Removal of the upper bearing shell
L48/60;L48/60B
2008-10-22

6644 021.01-01 EN 13 (14)

021.01 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies
L48/60;L48/60B

4 Cylinder crankcase 28 O-ring seal I-III Work steps

2008-10-22

9 Crankshaft C Groove for bearing shell fixation

27 Bearing shell, upper ST Control side
Figure 7: Installing the upper bearing shell

14 (14) 6644 021.01-01 EN

 MAN Diesel & Turbo 021.02

Crankshaft bearing shell (external bearing)

Crankshaft bearing/main thrust bearing

inspecting

Summary
Execute work in time according to the maintenance schedule,
Ensure operating safety of bearings.
Bearing shells must be checked at regular intervals. The wear condition and
running profile will give a clue to the load ratios, lubricating oil care etc.
The work/work steps include:
Removal of the cross tie rod,
Lowering bearing cover,
Checking bearing shell and
Restoring the initial state.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Pilot rod 034.006 Standard
2 Extension 021.283 Standard
2 Guide pipe 021.282 Standard
1 Cross tie 021.281 Standard
1 Bracket 021.277 Standard
1 Raising and lowering fixture 021.275 Standard

Work Cards, classified into sub-assemblies

6 Tommy bar, 12 021.275-17 Standard
1 Centring template 021.164 Standard
1 Turning block 021.163 Standard
1 Turning block 021.162 Standard
1 Foot board (for oil sump) 011.007 Standard
1 Hydraulic hand pump with hose pipe 009.138 Standard
1 Telescopic cylinder 009.137 Standard
1 Thickness gauges 0.05-1 000.454 Standard
1 Tommy bar, 12 000.264 Standard
1 Tommy bar, 8 000.262 Standard
L48/60;L48/60B

1 Eye bolt M6 000.023 Standard

2008-10-22

1 Combination spanner (set) - Inventory

1 Lubricant (containing molybdenum disulphide) - Inventory
1 Securing compound, Loctite 243 - Inventory

6644 021.02-01 EN 1 (14)

021.02 MAN Diesel & Turbo

Corresponding Work Cards

Crankshaft bearing/main thrust bearing

Work card Work card Work card

000.10 000.11 000.19
012.02 012.03

Work sequence 1 - Dismantle and inspection of the lower bearing shell

It is recommended that the following work be done when the engine is

hot!

Starting position Casing cover on camshaft drive as well as cover of the crankcase covering
of the adjacent cylinder are removed.
Preliminary Remark Read through the manufacturer's operating instructions carefully before commis-
sioning the hydraulic hand pump (009.138) and the telescopic cylinder (009.137)!
Work steps 1. Insert foot board (011.007) in oil sump (13).

2. Dismantle temperature sensor (35) from main bearing cap (14) and place
it safely outside the camshaft drive.

It may be necessary to remove a few clamps used for fastening the

temperature sensor line.

3. Release main bearing bolts (12) and cross tie rods (9) (see Work Card
012.03).
4. Unscrew nuts (8) and remove rings (17) including O-rings (18).
5. Remove both cross tie rods (9).
6. Release cross tie rod of the adjacent crankshaft bearing (see Work Card
Work Cards, classified into sub-assemblies

012.02) and loosen nuts.

7. Screw guide tubes (021.282) hand-tight into crankshaft bearing bolts
(12).
8. Place cross tie (021.281) in oil sump (13), stand extensions (021.283) in
holes in the cross tie and slide under crankshaft bearing cap (14) or
crankshaft bearing bolts (12).
9. Thread extensions into guide tubes and tighten by hand, raise cross tie
and fix by inserting one tommy bar (021.275-17) each into the bottom
hole (6) in the extension. See Fig. 2.
10. Insert one more tommy bar each into the second hole (5) in the exten-
sions.
L48/60;L48/60B

11. Place retracted telescope cylinder (009.137) on cross tie and fix in posi-
2008-10-22

tion.

2 (14) 6644 021.02-01 EN

 MAN Diesel & Turbo 021.02

Tighten hexagon bolts (24) hand-tight only to the extent that telescope

Crankshaft bearing/main thrust bearing

cylinder still remains movable and can be aligned for further work!

12. Fit holder (021.277) on cylinder crankcase footing and fasten on cylinder
crankcase side wall.
13. Slide in and lock hydraulic pump (009.138) in guide on support.
14. Connect hydraulic hoses (25) to telescope cylinder.

Ensure correct connection of the hydraulic hoses to the telescope

cylinder! See Fig. 3.

15. Check oil level in hydraulic hand pump by means of oil dipstick (22).

Hydraulic hand pump must always have sufficient clean slushing oil in it!
Otherwise there is the danger that air could enter the hydraulic system
which would necessitate complete bleeding of the entire hydraulic
system of the raising and lowering device!

16. Set lever (28) on the hydraulic hand pump to up (position "Raise"). See
Fig. 3/Z.
17. Fit pilot rod (034.006) to lever (19). Operate hydraulic hand pump by an
up/down movement of the lever, thereby raising telescope cylinder.
18. Raise telescope cylinder up to contact with the main bearing cap (14).
Move lever (28) into middle setting (rest position). See figure 2 and figure
3/X.
19. Fasten telescope cylinder to main bearing cap (14).
20. Thread off nut (11) and set aside. See Fig. 4.

Work Cards, classified into sub-assemblies

21. Insert two more tommy bars in holes (2) in the guide tubes.
22. Lock locating bearing ring (7).

If the locating bearing ring is not locked before lowering the main bearing
cap, there is the danger that the locating bearing ring could also be
rotated when turning the crankshaft, and fall down!

23. Point lever (28) downwards (position "Lower"). See figure 3/Y.
24. Operate hydraulic hand pump by up/down movement of the lever (19)
thus lowering telescope cylinder. Watch the pressure gauge (29)!
L48/60;L48/60B

Pressure must not exceed 100 bar during the lowering of the main
2008-10-22

bearing cap!

6644 021.02-01 EN 3 (14)

021.02 MAN Diesel & Turbo

A large pressure increase during lowering indicates tilting of the main

Crankshaft bearing/main thrust bearing

bearing cap! Stop the lowering process!

Continue the lowering process of the main bearing cap only after
correcting the tilt!

25. Lower main bearing cap (14) onto the tommy bars. See Fig. 5.
26. Dismantle bearing shell (30).
27. Carefully clean running surface of the bearing shell (30), do not damage
whilst doing so.
28. Check the condition of the running surface, (see Work Card 000.11).

Do not perform any rework on the bearing shell!

Replace bearing shell if damaged or if there is severe scoring caused by

dirt!
If the bearing shell has scoring caused by dirt, the crank journal must be
checked and, if necessary, repolished (polishing cloth with grain <15µm)!

Work sequence 2 - Removing and checking the upper bearing shell

Starting position Main bearing cap is lowered, lower bearing shell is removed.

Work steps 1. Insert the turning block (021.162) into the oil hole (16) in the crankshaft,
if needed, turn the crankshaft slightly. See Fig. 6.

Turning block must be completely in contact with the crankshaft!

Work Cards, classified into sub-assemblies

2. Turn out bearing shell (32) carefully, without damaging it.

3. Pull out turning block with eye bolt (000.023).
4. Carefully clean running surface of the bearing shell (32), do not damage
whilst doing so.
5. Check the condition of the running surface, (see Work Card 000.11).

Do not perform any rework on the bearing shell!

L48/60;L48/60B

2008-10-22

Replace bearing shell if damaged or if there is severe scoring caused by

dirt!
If the bearing shell has scoring caused by dirt, the crank journal must be
checked and, if necessary, repolished (polishing cloth with grain <15µm)!

4 (14) 6644 021.02-01 EN

 MAN Diesel & Turbo 021.02

Work sequence 3 - Installing the upper bearing shell

Crankshaft bearing/main thrust bearing

New bearing shells are delivered ready for installation and must not be
rescraped or adapted in any way!

Starting position Bearing shell is cleaned.

Work steps 1. Place the centring template (021.164) onto the cylinder crankcase (10).
Insert centring bolt of the centring template in hole for bearing shell fix-
ation (centring template is held magnetically). See Fig. 7.
2. Oil the running surface of the bearing shell (32) liberally (reverse side of
the bearing shell remains dry).
3. Place bearing shell (32) on the centring template and push in as far as
possible by hand.

Note the position of the groove for bearing shell fixation (C), even before
sliding in the bearing shell!

4. Turn the crankshaft (16) until the turning block (021.163) can be inserted
through a hole in the bearing shell (32) into the crankshaft's oil hole.

In order to avoid warping of the thin bearing shell when screwing in, set
turning block as close as possible to the parting line of the crankshaft
bearing!

5. Turn in bearing shell (32) in several steps (depending on the hole spac-
ing). Pull out the turning block after the first turn, turn crankshaft (16) one
back by on hole and insert turning block again. Repeat process up to
the last hole.

Work Cards, classified into sub-assemblies

6. Pull out turning block, turn back crankshaft (16) until oil hole is free.
7. Insert the turning block (021.162) directly into the oil bore of the crank-
shaft (16) and screw the bearing shell (32) in completely.

Ensure even end position of the joint face of the bearing shells!

8. Remove centring template and pull out turning block with eye bolt
(000.023).

Work sequence 4 - Installing the lower bearing shell

L48/60;L48/60B
2008-10-22

New bearing shells are delivered ready for installation and must not be
rescraped or adapted in any way!

6644 021.02-01 EN 5 (14)

021.02 MAN Diesel & Turbo

Starting position Bearing shell and cross tie rod is/are cleaned.
Crankshaft bearing/main thrust bearing

Preliminary remark Read through the manufacturer's operating instructions carefully before commis-
sioning the hydraulic hand pump (009.138) and the telescopic cylinder (009.137)!
Work steps 1. Oil the running surface of the bearing shell (30) liberally (reverse side of
the bearing shell remains dry).
2. Insert bearing shell (30) in main bearing cap (14).

Pay attention to the position of the groove for bearing shell fixation when
assembling the bearing shell! See Fig. 5.

3. Set lever (28) on the hydraulic hand pump (009.138)upwards (position

"Raise"). See Fig. 3/Z.
4. Fit pilot rod (034.006) to lever (19). Operate hydraulic hand pump by up/
down movement of the lever thus raising telescope cylinder (009.137).
Watch pressure gauge (29)!

Pressure must not exceed 100 bar when raising the main bearing cap!

Large pressure increase during raising indicates tilting of the main

bearing cap! Stop raising process!
Continue the raising process of main bearing cap only after correcting
the tilt!

5. Raise main bearing cap (14) up to contact with the cylinder crankcase
(10). Move lever (28) into middle setting (rest position). See figure 3/X.
6. Remove upper tommy bars (021.275-17) and screw the nuts (11) onto
crankshaft bearing caps (12) until they rest on crankshaft bearing cap
Work Cards, classified into sub-assemblies

(14) and tighten by hand.

7. Remove hexagon bolt (23).
8. Point lever (28) downwards (position "Lower"). See figure 3/Y.
9. Operate hydraulic hand pump by up/down movement of the lever (19)
thus lowering telescope cylinder.

Operate lever until telescope cylinder is driven completely in.

10. Uncouple hydraulic hoses (25) from telescope cylinder and remove
L48/60;L48/60B

complete raising and lowering fixture (021.275).

2008-10-22

11. Remove lock on the locating bearing ring (7).

12. Apply MoS2 lubricant to the screw threads of the cross tie rods (9) and
screw into the crankshaft bearing cap (14) hand-tight until it comes to
rest.

6 (14) 6644 021.02-01 EN

 MAN Diesel & Turbo 021.02

13. Insert new O-ring seal (18) and rings (17) over cross tie rod (9), tighten

Crankshaft bearing/main thrust bearing

nuts (8) by hand until they come to rest.
14. Tighten the main bearing bolts (12) and cross tie rods (9) (see Work Card
012.03).
15. Tighten nuts of the cross tie rod of the adjacent crankshaft bearing by
hand. Clamp cross tie rod of the adjacent main bearing (see Work Card
012.02).
16. Check crankshaft bearing clearance with thickness gauges (000.454),
by inserting the thickness gauge about 10 mm deep from the coupling
side and from the free engine end.
17. Measure the crank web deflection (see Work Card 000.10) and note in
the operating log sheets.
18. Install temperature sensors (35) in main bearing caps (14).

If the clamps which are used for fastening the temperature sensor line
have been removed, their hexagon bolts must be locked with securing
compound Loctite 243 when re-fitting them.

19. Remove foot boards (011.007) from oil sump (13).

Observe the running-in guidelines

For information about running in new bearing shells refer to the running-
in guidelines in Volume 010.005 Engine - Operating Instructions!

Work Cards, classified into sub-assemblies

L48/60;L48/60B
2008-10-22

6644 021.02-01 EN 7 (14)

021.02 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies

7 Locating bearing ring 12 Crankshaft bearing bolt 17 Ring

8 Nut 13 Oil sump 18 O-ring seal
9 Cross tie rod 14 Main bearing cap 35 Temperature sensor
10 Cylinder crankcase 15 Crankshaft gearwheel ST Control side
11 Nut 16 Crankshaft
L48/60;L48/60B

2008-10-22

Figure 1: Crankshaft bearing (external bearing) - Illustration shows engine L 48/60

8 (14) 6644 021.02-01 EN

 MAN Diesel & Turbo 021.02

Crankshaft bearing/main thrust bearing

Work Cards, classified into sub-assemblies

1-3 Hole in guide pipe 20 Stud 27 Hexagon nut M10

4-6 Hole in extension 21 Hexagon nut 28 Lever
10 Cylinder crankcase 22 Oil dipstick 29 Pressure gauge
L48/60;L48/60B
2008-10-22

12 Crankshaft bearing bolt 23 Hexagon bolt M20x45 KS Coupling side

13 Oil sump 24 Hexagon bolt M12x45 ST Control side
14 Main bearing cap 25 Hydraulic hose
19 Lever 26 Hexagon bolt M10x30
Figure 2: Crankshaft bearing (external bearing) and attached raising and lowering fixture

6644 021.02-01 EN 9 (14)

021.02 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies

19 Lever 28 Lever A Connection for hydraulic hose

22 Oil dipstick 29 Pressure gauge B Connection for hydraulic hose
L48/60;L48/60B

25 Hydraulic hose
2008-10-22

Figure 3: Hydraulic hand pump and telescope cylinder (Illustration "X": Lever (28) in middle position - telescope
cylinder in stop position /Illustration "Y": Lever (28) down - Lower the telescope cylinder /Illustration "Z": Lever
(28) up - Raise telescope cylinder)

10 (14) 6644 021.02-01 EN

 MAN Diesel & Turbo 021.02

Crankshaft bearing/main thrust bearing

11 Nut 14 Main bearing cap ST Control side
12 Crankshaft bearing bolt
Figure 4: Crankshaft bearing (external bearing) and attached raising and lowering fixture

Work Cards, classified into sub-assemblies

L48/60;L48/60B
2008-10-22

6644 021.02-01 EN 11 (14)

021.02 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing

10 Cylinder crankcase 28 Lever ST Control side

14 Main bearing cap 30 Bearing shell, lower
Work Cards, classified into sub-assemblies

19 Lever 31 Fixing piece

Figure 5: Crankshaft bearing (external bearing) and attached raising and lowering fixture
L48/60;L48/60B

2008-10-22

12 (14) 6644 021.02-01 EN

 MAN Diesel & Turbo 021.02

10 Cylinder crankcase 33 O-ring seal

Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies
16 Crankshaft ST Control side
32 Bearing shell, upper I - II Work steps
Figure 6: Removal of the upper bearing shell
L48/60;L48/60B
2008-10-22

6644 021.02-01 EN 13 (14)

021.02 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies
L48/60;L48/60B

2008-10-22

10 Cylinder crankcase 32 Bearing shell, upper C Groove for bearing shell fixation
16 Crankshaft 33 O-ring seal ST Control side
I-III Work steps
Figure 7: Installing the upper bearing shell

14 (14) 6644 021.02-01 EN

 MAN Diesel & Turbo 021.03

Main thrust bearing

Crankshaft bearing/main thrust bearing

Measure axial clearance/check locating bearing rings

Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components dimensionally, evaluate contact pattern/wear
condition.
Check axial clearance and locating bearing rings at regular intervals.
The work/work steps include:
Measuring components and
Assessing contact pattern /wear condition.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
2 Hydraulic cylinder 009.075 Standard
1 Thickness gauges 0.05-1 000.451 Option
1 Combination spanner (set) - Inventory
1 Hammer - Inventory
2 Wooden wedge - Inventory
1 Measuring gauge with holder - Inventory

Work Cards, classified into sub-assemblies

Corresponding Work Cards
Work card Work card Work card
000.33 009.03 009.05

Technical data
Designation Information
L48/60;L48/60B;L51/60DF

Reference dimension (A) 0,5 mm

Work sequence 1 - Measuring the axial clearances of the crankshaft

Starting position Drive chamber window opened in the area of the camshaft drive and on two
2008-10-22

cylinders.
Work steps 1. Check that pistons of the hydraulic cylinder (009.075) are fully retracted
(stroke = zero), reset the piston by hand if necessary.

6644 021.03-01 EN 1 (4)

021.03 MAN Diesel & Turbo

The hydraulic cylinder must be coupled to the hydraulic pump and its
Crankshaft bearing/main thrust bearing

relief valve must be opened for resetting the piston (see Work Card
009.03).

2. Set two hydraulic cylinders between crankcase wall and balance weight
such that crankshaft (4) can be displaced axially in one direction.

Type and source of danger

Hydraulic cylinders must be set on different cylinders!

3. Connect high-pressure hoses (009.306) to hydraulic cylinders and high-

pressure pump (009.338).
4. Set high-pressure pump in operation (see Work Card 009.03) and slide
crankshaft (4) with carefully controlled pressure until it abuts.

The pressure must not exceed 500 bar! Reduce the pressing power on
reaching the end position!

5. Set measuring gauge on coupling flange or at another accessible posi-

tion and set it to "ZERO".
6. Release pressure and remove hydraulic cylinder.
7. Set piston of the hydraulic cylinder back by hand.

The hydraulic cylinder must be coupled to the hydraulic pump and its
relief valve must be opened for resetting the piston (see Work Card
009.03).

8. Reset hydraulic cylinder.

Work Cards, classified into sub-assemblies

9. Set high-pressure pump in operation and bring the crankshaft (4) to

contact in the opposite direction by means of carefully controlled pres-
sure.

The pressure must not exceed 500 bar! Reduce the pressing power on
reaching the end position!
L48/60;L48/60B;L51/60DF

10. Read off displacement on the measuring gauge.

11. Note axial clearance and compare it to the permissible clearance (see
"Dimensions, Clearances, Tolerances" in Volume 010.005 Engine -
Operating Instructions). Record the axial clearance in the operation
2008-10-22

notes.

Type and source of danger

If the permissible clearance is exceeded, dismantle crankshaft locating
bearing ring (2), check and, if necessary, replace (see Work Sequence 2).

2 (4) 6644 021.03-01 EN

 MAN Diesel & Turbo 021.03

12. Release pressure and remove hydraulic cylinder.

Crankshaft bearing/main thrust bearing

13. Remove magnetic support and measuring gauge.
14. Set piston of the hydraulic cylinder back by hand.
15. Uncouple high-pressure hoses from hydraulic cylinders and high-pres-
sure pump.

Work sequence 2 - Removing and installing the locating bearing rings

Starting position Drive chamber window opened in the area of the camshaft drive.

The locating bearing rings (2) can only be assessed only in the
disassembled state by the running profile.

Work steps 1. Detach one strip (7 or 9) each per locating bearing ring (2).

2. Fix crankshaft (4) in position with two wooden wedges axially, so that
thrust locating bearing rings (2) are free.
3. Unscrew both locating bearing rings (2) in the direction of rotation, do
not rotate crankshaft (4) at this time.
4. Clean locating bearing ring (2) carefully, without damaging it.
5. Check state of the running surface of the locating bearing rings (2).
6. Oil the locating bearing rings (2) lightly before installing.
7. Drive in locating bearing rings (2) and place on crankshaft (4).
8. Attach strip (7 or 9), observing reference dimension (A), on both sides.
9. Remove both wooden wedges.
10. Measure axial clearance (see work sequence 1) and enter in operating
log sheets.

Work Cards, classified into sub-assemblies

L48/60;L48/60B;L51/60DF
2008-10-22

6644 021.03-01 EN 3 (4)

021.03 MAN Diesel & Turbo
Crankshaft bearing/main thrust bearing
Work Cards, classified into sub-assemblies

1 Cylinder crankcase (bearing support) 5 Main bearing cap 9 Rail

2 Locating bearing ring 6 Dowel pin 10 Main bearing cap (external bearing)
3 Crankshaft gearwheel 7 Rail A Control dimension
4 Crankshaft 8 Hexagon bolt
Figure 1: Crankshaft bearing (main thrust bearing)
L48/60;L48/60B;L51/60DF

2008-10-22

4 (4) 6644 021.03-01 EN

MAN Diesel & Turbo 027

Torsional vibration damper

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.6-1 EN 1 (2)

 MAN Diesel & Turbo
Torsional vibration damper

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.6-1 EN

 MAN Diesel & Turbo 027.01

Bolts of the torsional vibration damper

Torsional vibration damper

inspection, loosening and tightening

Summary
Tighten and loosen important bolted connections using the correct values
as specified, ensure the tasks are carried out correctly.
The studs for the torsional vibration damper should be checked at regular
intervals using hydraulic tensioners.
The work / work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 055.100 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
2 Hydraulic tensioner 009.063 Standard
1 Tommy bar, 12 000.264 Standard
1 Sliding calliper Form C - Inventory

Corresponding Work Cards

Work card Work card Work card

Work Cards, classified into sub-assemblies

000.30 000.32 000.33
009.03 009.05 009.13
027.02

Technical data
Designation Information
Bolt projection (A) 153 mm

Work sequence 1- Checking the studs

L48/60B;L51/60DF

Starting position The crankcase cover and the covering on the free engine end have been
2008-07-01

removed.

Check one pair of studs (two studs opposite each other) at the same time.

6704 027.01-02 EN 1 (9)

027.01 MAN Diesel & Turbo

Work steps 1. Clean thread of studs (5).

Torsional vibration damper

2. Place the thrust pieces (055.100) over two nuts (2) which are opposite
each other.
3. Screw hydraulic tensioner (009.063) on both studs (5), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
4. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
5. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
6. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

Ensure that no one is standing near the extended axle!

7. Pump the hydraulic tensioners until the nuts (2) can be released.

The pressure may be max. 7 % below or max. 5 % above the clamping

pressure (see Work Card 000.30)!
If the pressure is below 7%, all studs (5) should be released and removed,
the gear wheel (1) should be detached (see Work Card 027.02) and all the
studs (4) should be checked! See point 1 to 12.

While pumping up, watch the stroke controls (8) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (9)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 3.

8. Make a note of the release pressure and compare it to the clamping

Work Cards, classified into sub-assemblies

pressure.
9. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
10. Hand-tighten both nuts (2) through the cut-out in the thrust piece with
the tommy bar (000.264).
11. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

The hydraulic tensioner returns to the zero position automatically by the

L48/60B;L51/60DF

compression springs (resetting duration about 2 to 3 minutes). However,

the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).
2008-07-01

12. Detach the tensioners.

13. Place the tensioners onto the next pair of studs and repeat the process
until all of the studs (5) have been checked. See point 2 to 12.

2 (9) 6704 027.01-02 EN

 MAN Diesel & Turbo 027.01

14. Uncouple high-pressure hoses from high-pressure pump after conclud-

Torsional vibration damper

ing the inspection work.

Work sequence 2 - Releasing the pressure from the studs

Starting position The crankcase cover and the covering on the free engine end have been
removed.

Untighten one pair of studs (two studs opposite each other) at the same
time.

Work steps 1. Clean threads of the studs (4 and 5).

2. Place the thrust pieces (055.100) over two nuts (2) which are opposite
each other.
3. Screw hydraulic tensioner (009.063) on both studs (5), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
4. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
5. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
6. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

While releasing, take care that no one is present in the extended axis of
the studs to be released!

7. Pump the hydraulic tensioners until the nuts (2) can be released.

In the process, the pressure must not be more than max. 7 % below or

Work Cards, classified into sub-assemblies

max. 5 % above the tensioning pressure (see Work Card 000.30)!

While pumping up, watch the stroke controls (8) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (9)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 3.

8. Make a note of the release pressure and compare it to the clamping

L48/60B;L51/60DF

pressure.
9. Rotate both nuts (2) back with the tommy bar (000.264) manually
2008-07-01

through the cut-out in the thrust piece (turn-back angle see Work Card
000.30).
10. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

6704 027.01-02 EN 3 (9)

027.01 MAN Diesel & Turbo

The hydraulic tensioner returns to the zero position automatically by the

Torsional vibration damper

compression springs (resetting duration about 2 to 3 minutes). However,

the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

11. Detach the tensioners.

12. Place the tensioner onto the next pair of studs and repeat the process
until all of the studs (5) have been released. See point 2 to 11.
13. Disassemble studs (5) disassemble gear wheel (1) (see Work Card
027.02).
14. Place thrust pieces (055.100) over nuts (2).
15. Screw hydraulic tensioner (009.063) on both studs (4), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 4 and 5.
16. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
17. Connect high-pressure hoses (009.306) to hydraulic tensioners.
18. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

While releasing, take care that no one is present in the extended axis of
the studs to be released!

19. Pump the hydraulic tensioners until the nuts (2) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!
Work Cards, classified into sub-assemblies

While pumping up, watch the stroke controls (8) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (9)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 5.

20. Make a note of the release pressure and compare it to the clamping
pressure.
21. Rotate both nuts (2) back with the tommy bar (000.264) manually
through the cut-out in the thrust piece (turn-back angle see Work Card
000.30).
L48/60B;L51/60DF

22. Release pressure, uncouple high-pressure hoses from hydraulic ten-

2008-07-01

sioners and from high-pressure pump.

The hydraulic tensioner returns to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

4 (9) 6704 027.01-02 EN

 MAN Diesel & Turbo 027.01

23. Detach the tensioners.

Torsional vibration damper

Work sequence 3 - tightening the studs
Starting position Threads of the studs are cleaned, studs (4) are installed, nuts are threaded
up by hand up to contact.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Check the bolt projection (A) of the studs (4). See Fig. 1.

2. Place thrust pieces (055.100) over nuts (2).

3. Screw hydraulic tensioner (009.063) on both studs (4), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 4 and 5.
4. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
5. Set high-pressure pump in operation (see Work Card 009.03) and studs
(4) with specified clamping pressure (see Work Card 000.30).

While tensioning, take care that no one is present in the extended axis
of the studs to be tensioned!

While pumping up, watch the stroke controls (8) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (9)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 5.

6. Hand-tighten both nuts (2) through the cut-out in the thrust piece with

Work Cards, classified into sub-assemblies

the tommy bar (000.264).
7. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

The hydraulic tensioners return to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

8. Detach the tensioners.

L48/60B;L51/60DF

9. Assemble gear wheel (1) and install studs (5) (see Work Card 027.02).
10. Check the bolt projection (A) of the studs (5). See Fig. 1.
2008-07-01

11. Place the thrust pieces (055.100) over two nuts (2) which are opposite
each other.

6704 027.01-02 EN 5 (9)

027.01 MAN Diesel & Turbo

Tighten one pair of studs (two studs opposite each other) at the same
Torsional vibration damper

time.

12. Screw hydraulic tensioner (009.063) on both studs (5), ensuring that
thrust pieces are centred by the hydraulic tensioner. See Figs. 2 and 3.
13. Connect high-pressure hoses (009.306) to hydraulic tensioners.
14. Set high-pressure pump in operation (see Work Card 009.03) and studs
(5) with specified clamping pressure (see Work Card 000.30).

While tensioning, take care that no one is present in the extended axis
of the studs to be tensioned!

While pumping up, watch the stroke controls (8) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (9)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 3.

15. Hand-tighten both nuts (2) through the cut-out in the thrust piece with
the tommy bar (000.264).
16. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

The hydraulic tensioners return to the zero position automatically by the

compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).
Work Cards, classified into sub-assemblies

17. Detach the tensioners.

18. Place the tensioner on the next pair of studs and repeat the process until
all of the studs (5) have been tensioned. See point 11 to 17.
19. Once all studs (5) are tensioned, uncouple high-pressure hoses from the
high-pressure pump.
L48/60B;L51/60DF

2008-07-01

6 (9) 6704 027.01-02 EN

 MAN Diesel & Turbo 027.01

Torsional vibration damper

1 Gear wheel 4 Stud 7 Crankshaft
2 Nut 5 Stud A Bolt projection
3 Nut 6 Torsional vibration damper
Figure 1: Torsional vibration damper and gear wheel

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF

1 Gear wheel 5 Stud

2008-07-01

Figure 2: Torsional vibration damper and gearwheel - studs with attached tensioners

6704 027.01-02 EN 7 (9)

027.01 MAN Diesel & Turbo
Torsional vibration damper

1 Gear wheel 8 Stroke control

2 Nut 9 Threaded stop ring
5 Stud M Marking on the stroke control
Figure 3: Stud with attached tensioner
Work Cards, classified into sub-assemblies

4 Stud 6 Torsional vibration damper

L48/60B;L51/60DF

Figure 4: Torsional vibration damper - studs with attached tensioners

2008-07-01

8 (9) 6704 027.01-02 EN

 MAN Diesel & Turbo 027.01

Torsional vibration damper

2 Nut 8 Stroke control
4 Stud 9 Threaded stop ring
6 Torsional vibration damper M Marking on the stroke control
Figure 5: Stud with attached tensioner

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2008-07-01

6704 027.01-02 EN 9 (9)

 MAN Diesel & Turbo 027.02

Torsional vibration damper of the crankshaft

Torsional vibration damper

removal and installation

Summary
Carry out the work in good time according to maintenance schedule, ensure
the work is properly performed, ensure / return to operational safety.
The torsional vibration damper on the crankshaft is to be replaced at speci-
fied intervals according to the maintenance schedule.
The work/work steps include:
removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Attachment eye 027.034 Option
1 Removal and fitting fixture 027.023 Option
1 Pipe 027.023-1 Option
1 Suspension plate 027.023-3 Option
1 Slide piece 027.023-6 Option
1 Bracket 027.023-15 Option
1 Pipe 027.023-22 Option
1 Pipe 027.023-23 Option

Work Cards, classified into sub-assemblies

1 Slide piece 027.023-24 Option
1 Ratchet hoist 027.023-27 Option
3 Threaded rod 027.023-30 Option
3 Sleeve 027.023-35 Option
3 Sleeve 027.023-36 Option
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic cylinder 009.165 Option
1 Shackle A1.6 002.454 Standard
L48/60B;L51/60DF

1 Shackle A0.6 002.452 Standard

2007-11-19

1 Adapter 20x12.5 001.923 Standard

1 Socket spanner insert 36x20 001.771 Standard
1 Ratchet tool 001.521 Standard
1 Tommy bar, 12 000.264 Standard
1 Lifting eye bolt M24 000.156 Standard

6704 027.02-02 EN 1 (25)

027.02 MAN Diesel & Turbo

Quantity Designation Number Status

Torsional vibration damper

1 Lifting eye bolt M10 000.141 Standard

1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
2 Wooden support - Inventory
1 Lifting tackle - Inventory
1 Marker pen - Inventory
2 Shackle - Standard
2 Rope - Inventory
1 Depth gauge - Inventory
1 Lubricating oil, clean - Inventory
1 Securing compound, Loctite 243 - Inventory

Corresponding Work Cards

Work card Work card Work card
000.19 009.03 009.05
027.01

Technical data
Designation Information
Torsional vibration damper 2240 - 3760 kg
Cover 46 kg
Stud with nut 18,5 kg
Gear wheel 315 kg

Preliminary remark
Each torsional vibration damper is a special component specifically
Work Cards, classified into sub-assemblies

designed for an individual piece of equipment. Improper installation can lead

to damage of the equipment or to the torsional vibration damper.
Work sequence 1 - removing the torsional vibration damper
Starting position All pipes obstructing the dismantling of the torsional vibration damper are
removed, attached pumps (lubricating oil and/or cooling water pump) are
detached, crankcase cover and casing on free engine end are detached.
Work steps 1. Rotate the crankshaft (13) until the marking "OT 1 / TDC 1" on the tor-
sional vibration damper (10) is at the top.
2. Screw lifting eye bolt (000.141) into cover (4). See Fig. 2/I.
L48/60B;L51/60DF

3. Fasten the rope (15) with the shackle (002.452) to the lifting eye bolt and
2007-11-19

attach it to lifting tackle.

4. Unscrew hexagon bolts (3) and remove cover (4). Place cover on pack-
ing. See Fig. 2/II.
5. Detach the tool.

2 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

6. Turn crankshaft (13) through about 45°, so that tapped hole on the front

Torsional vibration damper

end of the gear wheel (2) is at the top. See Fig. 4.
7. Slacken the studs (9) (see Work Card 027.01).
8. Turn back nut (6) by several turns, unscrew nut (7), remove stud (9),
including nut, and place on packing. See Fig. 3.
9. Remove the remaining studs (9) in the same manner. See point 8.
10. Screw the lifting eye bolt (000.156) into the gear wheel (2). See Fig. 4/I.
11. Fasten the rope (15) with the shackle (002.454) to the lifting eye bolt and
attach it to lifting tackle. Tension rope.
12. Mark position of the gear wheel (2) with respect to torsional vibration
damper (10).
13. Unscrew and remove the hexagon socket bolts (1).
14. Remove the gearwheel (2) and set it down on a support. See Fig. 4/II.

Do not damage studs (8) when removing the gear wheel!

15. Detach the tool.

16. Turn crankshaft (13), until marking "OT 1 / TDC 1" on torsional vibration
damper (10) is at the top again.
17. Slacken the studs (8) (see Work Card 027.01).
18. Turn back nut (6) by several turns, unscrew nut (7), remove stud (8),
including nut, and place on packing. See Fig. 5.
19. Remove the second stud (8) in the same manner. See point 18.
20. Attach the suspension plate (027.023-3) to the crankshaft (13); in doing
so, make sure it is correctly centred and in the correct attachment posi-
tion. See Fig. 6.

Work Cards, classified into sub-assemblies

21. Fasten the bracket (027.023-15) to the foundation at the height of the
lower edge of the cylinder crankcase (C) and at a distance (E) of 1750.5
mm to the end edge of the cylinder crankcase (D). See Fig. 6.
22. Push the pipe (027.023-1) over the pin (18) on the suspension plate and
lay it on the bracket. See Fig. 7.
23. Screw the hexagon bolt (21) into the pin (18) and fasten the pipe to the
bracket. See Fig. 7.
24. Oil the sliding surface of the slide piece (027.023-6) and slide it between
the pipe and the torsional vibration damper (10). See Fig. 8.
L48/60B;L51/60DF

25. Screw in the hexagon bolts (22) until they make contact, but do not
tighten them yet at this stage.
2007-11-19

26. Screw in the hexagon bolt (21) until the slide piece abuts on the torsional
vibration damper (10).
27. Tighten the hexagon bolts (22).
28. Hook in the ratchet hoist (027.023-27) at the slide piece and pipe. See
Fig. 9.

6704 027.02-02 EN 3 (25)

027.02 MAN Diesel & Turbo

29. Oil the pipe.

Torsional vibration damper

30. Unscrew and remove the hexagon socket bolts (14).

31. Carefully pull the torsional vibration damper (10) outwards by operating
the ratchet hoist. See Fig. 10.

When removing, make sure that the cylinder crankcase is not damaged!

32. Screw the attachment eyes (027.034) into the torsional vibration damper
(10) and tighten them hand-tight with a open-jaw wrench. See Fig. 11.
33. Fasten the ropes (15) with the shackle (28) to the bearing blocks and
attach them to lifting tackle.

Ensure proper use of the bearing blocks! See Fig. 9.

34. Unhook the ratchet hoist from the slide piece and pipe.
35. Slightly lift up the torsional vibration damper (10). See Fig. 12/I.
36. Unscrew and remove the hexagon bolt (21), unscrew and remove the
hexagon nuts (19), remove the hexagon nuts (20) and detach the pipe.
See Fig. 12/II.
37. Transport the torsional vibration damper (10) away and carefully set it
down on wooden supports.
38. Detach the tool(s) from the torsional vibration damper (10).
39. Clean studs (8 and 9) and nuts (6 and 7) and check for damages.
40. Clean gear wheel (2).
Transporting the torsional The torsional vibration damper (10) must only be transported in a horizontal
Work Cards, classified into sub-assemblies

vibration damper position. Only use the designated attachment points for this purpose. The
torsional vibration damper should be supported from at least two attach-
ment points both during removal/installation and during transportation. See
Fig. 13.
Work sequence 2 - installing the torsional vibration damper
Starting position Piston of cylinder 1 is at TDC. The suspension plate (027.023-3) is attached
to the crankshaft, the bracket (027.023-15) is mounted on the support.
Work steps 1. Clean the flange on the crankshaft (13).

2. Blow out the supply bore in the crankshaft (13) with compressed air.
L48/60B;L51/60DF

3. Clean all slushing oil from the torsional vibration damper (10).
2007-11-19

4. Blow out the oil bores in the torsional vibration damper (10) with com-
pressed air.
5. Secure the slide piece (027.023-6) on the torsional vibration damper
(10); in doing so note that the slide piece abuts on the torsional vibration
damper.

4 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Ensure correct attachment position! The slide piece must lie in vertical

Torsional vibration damper

axis with the marking "OT 1 / TDC 1" on torsional vibration damper!

6. Screw the attachment eyes (027.034) into the torsional vibration damper
(10) and tighten them hand-tight with a open-jaw wrench. See figure 13/
I and 14/I.
7. Fasten the ropes (15) with the shackle (28) to the bearing blocks and
attach them to lifting tackle.

Ensure proper use of the bearing blocks! See Figs. 13/I and 14/I.

8. Lift up the torsional vibration damper (10) and move it between the cyl-
inder crankcase (11) and the bracket (027.023-15).
9. Push the pipe (027.023-1) through the torsional vibration damper (10)
and lay it on the pin (18) on the suspension plate and on the bracket.
See Fig. 14/I.
10. Screw the hexagon bolt (21) into the pin (18) and fasten the pipe to the
bracket. See Fig. 14/I.
11. Lightly oil the pipe.
12. Lower the torsional vibration damper (10) onto the pipe. See Fig. 14/I.
13. Detach cables (15), shackle and attachment eyes.
14. Push the pipe (027.023-23) through the pipe (027.023-1). See Fig. 14/I.
15. Oil the sliding surface of the slide piece (027.023-24) place it on the pipe
(027.023-1) and push it into the pipe (027.023-23). See Fig. 14/I.
16. Insert the pin (25) in the pipe (027.023-23). See Fig. 14/I.

Work Cards, classified into sub-assemblies

17. Insert the hydraulic cylinder (009.165) in the slide piece. See Fig. 14/I.
18. Connect high-pressure hose (009.306) to hydraulic cylinders and high-
pressure pump (009.338). Connect an oil pressure gauge (0 - 400 bar)
to the high-pressure pump.
19. Set high-pressure pump in operation and slide torsional vibration
damper (10) in the direction of crankshaft (13). See Fig. 14/II.

Observe the oil pressure gauge during the displacement! Sudden

increase in pressure during the displacement indicates tilting!
L48/60B;L51/60DF

20. Release the pressure.

2007-11-19

21. Reset the piston of the hydraulic cylinder by hand. To do this, the relief
valve on the high-pressure pump needs to be opened (see Work Card
009.03).
22. Remove the pin (25), move the pipe and slide piece and insert the pin in
the next bore.

6704 027.02-02 EN 5 (25)

027.02 MAN Diesel & Turbo

23. Start up the high-pressure pump and slide the torsional vibration
Torsional vibration damper

damper (10) again in the direction of the crankshaft (13).

24. Repeat the process until the torsional vibration damper (10) abuts
against the crankshaft (13). See points 19 to 23 / see figures 14 ,15 and
16.

To bring the torsional vibration damper into the end position, the pipe
(027.023-22) must be fitted as an extension on the pipe (027.023-23).

When assembling, see that the cylinder crankcase is not damaged!

25. Release the pressure.

26. Check that the marking "OT 1 / TDC 1" on the torsional vibration damper
(10) is at the top. See Fig. 17.
27. Insert threaded rods (027.023-30) through the bores, push on the
sleeves (027.023-35 and 027.023-36) and screw on the hexagon nuts
(26 and 27). See Fig. 17.
28. Set length of projection of thread end (G = 55 mm) on the threaded rods
and tighten hexagon nuts (27). See Fig. 17.
29. By evenly tightening the hexagon nuts (27) in an alternating sequence,
attach the torsional vibration damper (10) until it makes contact on the
crankshaft (13). See Fig. 18.
30. Coat the thread and contact face of the hexagon socket bolts (14) with
Loctite 243 securing compound, screw them in and tighten them. See
Fig. 1.
31. Completely detach the tool.
Work Cards, classified into sub-assemblies

32. Install stud (8) and screw nuts (6 and 7) on. See Fig. 5.
33. Set length of projection of thread end (A = 153 mm) on stud (8) and
tighten nut (6) by hand using a tommy bar (000.264). See Figs. 1 and 5.
34. Install the second stud (8) in the same manner. See Point 32 and Point
33.
35. Tighten the studs (8) (see Work Card 027.01).
36. Rotate the crankshaft (13) through approximately 45°. See Fig. 4.
37. Screw the lifting eye bolt (000.156) into the gear wheel (2).
L48/60B;L51/60DF

Ensure that the lifting eye bolt is screwed into the correct threaded hole.
The markings that were made (see work sequence 1 / point 12) must be
2007-11-19

in the same position during the refitting process.

38. Fasten the rope (15) with the shackle (002.454) to the lifting eye bolt and
attach it to lifting tackle.

6 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

39. Lift up the gear wheel (2) and move it in front of the torsional vibration

Torsional vibration damper

damper (10). See Fig. 4/II.
40. Attach the gear wheel (2) to the torsional vibration damper (10). See Fig.
4/I.

Do not damage studs (8) when installing the gearwheel! Check that the
gear wheel/torsional vibration damper are positioned correctly (see work
sequence 1 / point 12)!

41. Coat the thread and contact face of the hexagon socket bolts (1) with
Loctite 243 securing compound, screw them in and tighten them. See
Fig. 4.
42. Detach the tool.
43. Install stud (9) and screw nuts (6 and 7) on. See Fig. 3.
44. Set length of projection of thread end (A = 153 mm) on stud (9) and
tighten nut (6) by hand using a tommy bar (000.264). See Figs. 1 and 3.
45. Install the remaining studs (9) in the same manner. See Point 43 and
Point 44.
46. Tighten the studs (9) (see Work Card 027.01).
47. Rotate the crankshaft (13) until the marking "OT 1 / TDC 1" on the tor-
sional vibration damper (10) is at the top.
48. Screw lifting eye bolt (000.141) into cover (4).
49. Fasten the rope (15) with the shackle (002.452) to the lifting eye bolt and
attach it to lifting tackle.
50. Attach cover (4). See Fig. 2.
51. Coat screw thread and contact surface of the hexagon bolts (3) with
securing compound Loctite 243, screw in and tighten.
52. Detach the tool.

Work Cards, classified into sub-assemblies

53. Clean the pipe and slide pieces, reset the piston of the hydraulic cylin-
der.
Commissioning Before commissioning the engine, the torsional vibration damper must be
lubricated with lube oil by means of the priming pump, until lube oil emits
from the return holes (B) in the side disc (12). See Fig. 1.
L48/60B;L51/60DF
2007-11-19

6704 027.02-02 EN 7 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper

1 Hexagon socket bolt 7 Nut 13 Crankshaft

2 Gear wheel 8 Stud 14 Hexagon socket bolt
3 Hexagon bolt 9 Stud A Bolt projection
4 Cover *10 Torsional vibration damper B Return hole
5 Oil sump 11 Cylinder crankcase
6 Nut 12 Cover ring
Work Cards, classified into sub-assemblies

Figure 1: Torsional vibration damper and gear wheel

L48/60B;L51/60DF

2007-11-19

8 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

3 Hexagon bolt *10 Torsional vibration damper I - II Work steps
4 Cover 15 Rope
Figure 2: Removal/ fitting of the cover

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2007-11-19

6704 027.02-02 EN 9 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper

2 Gear wheel 9 Stud A Bolt projection

6 Nut *10 Torsional vibration damper I - II Work steps
7 Nut 13 Crankshaft
Figure 3: Fitting/removal of the studs
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-19

10 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

Work Cards, classified into sub-assemblies

1 Hexagon socket bolt 8 Stud 15 Rope

L48/60B;L51/60DF

2 Gear wheel *10 Torsional vibration damper I - II Work steps

Figure 4: Removal/ fitting of the gear wheel
2007-11-19

6704 027.02-02 EN 11 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper

6 Nut 8 Stud A Bolt projection

7 Nut *10 Torsional vibration damper I - II Work steps
Figure 5: Fitting/removal of the studs
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-19

12 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

Work Cards, classified into sub-assemblies

*10 Torsional vibration damper 16 Hexagon bolt M24x55 C Lower edge of cylinder crankcase
L48/60B;L51/60DF

13 Crankshaft 17 Hexagon bolt M16 D End edge of cylinder crankcase

E Distance (end edge of cylinder crank-
2007-11-19

case to bracket)
Figure 6: Removal of the torsional vibration damper

6704 027.02-02 EN 13 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper

*10 Torsional vibration damper 19 Hexagon nut M16 21 Hexagon bolt

18 Pin 20 Hexagon bolt M16x40
Figure 7: Removal of the torsional vibration damper
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-19

14 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

Work Cards, classified into sub-assemblies
L48/60B;L51/60DF
2007-11-19

*10 Torsional vibration damper 21 Hexagon bolt 22 Hexagon bolt M16x75

Figure 8: Removal of the torsional vibration damper

6704 027.02-02 EN 15 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper

*10 Torsional vibration damper 14 Hexagon socket bolt

Figure 9: Removal of the torsional vibration damper
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-19

16 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

Figure 10: Removal of the torsional vibration damper

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2007-11-19

6704 027.02-02 EN 17 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper

*10 Torsional vibration damper 15 Rope 28 Shackle

Figure 11: Removal of the torsional vibration damper
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-19

18 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

Work Cards, classified into sub-assemblies
L48/60B;L51/60DF
2007-11-19

*10 Torsional vibration damper 20 Hexagon bolt M16x40 I - II Work steps

19 Hexagon nut M16 21 Hexagon bolt
Figure 12: Removal of the torsional vibration damper

6704 027.02-02 EN 19 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper

*10 Torsional vibration damper 24 Lifting tackle I Removal/installation

15 Rope 28 Shackle II Transportation
23 Suspension element F Angle, 60° max.
Figure 13: Suspending the torsional vibration damper during removal/installation/transport of the torsional
vibration damper
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-19

20 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

Work Cards, classified into sub-assemblies

*10 Torsional vibration damper 20 Hexagon bolt M16x40 28 Shackle

L48/60B;L51/60DF

15 Rope 21 Hexagon bolt I - II Work steps

19 Hexagon nut M16 25 Pin
2007-11-19

Figure 14: Installation of the torsional vibration damper

6704 027.02-02 EN 21 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper
Work Cards, classified into sub-assemblies

*10 Torsional vibration damper 25 Pin I - II Work steps

L48/60B;L51/60DF

Figure 15: Installation of the torsional vibration damper

2007-11-19

22 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

*10 Torsional vibration damper 13 Crankshaft 25 Pin
Figure 16: Installation of the torsional vibration damper

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2007-11-19

6704 027.02-02 EN 23 (25)

027.02 MAN Diesel & Turbo
Torsional vibration damper
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-19

*10 Torsional vibration damper 26 Hexagon nut M30 G Bolt projection

13 Crankshaft 27 Hexagon nut M30
Figure 17: Installation of the torsional vibration damper

24 (25) 6704 027.02-02 EN

 MAN Diesel & Turbo 027.02

Torsional vibration damper

*10 Torsional vibration damper 13 Crankshaft 26 Hexagon nut M30
27 Hexagon nut M30
Figure 18: Installation of the torsional vibration damper
* The form and size of the torsional vibration damper may differ from the one shown in the illustrations. ≙

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2007-11-19

6704 027.02-02 EN 25 (25)

 MAN Diesel & Turbo 027.04

Torsional vibration damper

Torsional vibration damper

inspecting

Summary
Carry out all work on time in accordance with the maintenance schedule,
ensure that all work is carried out properly, and make sure that operational
safety is established (or re-established if necessary).
The torsional vibration damper on the crankshaft/camshaft (if equipped)
should be inspected at the intervals specified in the maintenance schedule.
The work/ work steps include:
Disassembling components,
Assembling components,
Checking components.
Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Inventory
1 Data sheet (Geislinger & Co.) - Special
1 Measuring wedge (Geislinger & Co.) - Special
1 Sliding calliper Form A - Inventory
1 Sliding calliper Form C - Inventory
1 Ratchet tool - Inventory
1 Torque wrench - Inventory
1 Socket spanner (set) - Inventory
2 lifting eye bolt (high-strength design) - Inventory
2 Shackle - Inventory
1 Lifting tackle - Inventory

Work Cards, classified into sub-assemblies

2 Rope - Inventory
1 Hammer - Inventory
1 Rubber mallet - Inventory
1 Centre-punch - Inventory
1 Brass wedge - Inventory
1 Securing compound, Loctite 275 - Inventory
1 Securing compound, Loctite 243 - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory
1 Silicone grease - Inventory
2009-01-23

Preliminary remark
Each torsional vibration damper is a special component specifically
General

designed for an individual piece of equipment. Incorrect disassembly or

assembly may cause serious damage to the system or the torsionial vibra-
tion damper.

6682 027.04-01 EN 1 (10)

027.04 MAN Diesel & Turbo

The manufacturer's instructions must be followed when carrying out work on the
Torsional vibration damper

torsional vibration damper.

Lifting eye bolts, shackles and lifting tackle must be appropriately selected
for the respective torsional vibration damper.
Work Cards, classified into sub-assemblies

1 Spring pack 15 Bearing bush 851 O-ring seal

2009-01-23

5 Flange 750 Hexagon bolt

7 Side plate 810 Cup spring I Torsional vibration damper without bearing bush
9 Inner star 850 O-ring seal II Torsional vibration damper with bearing bush
General

Figure 1: Torsion vibration damper*

2 (10) 6682 027.04-01 EN

 MAN Diesel & Turbo 027.04

Work sequence 1 - Disassembling and checking torsional vibration damper

Torsional vibration damper

Starting position Torsion vibration damper dismantled and placed on flange (5) with a wooden
support. Crankshaft flange side of the inner star (9) points towards the top.

Danger of death when lifting and moving loads!

Do not stand under suspended loads unless absolutely necessary!

Work steps 1. Mark position of the flange (5) and the side plate (7) on the spring packet
(1) of the torsional vibration damper. Mark with a centre-punch.
2. Unscrew hexagon bolts (750) with cup springs (810). See Fig. 2/I.
3. Screw lifting eye bolts into side plate (7). See Fig. 2/II.
4. Attach rope with shackle to lifting eye bolts and suspend from lifting
tackle. See Fig. 2/II.
5. Lift side plate (7) from spring packet (1), turn and place on wooden sup-
port. See Fig. 2/II.
6. Remove slings.
7. Remove O-ring seals (850 and 851) from side plate (7) and spring packet
(1). See Fig. 2/III.
8. Check sealing face of the side plate (7). Refer to data sheet for permis-
sible wear limit.

Exchange of the complete torsion vibration damper

Replace the torsion vibration damper when the threshold values
indicated on the data sheet are exceeded.

9. Checking the permissible wear limit with measuring wedge or sliding

calliper. See work sequence 2 - Measuring the wear limit.
10. Screw lifting eye bolts into inner star (9). See Fig. 3/V.

Work Cards, classified into sub-assemblies

11. Attach rope with shackle to lifting eye bolts and suspend from lifting
tackle. See Fig. 3/V.
12. Carefully lift inner star (9) from spring pack (1) and place on wooden
support. Do not tilt inner ring or damage adjacent components in the
process. See Fig. 3/V.
13. Remove slings.
14. Check sealing surfaces of the inner star (9). Refer to data sheet for per-
missible wear limit.

Exchange of the complete torsion vibration damper

Replace the torsion vibration damper when the threshold values
2009-01-23

indicated on the data sheet are exceeded.

General

15. Screw lifting eye bolts into spring packet (1). See fig. 3/VI.
16. Attach rope with shackle to lifting eye bolts and suspend from lifting
tackle. See fig. 3/VI.

6682 027.04-01 EN 3 (10)

027.04 MAN Diesel & Turbo

17. Lift spring pack (1) and place on wooden support. See fig. 3/VI.
Torsional vibration damper

18. Remove slings.

19. Check sealing surfaces of the flange (5). Refer to data sheet for permis-
sible wear limit.

Exchange of the complete torsion vibration damper

Replace the torsion vibration damper when the threshold values
indicated on the data sheet are exceeded.

20. Remove O-ring seals (850 and 851) from flange (5) and spring packet
(1). See Figure 3/VII.
21. Clean all the components.

Work sequence 2 - Measuring the wear limit

Number of measuring points:

Approximately every fourth spring pack shall be checked.

Measuring wedge 1. Place measuring wedge between spring-leaf tips at the base of groove.

2. Press measuring wedge down (manually or using a rubber mallet) until

both sides of the spring-leaf tips are in contact with the groove flanks.
See data sheet and fig. 2/IV.

Exchange of the complete torsion vibration damper

The torsional vibration damper must be replaced when the measuring
wedge can be inserted between the spring leaf end up to the parallel end
(max. marking).

Sliding calliper 1. Place brass wedge between the spring-leaf tips approx. 10 mm above
the base of groove.
Work Cards, classified into sub-assemblies

2. Press brass wedge down (manually or using a rubber mallet) until both
sides of the spring-leaf tips are in contact with the groove flanks.
3. Measure dimension between the spring-leaf tips and enter results into
measurement log.

Exchange of the complete torsion vibration damper

Replace the torsion vibration damper when the threshold values
indicated on the data sheet are exceeded.

Work sequence 3 - Assembling the torsionial vibration damper

2009-01-23

Starting position All parts cleaned and lightly oiled with clean lubricating oil.

Work steps 1. Insert a new O-ring seal (850) wetted with clean lubricating oil in the
General

sealing ring groove of the flange (5). Make sure that it is evenly tensioned
along the entire circumference and is not twisted.

4 (10) 6682 027.04-01 EN

 MAN Diesel & Turbo 027.04

2. Screw lifting eye bolts into spring packet (1).

Torsional vibration damper

3. Attach rope with shackle to lifting eye bolts and suspend from lifting
tackle.
4. Lift spring pack (1) over flange (5). In doing so, pay attention to the
marking.
5. Insert a new O-ring seal (851) wetted with clean lubricating oil in the
lower sealing ring groove of the spring packet (1). Make sure that it is
evenly tensioned along the entire circumference and is not twisted.
Apply silicone grease to the O-ring seal at several points to prevent it
from falling out during the assembly.
6. Screw two hexagon bolts (750) into the guide. See Fig. 4.
7. Lower spring pack (1) over flange (5).
8. Use a dial gauge with magnetic post or sliding calliper to align spring
packet (1) with the flange (5). Take the maximum permissible radial run-
out into account (see drawing).
9. Remove slings.
10. Use two hexagon bolts (750) and old cup springs (810) as spacer wash-
ers to screw down the spring packet (1) on the flange (5). See Fig. 4.
11. Unscrew the guide bolts from work step 6.
12. Screw lifting eye bolts into inner star (9).
13. Attach rope with shackle to lifting eye bolt and suspend from lifting
tackle.
14. Carefully insert inner star (9) into spring pack (1). Do not tilt inner ring or
damage adjacent components in the process.
15. Align inner star (9) with the spring pack (1). Provide even clearance
between inner ring and spring packet in the process.
16. Remove slings.
17. Unscrew fixing screws from spring pack.

Work Cards, classified into sub-assemblies

18. Insert a new O-ring seal (851) wetted with clean lubricating oil in the
sealing ring groove of the spring packet (1). Make sure that it is evenly
tensioned along the entire circumference and is not twisted.
19. Screw lifting eye bolts into side plate (7).
20. Attach rope with shackle to lifting eye bolts and suspend from lifting
tackle.
21. Lift side plate (7) over the spring pack (1). In doing so, pay attention to
the marking.
22. Insert a new O-ring seal (850) wetted with clean lubricating oil in the
lower sealing ring groove of the side plate (7). Make sure that it is evenly
tensioned along the entire circumference and is not twisted. Apply sili-
2009-01-23

cone grease to the O-ring seal at several points to prevent it falling out
during the assembly.
23. Carefully lower side plate (7) over the spring pack (1).
General

6682 027.04-01 EN 5 (10)

027.04 MAN Diesel & Turbo

24. Use a dial gauge with magnetic post or sliding calliper to align side plate
Torsional vibration damper

(7) with the spring packet (1) (see Figure 8). Take the maximum permis-
sible radial run-out into account (see drawing).
25. Remove slings.
26. Place new cup springs (810) coated with Loctite on both sides over the
holes in the side plate (7).
27. Apply MoS2 lubricant to threads and contact faces of hexagon bolts
(750). Screw in hexagon bolts, tighten with contact torque (see table)
until cup springs are completely pressed down. Subsequently tighten up
with the prescribed torsion angle (see data sheet).

cup springs must have flat contact!

If the cup springs do not have flat contact, the tightening torque of the
hexagon bolts becomes distorted.

Correct tightening of the hexagon bolts

First of all, tighten four hexagon bolts in a diagonally opposed sequence.
Tighten the remaining bolts in a circle. In the case of torsional vibration
dampers with two hole circles, the inner one must be tightened first and
then the outer one.
Work Cards, classified into sub-assemblies

2009-01-23
General

6 (10) 6682 027.04-01 EN

 MAN Diesel & Turbo 027.04

Torsional vibration damper

Work Cards, classified into sub-assemblies

1 Spring pack 750 Hexagon bolt 1001 Measuring wedge

2009-01-23

5 Flange 810 Cup spring

7 Side plate 850 O-ring seal I-IV Work steps
9 inner star 851 O-ring seal
General

Figure 2: Dismantling and assembling the torsional vibration damper

6682 027.04-01 EN 7 (10)

027.04 MAN Diesel & Turbo
Torsional vibration damper
Work Cards, classified into sub-assemblies

1 Spring pack 9 inner star 851 O-ring seal

2009-01-23

5 Flange 850 O-ring seal V - VII Work steps

Figure 3: Dismantling and assembling the torsional vibration damper
General

8 (10) 6682 027.04-01 EN

 MAN Diesel & Turbo 027.04

Torsional vibration damper

1 Spring pack 750 Hexagon bolt
5 Flange 810 Cup spring
Figure 4: Dismantling and assembling the torsional vibration damper
Nominal width of cup spring Contact torque
M8 8 Nm
M 10 13 Nm
M 12 21 Nm
M 14 30 Nm

Work Cards, classified into sub-assemblies

M 16 40 Nm
M 18 50 Nm
M 20 70 Nm
M 22 100 Nm
M 24 - with 2.5 mm cup-spring width 105 Nm
M 24 - with 3.6 mm cup-spring width 125 Nm
M 27 - with 3 mm cup-spring width 177 Nm
M 27 - with 4 mm cup-spring width 160 Nm
M 30 205 Nm
M 33 345 Nm
M 36 350 Nm
2009-01-23

Table 1: Contact torque for cup springs*

* The values only apply when the specified installation specifications for bolts
General

are complied with: "Thread lubricated or treated with Molykote and Loctite
applied to both sides of cup springs."
See drawing by Co. Geislinger

6682 027.04-01 EN 9 (10)

027.04 MAN Diesel & Turbo
Torsional vibration damper
Work Cards, classified into sub-assemblies

Figure 5: Sample of a data sheet

2009-01-23

* Shape and size of the torsion vibration damper may differ from the illustration in the figures
General

10 (10) 6682 027.04-01 EN

MAN Diesel & Turbo 030

Connecting rod/Big-end bearing

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.7-1 EN 1 (2)

 MAN Diesel & Turbo
Connecting rod/Big-end bearing

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.7-1 EN

 MAN Diesel & Turbo 030.01

Conrod shank bolts

Connecting rod/Big-end bearing

inspection, loosening and tightening

Summary
Tension and release important bolted connections with the correct values,
ensure correct execution of work.
Conrod shank bolts should be inspected at regular intervals by means of
hydraulic tensioners.
The work / work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
4 Thrust piece 030.206 Standard
4 Tension nut 030.205 Standard
1 Measuring device 030.202 Standard
1 Test mandrel 030.202-1 Standard
1 Hand rail 011.013 Standard
1 Foot board (for oil sump) 011.012 Standard
1 Foot board (for oil sump) 011.011 Standard
4 Hydraulic tensioner 009.346 Standard
1 High-pressure pump 009.342 Standard

Work Cards, classified into sub-assemblies

2 High-pressure hose 009.306 Standard
1 Tommy bar, 6 009.068 Standard
1 Open-jaw wrench 55 000.570 Standard
1 Thickness gauges 0.05-1 000.451 Option
1 Sliding calliper - Inventory

Corresponding Work Cards

Work card Work card Work card
L48/60B;L51/60DF

000.30 000.32 000.33

009.03 009.05 009.07
2007-11-20

Work sequence 1 - Checking the conrod shank bolts

Starting position Crankcase is opened, crank pin of the concerned cylinder is at BDC.

Work steps 1. Fasten handle (011.013) to cylinder crankcase (12).

6704 030.01-01 EN 1 (11)

030.01 MAN Diesel & Turbo

2. Insert foot board (011.012 for normal oil sump or 011.011 for V oil sump)
Connecting rod/Big-end bearing

in oil sump (13).

3. Clean the threads of the conrod shank bolts (10).
4. Check with open-jaw wrench (000.570) that tension nuts (030.205) are
tightly screwed onto the hydraulic tensioners (009.346).
5. Insert thrust piece (030.206) over nut (9) on conrod shank bolt (bolt 1) and
bolt the hydraulic tensioner on. See Figs. 2 and 4.
6. Attach tensioners to the conrod shank bolts (bolts 4, 5 and 8) in the same
manner. See point 5 / see figure 2.
7. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
8. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
9. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

Ensure that no is present in the extension of the axis of the conrod shank
bolts!

10. Pump the hydraulic tensioners until the nuts (9) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

11. Make a note of the release pressure and compare it to the clamping
pressure.
12. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
Work Cards, classified into sub-assemblies

13. Hand-tighten nuts (9) using tommy bar (009.068) through cut-out in the
thrust pieces.
14. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

The hydraulic tensioners return to the zero position automatically by

means of a set of cup springs (resetting duration about 2 to 3 minutes).
However, the high-pressure pump must be connected, and its relief valve
must be open (see Work Card 009.03).
L48/60B;L51/60DF

15. Detach the tensioners.

16. Place thrust pieces (030.206) and hydraulic tensioners (009.346) on
2007-11-20

conrod shank bolts (bolts 2, 3, 6 and 7). See point 5 and 6 / see figure 3 and
4.
17. Check conrod shank bolts (bolts 2, 3, 6 and 7) in the same manner. See point
7 to 13.

2 (11) 6704 030.01-01 EN

 MAN Diesel & Turbo 030.01

18. Release pressure, uncouple high pressure hoses from hydraulic ten-

Connecting rod/Big-end bearing

sioners and high pressure pump.
19. Detach the tensioners.
20. Remove foot board from the oil sump (13).
21. Remove handle.

Work sequence 2 - Untightening the conrod shank bolts

Starting position Crankcase is opened, crank pin of the concerned cylinder is at BDC.

Work steps 1. Fasten handle (011.013) to cylinder crankcase (12).

2. Insert foot board (011.012 for normal oil sump or 011.011 for V oil sump)
in oil sump (13).
3. Clean the threads of the conrod shank bolts (10).
4. Check with open-jaw wrench (000.570) that tension nuts (030.205) are
tightly screwed onto the hydraulic tensioners (009.346).
5. Insert thrust piece (030.206) over nut (9) on conrod shank bolt (bolt 1) and
bolt the hydraulic tensioner on. See Figs. 2 and 4.
6. Attach tensioners to the conrod shank bolts (bolts 4, 5 and 8) in the same
manner. See point 5 / see figure 2.
7. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
8. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
9. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

When releasing, ensure that no one is in the extended axis of the conrod
shank bolts to be released!

Work Cards, classified into sub-assemblies

10. Pump the hydraulic tensioners until the nuts (9) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

11. Make a note of the release pressure and compare it to the clamping
pressure.
12. Turn back nuts (9) using tommy bar (009.068) through cut-out in the
L48/60B;L51/60DF

thrust pieces (for turn-back angle see Work Card 000.30).

2007-11-20

13. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

6704 030.01-01 EN 3 (11)

030.01 MAN Diesel & Turbo

The hydraulic tensioners return to the zero position automatically by

Connecting rod/Big-end bearing

means of a set of cup springs (resetting duration about 2 to 3 minutes).

However, the high-pressure pump must be connected, and its relief valve
must be open (see Work Card 009.03).

14. Detach the tensioners.

15. Place thrust pieces (030.206) and hydraulic tensioners (009.346) on
conrod shank bolts (bolts 2, 3, 6 and 7). See point 5 and 6 / see figure 3 and
4.
16. Release conrod shank bolts (bolts 2, 3, 6 and 7) in the same manner. See
point 7 to 12.
17. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.
18. Detach the tensioners.

Work sequence 3 - Tightening the conrod shank bolts

Starting position Small end is fitted on the connecting rod shank, conrod shank bolts are
screwed in by hand until they fit in the connecting rod shank, nuts are threa-
ded-on and tightened by hand, threads of the conrod shank bolt are
cleaned. Crank pin is at BDC, hand rail is attached to the cylinder crankcase,
foot board is inserted in oil sump.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Check that parting line between connecting rod shank and small end
over its entire periphery is less than 0.05 mm in thickness.
2. Check length of the conrod shank bolts (10) using a sliding calliper.
Work Cards, classified into sub-assemblies

As a result of irregular circumstances, the conrod shank bolts can be

permanently stretched! If a length of 277.60 mm (untensioned) is
exceeded, the conrod shank bolt should be changed!

3. Clamp the measuring mandrel (030.202-1) in measuring device

(030.202) and set the scale of the measuring gauge (15) to "Zero".
Remove test mandrel. See Fig. 5/I.
4. Suspend measuring device between centrings of a conrod shank bolt
(10). Read off measuring gauge (15) and note the value. See Fig. 5/II.

It is advisable to prepare a separate measurement log for the tensioning

L48/60B;L51/60DF

of the conrod shank bolts.

2007-11-20

5. Measure all the other conrod shank bolts (10) in the same manner and
note the values. See point 4.

4 (11) 6704 030.01-01 EN

 MAN Diesel & Turbo 030.01

6. Check with open-jaw wrench (000.570) that tension nuts (030.205) are

Connecting rod/Big-end bearing

tightly screwed onto the hydraulic tensioners (009.346).
7. Insert thrust piece (030.206) over nut (9) on conrod shank bolt (bolt 2) and
bolt the hydraulic tensioner on. See Figs. 3 and 4.
8. Attach tensioners to the conrod shank bolts (bolts 3, 6 and 7) in the same
manner. See point 7 / see figure 3.
9. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
10. Set high-pressure pump in operation (see Work Card 009.03) and
tighten conrod shank bolts with specified clamping pressure (see Work
Card 000.30).

When tightening, ensure that no one is in the extended axis of the conrod
shank bolts to be tightened!

11. Hand-tighten nuts (9) using tommy bar (009.068) through cut-out in the
thrust pieces.
12. Release the pressure, uncouple the high-pressure hoses from the
hydraulic tensioners.

The hydraulic tensioners return to the zero position automatically by

means of a set of cup springs (resetting duration about 2 to 3 minutes).
However, the high-pressure pump must be connected, and its relief valve
must be open (see Work Card 009.03).

13. Detach the tensioners.

14. Place thrust pieces (030.206) and hydraulic tensioners (009.346) on
conrod shank bolts (bolts 1, 4, 5 and 8). See point 7 and 8 / see figure 2 and
4.
15. Clamp conrod shank bolts (bolts 1, 4, 5 and 8) in the same manner. See point

Work Cards, classified into sub-assemblies

9 to 11.
16. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.
17. Detach the tensioners.
18. Clamp the measuring mandrel (030.202-1) in measuring device
(030.202) and set the scale of the measuring gauge (15) to "Zero".
Remove test mandrel. See Fig. 5/I.
19. Suspend measuring device between centrings of a conrod shank bolt
(10). Read off measuring gauge (15) and note the value. See Fig. 5/II.
L48/60B;L51/60DF

20. Measure all the other conrod shank bolts (10) in the same manner and
note the values. See point 19.
2007-11-20

21. Determine the quantity difference of the individual conrod shank bolts
(10) from the measured values from Points 4/5 and 19/20.

6704 030.01-01 EN 5 (11)

030.01 MAN Diesel & Turbo

Difference values are elongation values of the individual conrod shank

Connecting rod/Big-end bearing

bolts.

22. Compare bolt elongation Δl of the individual conrod shank bolts (10) with
the required value (see Work Card 000.30).

Tension conrod shank bolts with the specified tensioning pressure, not
according to the bolt elongation Δl! The measurement of the screw
elongation Δl is only for checking!

In the event of larger deviations from the nominal value, repeat the
tensioning process, if needed, check the hydraulic tensioners, the bolt
connections and pressure gauges.

23. Remove foot board from the oil sump (13).

24. Remove handle (011.013).
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-20

6 (11) 6704 030.01-01 EN

 MAN Diesel & Turbo 030.01

1-8 Bolt number/Tightening order 10 Conrod shank bolt 12 Cylinder crankcase

Connecting rod/Big-end bearing
Work Cards, classified into sub-assemblies
9 Nut 11 Connecting rod 13 Oil sump
Figure 1: Connecting rod - Illustration shows engine with normal oil sump
L48/60B;L51/60DF
2007-11-20

6704 030.01-01 EN 7 (11)

030.01 MAN Diesel & Turbo
Connecting rod/Big-end bearing

11 Connecting rod 13 Oil sump 14 Hexagon bolt M20x40

12 Cylinder crankcase
Work Cards, classified into sub-assemblies

Figure 2: Conrod shank bolts with attached tensioners - Illustration shows tightening order 1-4-5-8
L48/60B;L51/60DF

2007-11-20

8 (11) 6704 030.01-01 EN

 MAN Diesel & Turbo 030.01

Connecting rod/Big-end bearing

11 Connecting rod 13 Oil sump 14 Hexagon bolt M20x40
12 Cylinder crankcase

Work Cards, classified into sub-assemblies

Figure 3: Conrod shank bolts with attached tensioners - Illustration shows tightening order 2-3-6-7 L48/60B;L51/60DF
2007-11-20

6704 030.01-01 EN 9 (11)

030.01 MAN Diesel & Turbo
Connecting rod/Big-end bearing

9 Nut
10 Conrod shank bolt
11 Connecting rod

Figure 4: Conrod shank bolt with attached tensioner

Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2007-11-20

10 Conrod shank bolt 15 Dial gauge

11 Connecting rod I - II Work steps
Figure 5: Measuring the bolt elongation - Illustration on the left: Setting the
measuring gauge to "Zero" / Illustration on the right: Measuring the conrod
shank bolt

10 (11) 6704 030.01-01 EN

 Connecting rod/Big-end bearing
030.01

11 (11)
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

6704 030.01-01 EN
MAN Diesel & Turbo
2007-11-20
 MAN Diesel & Turbo 030.02

Big-end bearing bolts

Connecting rod/Big-end bearing

inspection, loosening and tightening

Summary
Tension and release important threaded connections with the correct val-
ues, ensure correct execution of work.
Big-end bearing bolts should be inspected at regular intervals by means of
hydraulic tensioners.
The work/work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 055.100 Standard
1 Foot board (for oil sump) 011.007 Standard
1 Foot board (for oil sump) 011.003 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
2 Hydraulic tensioner 009.063 Standard
1 Sliding calliper 009.060 Standard
1 Thickness gauges 0.05-1 000.451 Option
1 Tommy bar, 12 000.264 Standard

Work Cards, classified into sub-assemblies

Corresponding Work Cards
Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.13

Work sequence 1 - Checking the big-end bearing bolts

Starting position Crankcase is opened, crank pin of the concerned cylinder is at BDC.
L48/60B;L51/60DF

Work steps 1. Insert foot board (011.007 for normal oil sump or 011.003 for V oil sump)
in oil sump (5).
2008-07-03

2. Clean the threads of the big-end bearing bolts (1).

3. Place thrust pieces (055.100) over nuts (2).
4. Screw hydraulic tensioner (009.063) onto big-end bearing bolts (1),
ensuring that thrust pieces are centred by the hydraulic tensioner. See
Figs. 2 and 3.

6704 030.02-01 EN 1 (8)

030.02 MAN Diesel & Turbo

5. Turn the hydraulic tensioner back by the turn back angle (see Work Card
Connecting rod/Big-end bearing

000.30).
6. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
7. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

Ensure that no one is in the extended axis of the big-end bearing bolts!

8. Pump the hydraulic tensioners until the nuts (2) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

While pumping up, watch the stroke controls (6) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (7)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 3.

9. Make a note of the release pressure and compare it to the clamping

pressure.
10. Regulate the high-pressure pump to the specified clamping pressure
(see Work Card 000.30).
11. Hand-tighten both nuts (2) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
12. Release pressure, uncouple high pressure hoses from hydraulic ten-
Work Cards, classified into sub-assemblies

sioners and high pressure pump.

The hydraulic tensioners return to the zero position automatically by

means of installed compression springs (resetting duration about 2 to 3
minutes). However, the high-pressure pump must be connected, and its
relief valve must be open (see Work Card 009.03).

13. Detach the tensioners.

14. Remove foot board from the oil sump (5).

Work sequence 2 - Releasing the big-end bearing bolts

L48/60B;L51/60DF

Starting position Crankcase is opened, crank pin of the concerned cylinder is at BDC.
2008-07-03

Work steps 1. Insert foot board (011.007 for normal oil sump or 011.003 for V oil sump)
in oil sump (5).
2. Clean the threads of the big-end bearing bolts (1).
3. Place thrust pieces (055.100) over nuts (2).

2 (8) 6704 030.02-01 EN

 MAN Diesel & Turbo 030.02

4. Screw hydraulic tensioner (009.063) onto big-end bearing bolts (1),

Connecting rod/Big-end bearing

ensuring that thrust pieces are centred by the hydraulic tensioner. See
Figs. 2 and 3.
5. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
6. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
7. Set the high-pressure pump in operation (see Work Card 009.03) and
close the gap that resulted from the turning back.

When releasing, ensure that no one is in the extended axis of the big-end
bearing bolts to be released!

8. Pump the hydraulic tensioners until the nuts (2) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

While pumping up, watch the stroke controls (6) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (7)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 3.

9. Make a note of the release pressure and compare it to the clamping

pressure.
10. Turn back both nuts (2) using tommy bar (000.264) through the cut-out
in the thrust pieces (for turn-back angle see Work Card 000.30).

Work Cards, classified into sub-assemblies

11. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

The hydraulic tensioners return to the zero position automatically by

means of installed compression springs (resetting duration about 2 to 3
minutes). However, the high-pressure pump must be connected, and its
relief valve must be open (see Work Card 009.03).

12. Detach the tensioners.

Work sequence 3 - Tightening the big-end bearing bolts

L48/60B;L51/60DF

Starting position Big-end bearing is pre-assembled, threads of the big-end bearing bolts are
cleaned. Crank pin of the concerned cylinder is at BDC. Foot board is inser-
2008-07-03

ted in the oil sump.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

6704 030.02-01 EN 3 (8)

030.02 MAN Diesel & Turbo

Work steps 1. Check that parting line between big-end bearing cap and connecting
Connecting rod/Big-end bearing

rod shank is equal on both sides.

2. Measure and note bolt length of both big-end bearing bolts (1) by sliding
calliper (009.060). See Fig. 4.

As a result of irregular circumstances, the big-end bearing bolts can be

permanently stretched! If a length of 686.90 mm (untensioned) is
exceeded, the big-end bearing bolt should be replaced!

Dimensions are needed as the basis for the bolt elongation Δl of the big-
end bearing bolts after tensioning.

It is advisable to prepare a separate measurement log for the tensioning

of the big-end bearing bolts.

3. Place thrust pieces (055.100) over nuts (2).

4. Screw hydraulic tensioner (009.063) onto big-end bearing bolts (1),
ensuring that thrust pieces are centred by the hydraulic tensioner. See
Figs. 2 and 3.
5. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
6. Set high-pressure pump in operation (see Work Card 009.03) and
tighten big-end bearing bolts (1) with a pre-tension pressure of 400 bar.

When tightening, ensure that no one is in the extended axis of the big-
end bearing bolts to be tensioned!
Work Cards, classified into sub-assemblies

While pumping up, watch the stroke controls (6) of the hydraulic
tensioners! The hydraulic tensioners must only be pumped up to the
point where the markings (M) on the stroke controls reach the upper edge
of the threaded stop ring (7)! Otherwise the hydraulic tensioners will be
damaged! See Fig. 3.

7. Hand-tighten both nuts (2) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
8. Release the pressure.
L48/60B;L51/60DF

The hydraulic tensioners return to the zero position automatically by

2008-07-03

means of installed compression springs (resetting duration about 2 to 3

minutes). However, the high-pressure pump must be connected, and its
relief valve must be open (see Work Card 009.03).

9. Reset hydraulic tensioners, so that complete tensioners lie in full contact

with connecting rod shank.

4 (8) 6704 030.02-01 EN

 MAN Diesel & Turbo 030.02

10. Set high-pressure pump in operation (see Work Card 009.03) and

Connecting rod/Big-end bearing

tighten big-end bearing bolts (1) with specified clamping pressure (see
Work Card 000.30).
11. Hand-tighten both nuts (2) through the cut-out in the thrust pieces by
using a tommy bar (000.264).
12. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.
13. Detach the tensioners.
14. Measure and note bolt length of both big-end bearing bolts (1) using
sliding calliper.
15. Determine the different measurement results of the individual big-end
bearing bolts (1) from the measured values points 2 and 14.

Different measurement results are the elongation values of the individual

big-end bearing bolts.

16. Compare bolt elongation Δl of the individual big-end bearing bolts (1)
with the required value (see Work Card 000.30).

Tension big-end bearing bolts with the specified clamping pressure, not
according to the bolt elongation Δl! The measurement of the screw
elongation Δl is only for checking!

In the event of larger deviations from the nominal value, repeat the
tensioning process, if needed, check the hydraulic tensioners, the bolted
connections and pressure gauges.

17. Remove foot board from the oil sump (5).

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2008-07-03

6704 030.02-01 EN 5 (8)

030.02 MAN Diesel & Turbo
Connecting rod/Big-end bearing

1 Big-end bearing bolt 3 Connecting rod 5 Oil sump

2 Nut 4 Cylinder crankcase
Work Cards, classified into sub-assemblies

Figure 1: Connecting rod - Illustration shows engine with normal oil sump
L48/60B;L51/60DF

2008-07-03

6 (8) 6704 030.02-01 EN

 MAN Diesel & Turbo 030.02

Connecting rod/Big-end bearing

3 Connecting rod 4 Cylinder crankcase 5 Oil sump

Work Cards, classified into sub-assemblies

Figure 2: Big-end bearing bolts with attached tensioner
L48/60B;L51/60DF
2008-07-03

1 Big-end bearing bolt 6 Stroke control

2 Nut 7 Threaded stop ring
3 Connecting rod M Marking on the stroke control
Figure 3: Big-end bearing bolts with attached tensioner

6704 030.02-01 EN 7 (8)

030.02 MAN Diesel & Turbo
Connecting rod/Big-end bearing

1 Big-end bearing bolt 3 Connecting rod

Figure 4: Measuring the big-end bearing bolts
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2008-07-03

8 (8) 6704 030.02-01 EN

 MAN Diesel & Turbo 030.03

Big-end bearing shell (bottom)

Connecting rod/Big-end bearing

inspecting

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the operational safety of the bearings.
Bearing shells must be checked at regular intervals. The wear condition and
running profile will give a clue to the load ratios, lubricating oil care etc.
The work/work steps include:
Dismantling components,
Checking bearing shell and
Assembling components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 030.512 Standard
1 Rope guide 030.512-5 Standard
1 Rope guide 030.512-11 Standard
1 Wire rope 030.512-22 Standard
1 Rope clamp 030.512-23 Standard
2 Bracket 030.195-30 Standard
1 Guide tube 021.032 Standard

Work Cards, classified into sub-assemblies

1 Ratchet hoist 002.552 Standard
2 Shackle A0.6 002.452 Standard
1 Thickness gauges 0.05-1 000.454 Standard
1 Tommy bar, 12 000.264 Standard
1 Combination spanner (set) - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.11 030.02 030.08
2009-01-14

030.09

Technical data
L48/60B

Designation Information
Big-end bearing cap 125 kg

6704 030.03-05 EN 1 (10)

030.03 MAN Diesel & Turbo

Work sequence 1 - Removal of the bottom big-end bearing shell

Connecting rod/Big-end bearing

Starting position Crankcase is opened, crank pin of the concerned cylinder is at BDC.

Work steps 1. Release big-end bearing bolts (2) (see Work Card 030.02).

2. Fasten two supports (030.195) on big-end bearing cap (7) and connect-
ing rod shank (4) by means of hexagon bolts (9 and 10). See Fig. 2.
3. Unscrew and remove the nuts (3). See Fig. 2.
4. Unscrew by hand and remove big-end bearing bolts (2). See Fig. 3.
5. Fasten the rope guide (030.512-11) between the balance weights (1).
See Fig. 4.

The pins (11) of the rope guide must be screwed in until they abut against
the balance weights.

The running gear must no longer be turned after attaching the cable
guide!

6. Fasten the rope guide (030.512-5) with hexagon bolts (12) to the balance
weights (1). See Fig. 4.

Fasten rope guide to balance weights such that rope guide is still
movable!

7. Hook in the ratchet hoist (002.552) at a suitable place.

8. Lay a wire rope (030.512-22) over the rope guides. Fasten the ends of
the rope with shackles (002.452) to the supports. See Fig. 5.
Work Cards, classified into sub-assemblies

9. Hook the wire rope into the ratchet hoist and secure it with a rope clamp
(030.512-23). Tension the wire rope. See Fig. 5.
10. Unscrew and remove the hexagon bolts (9). See Fig. 6.
11. Lower the big-end bearing cap (7) by actuating the ratchet hoist until it
reaches the oil sump (6). See Fig. 7.
12. Removing big-end bearing shell (14).
13. Clean running surfaces of the big-end bearing shell (14) carefully, with-
out damaging them.
14. Check the condition of the running surface, (see Work Card 000.11).
2009-01-14

Do not undertake any rework on the big-end bearing shell!

L48/60B

2 (10) 6704 030.03-05 EN

 MAN Diesel & Turbo 030.03

Replace damaged or heavily dirt-scored big-end bearing shell!

Connecting rod/Big-end bearing

If the big-end bearing shell has dirt scores, the crank pin should be
inspected and repolished if necessary (polishing cloth with grain size <15
μm)!

Work sequence 2 - Fitting the lower big-end bearing shell

New big-end bearing shells are delivered ready to install and must not
be reworked or otherwise machined in any way!

Starting position Crank pin of the relevant cylinder is at BDC, big-end bearing shell has been
cleaned.
Work steps 1. Carefully clean the contact area (F) on the big-end bearing cap (7) and
check for fretting (see Work Card 030.08). Rework any areas affected
by fretting (see Work Card 030.09). See Fig. 8.
2. Thoroughly oil the running surface of the big-end bearing shell (14) (the
rear side of the big-end bearing shell remains dry).
3. Insert the big-end bearing shell (14) in the big-end bearing cap (7).

Observe the correct position of the locating pin (15) for fixing the big-end
bearing shells! See Fig. 7.

4. Lift up the big-end bearing cap (7) by operating the ratchet hoist
(002.552) until contact is made on the connecting rod shank (4).

When joining together the big-end bearing cap with the connecting rod
shank, note the locating pins (8)! See Figs. 1 and 7.

5. Screw the hexagon bolts (9) into the holders (030.195) in the connecting
rod shank (4) and tighten. See Figs. 5 and 6.
Work Cards, classified into sub-assemblies
6. Remove the rope clamp (030.512-23) from the wire rope (030.512-22)
and unhook the wire rope from the ratchet hoist.
7. Detach the wire rope from the supports and remove it.
8. Remove the ratchet hoist.
9. Remove the rope guides (030.512-5 and 030.512-11). See Fig. 4.
10. Clean the big-end bearing bolts (2), install them from above through the
connecting rod shank (4), screw them into the big-end bearing cap (7)
2009-01-14

and tighten them hand-tight until the collar of the big-end bearing bolt
makes contact. See Fig. 3.
L48/60B

11. Tighten the nuts (3) hand-tight until contact is made.

12. Detach the supports (030.195).

6704 030.03-05 EN 3 (10)

030.03 MAN Diesel & Turbo

13. Tighten the big-end bearing bolts (2) (see Work Card 030.02).
Connecting rod/Big-end bearing

14. Check the bearing clearance with thickness gauges (000.454); in doing
so, insert the thickness gauge approx. 10 mm deep from the coupling
side and from the free engine end.

Observe the running-in guidelines

For information about running in new bearing shells refer to the running-
in guidelines in Volume 010.005 Engine - Operating Instructions!
Work Cards, classified into sub-assemblies

1 Balance weight 4 Connecting rod shank 7 Big-end bearing cap

2 Big-end bearing bolt 5 Cylinder crankcase 8 Locating pin
3 Nut 6 Oil sump
Figure 1: Connecting rod - Big-end bearing
2009-01-14
L48/60B

4 (10) 6704 030.03-05 EN

 MAN Diesel & Turbo 030.03

2 Big-end bearing bolt 4 Connecting rod shank 9 Hexagon bolt M16x25

Connecting rod/Big-end bearing
Work Cards, classified into sub-assemblies
3 Nut 7 Big-end bearing cap 10 Hexagon bolt M16x25
Figure 2: Big-end bearing - Installing/removing the holders / screwing the nuts off/on
2009-01-14

L48/60B

6704 030.03-05 EN 5 (10)

030.03 MAN Diesel & Turbo
Connecting rod/Big-end bearing

2 Big-end bearing bolt 4 Connecting rod shank 7 Big-end bearing cap

Work Cards, classified into sub-assemblies

Figure 3: Big-end bearing - removing/fitting the big-end bearing bolts

2009-01-14
L48/60B

6 (10) 6704 030.03-05 EN

 MAN Diesel & Turbo 030.03

Connecting rod/Big-end bearing

Work Cards, classified into sub-assemblies
2009-01-14

1 Balance weight 7 Big-end bearing cap 12 Hexagon bolt M20x30

L48/60B

4 Connecting rod shank 11 Pin

Figure 4: Big-end bearing - attaching/detaching the rope guides

6704 030.03-05 EN 7 (10)

030.03 MAN Diesel & Turbo
Connecting rod/Big-end bearing

13 Suspension point
Figure 5: Big-end bearing - attaching/detaching the wire rope
Work Cards, classified into sub-assemblies

2009-01-14
L48/60B

8 (10) 6704 030.03-05 EN

 MAN Diesel & Turbo 030.03

Connecting rod/Big-end bearing

4 Connecting rod shank 9 Hexagon bolt M16x25
Figure 6: Big-end bearing - Removing/fitting the hexagon bolts (connection between connecting rod shank
and support)

Work Cards, classified into sub-assemblies

2009-01-14

L48/60B

6704 030.03-05 EN 9 (10)

030.03 MAN Diesel & Turbo
Connecting rod/Big-end bearing

6 Oil sump 8 Locating pin 15 Locating pin

7 Big-end bearing cap 14 Big-end bearing shell
Figure 7: Big-end bearing - lowering/raising the big-end bearing cap / inspecting the big-end bearing shell
Work Cards, classified into sub-assemblies

7 Big-end bearing cap

F Contact area

Figure 8: Big-end bearing cap - contact face for big-end bearing shell
2009-01-14
L48/60B

10 (10) 6704 030.03-05 EN

 MAN Diesel & Turbo 030.04

Big-end bearing shell (top)

Connecting rod/Big-end bearing

inspecting

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the operational safety of the bearings.
Bearing shells must be checked at regular intervals. The wear condition and
running profile will give a clue to the load ratios, lubricating oil care etc.
The work/work steps include:
Check bearing shell.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Support fixture 030.504 Standard
1 Strap 030.208 Standard
2 Holder 030.192 Standard
1 Combination spanner (set) - Inventory
1 Lifting tackle - Inventory
1 Rope - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work Cards, classified into sub-assemblies

Work card Work card Work card
000.11 030.03 030.08
030.09

Work sequence 1 - Removing the upper big-end bearing shell

Starting position Big-end bearing cap is lowered. Crank pin of the concerned cylinder is at
BDC.
Work steps 1. Remove the rope clamp (030.512-23) from the wire rope (030.512-22)
and unhook the wire rope from the ratchet hoist (002.552).
2. Release wire cable from supports (030.195) and remove.
2009-01-14

3. Remove the ratchet hoist.

4. Remove the rope guides (030.512-5 and 030.512-11). See Fig. 2.
L48/60B

5. Fasten two holders (030.192) to connecting rod shank (4). See Fig. 3.

6704 030.04-05 EN 1 (13)

030.04 MAN Diesel & Turbo

Holders are used for fixing the big-end bearing shell in the connecting
Connecting rod/Big-end bearing

rod shank.

6. Lay the strap (030.208) around the crank pin (16) and fasten it to the
connecting rod shank (4). See Fig. 3.

Assembly of the strap secures the connecting rod shank against the
crank pin slipping while turning.

7. Turn the running gear until the crank pin (16) is approximately 60° before/
after TDC. See Fig. 4.
8. Mount two supporting fixtures (030.504) on cylinder liner (20), thereby
fastening a supporting fixture each on coupling side (KS) and on free
engine end (KGS). See Fig. 5.
9. Turn piston (21) carefully downwards, until it rests on support fixture.
See Fig. 6.

Turn running gear only until piston rests on the support fixture!

10. Loop cable (22) around connecting rod shank (4), suspend on lifting
tackle and fix the connecting rod shank in this position. See Fig. 7.
11. Remove strap.
12. Turn out crank pin (16) downwards from connecting rod shank (4) until
big-end bearing shell (23) is easily accessible. See Fig. 8.
13. Hold on to the big-end bearing shell (23) by hand and remove holders.
Remove the big-end bearing shell.
Work Cards, classified into sub-assemblies

14. Clean running surfaces of the big-end bearing shell (23) carefully, with-
out damaging them.
15. Check the condition of the running surface, (see Work Card 000.11).

Do not undertake any rework on the big-end bearing shell!

Replace damaged or heavily dirt-scored big-end bearing shell!

If the big-end bearing shell has dirt scores, the crank pin should be
inspected and repolished if necessary (polishing cloth with grain size <15
2009-01-14

μm)!
L48/60B

2 (13) 6704 030.04-05 EN

 MAN Diesel & Turbo 030.04

Work sequence 2 - Installing the upper big-end bearing shell

Connecting rod/Big-end bearing

New big-end bearing shells are delivered ready to install and must not
be reworked or otherwise machined in any way!

Starting position Crank pin is turned out from connecting rod shank, connecting rod bearing
shell is cleaned.
Work steps 1. Carefully clean the contact face (F) on the connecting rod shank (4) and
check for fretting (see Work Card 030.08). Rework any areas affected
by fretting (see Work Card 030.09). See Fig. 9.
2. Thoroughly oil the running surface of the big-end bearing shell (23) (the
rear side of the big-end bearing shell remains dry).
3. Insert the big-end bearing shell (23) in the connecting rod shank (4),
attach the two holders (030.192) to the connecting rod shank. See Fig.
8.

Holders are used for fixing the big-end bearing shell in the connecting
rod shank.

Observe the correct position of the locating pin (24) for fixing the big-end
bearing shells! See Fig. 8.

4. Carefully turn the running gear until the crank pin (16) abuts against the
connecting rod shank/big-end bearing shell (4/23).
5. Lay the strap (030.208) around the crank pin (16) and fasten it to the
connecting rod shank (4). See Figs. 2 and 7.

Work Cards, classified into sub-assemblies

Assembly of the strap secures the connecting rod shank against the
crank pin slipping while turning.

6. Remove the rope (22).

7. Turn the running gear until the crank pin (16) is approximately 60° before/
after TDC. See Fig. 5.
8. Detach the support devices (030.504).
9. Turn the running gear until the crank pin (16) is at BDC. See Fig. 3.
10. Detach the strap (030.208) and the holders (030.192).
2009-01-14

11. Fasten the rope guide (030.512-11) between the balance weights (1).
See Fig. 2.
L48/60B

6704 030.04-05 EN 3 (13)

030.04 MAN Diesel & Turbo

The pins (11) of the rope guide must be screwed in until they abut against
Connecting rod/Big-end bearing

the balance weights.

The running gear must no longer be turned after attaching the cable
guide!

12. Fasten the rope guide (030.512-5) with hexagon bolts (12) to the balance
weights (1). See Fig. 2.

Fasten rope guide to balance weights such that rope guide is still
movable!

13. Hook in the ratchet hoist (002.552) at a suitable place.

14. Lay a wire rope (030.512-22) over the rope guides. Fasten the ends of
the rope with shackles (002.452) to the supports (030.195). See Fig. 1.
15. Hook the wire rope into the ratchet hoist and secure it with a rope clamp
(030.512-23). Tension the wire rope. See Fig. 1.

Observe the running-in guidelines

For information about running in new bearing shells refer to the running-
in guidelines in Volume 010.005 Engine - Operating Instructions!
Work Cards, classified into sub-assemblies

2009-01-14
L48/60B

4 (13) 6704 030.04-05 EN

 MAN Diesel & Turbo 030.04

Connecting rod/Big-end bearing

1 Balance weight 6 Oil sump 13 Suspension point
4 Connecting rod shank 7 Big-end bearing cap 16 Crankshaft/crank pin
Figure 1: Big-end bearing - offset big-end bearing cap

Work Cards, classified into sub-assemblies

2009-01-14

L48/60B

6704 030.04-05 EN 5 (13)

030.04 MAN Diesel & Turbo
Connecting rod/Big-end bearing
Work Cards, classified into sub-assemblies

2009-01-14

1 Balance weight 11 Pin 16 Crankshaft/crank pin

L48/60B

4 Connecting rod shank 12 Hexagon bolt M20x30

Figure 2: Big-end bearing - detaching/attaching the rope guides

6 (13) 6704 030.04-05 EN

 MAN Diesel & Turbo 030.04

Connecting rod/Big-end bearing

Work Cards, classified into sub-assemblies

4 Connecting rod shank 16 Crankshaft/crank pin 17 Hexagon bolt M16x25

18 Hexagon bolt M10x20
Figure 3: Big-end bearing - attaching/detaching the holders and the strap
2009-01-14

L48/60B

6704 030.04-05 EN 7 (13)

030.04 MAN Diesel & Turbo
Connecting rod/Big-end bearing

16 Crankshaft/crank pin
Figure 4: Big-end bearing - Crank pin approx. 60° before/after TDC
Work Cards, classified into sub-assemblies

2009-01-14
L48/60B

8 (13) 6704 030.04-05 EN

 MAN Diesel & Turbo 030.04

Connecting rod/Big-end bearing

4 Connecting rod shank 20 Cylinder liner KS Coupling side
19 Hexagon bolt M16x55 KGS Free engine end
Figure 5: Big-end bearing - attaching/detaching the support devices

Work Cards, classified into sub-assemblies

2009-01-14

L48/60B

6704 030.04-05 EN 9 (13)

030.04 MAN Diesel & Turbo
Connecting rod/Big-end bearing

4 Connecting rod shank 20 Cylinder liner 21 Piston

16 Crankshaft/crank pin
Figure 6: Big-end bearing - lowering the piston onto the support devices
Work Cards, classified into sub-assemblies

2009-01-14
L48/60B

10 (13) 6704 030.04-05 EN

 MAN Diesel & Turbo 030.04

Connecting rod/Big-end bearing

4 Connecting rod shank 16 Crankshaft/crank pin 22 Rope
Figure 7: Big-end bearing - Fixing the connecting rod shank

Work Cards, classified into sub-assemblies

2009-01-14

L48/60B

6704 030.04-05 EN 11 (13)

030.04 MAN Diesel & Turbo
Connecting rod/Big-end bearing

4 Connecting rod shank 22 Rope 24 Locating pin

16 Crankshaft/crank pin 23 Big-end bearing shell
Figure 8: Big-end bearing - turning back the crank pin/inspecting the big-end bearing shell
Work Cards, classified into sub-assemblies

2009-01-14
L48/60B

12 (13) 6704 030.04-05 EN

 MAN Diesel & Turbo 030.04

Connecting rod/Big-end bearing

4 Connecting rod shank
F Contact area

Figure 9: Connecting rod shank - Contact surface for big-end bearing shell

Work Cards, classified into sub-assemblies

2009-01-14

L48/60B

6704 030.04-05 EN 13 (13)

 MAN Diesel & Turbo 030.05

Connecting rod shank

Connecting rod/Big-end bearing

removal and installation

Summary
Ensure correct execution of work, enable emergency operation, rework
crank pin in case of slight damage.
The connecting rod shank is not to be disassembled for usual maintenance
work. This is necessary only in exceptional cases (e.g. for emergency oper-
ation).
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 030.512 Standard
1 Rope guide 030.512-5 Standard
1 Rope guide 030.512-11 Standard
1 Wire rope 030.512-22 Standard
1 Rope clamp 030.512-23 Standard
1 Suspension device 030.508 Standard
1 Carrier 030.507 Standard

Work Cards, classified into sub-assemblies

1 Carrier 030.506 Standard
1 Removal and fitting fixture 030.505 Standard
1 Washer 030.505-8 Standard
1 Strap 030.208 Standard
1 Locating clamp 030.207 Standard
1 Bracket 030.207-1 Standard
1 Thrust piece 030.207-3 Standard
2 Bracket 030.195-30 Standard
2 Holder 030.192 Standard
1 Guide tube 021.032 Standard
2009-02-11

1 Ratchet hoist 002.552 Standard

1 Shackle A1.0 002.453 Standard
L48/60B

2 Shackle A0.6 002.452 Standard

1 Thickness gauges 0.05-1 000.454 Standard
1 Tommy bar, 12 000.264 Standard

6704 030.05-05 EN 1 (23)

030.05 MAN Diesel & Turbo

Quantity Designation Number Status

Connecting rod/Big-end bearing

1 Lifting tackle - Inventory

1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Rope - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
030.02 034.01 050.01

Technical data
Designation Information
Connecting rod shank 300 kg
Big-end bearing cap 125 kg

Work sequence 1 - Removing the connecting rod shank

Preliminary remark Figures and text apply to the disassembly of the connecting rod shank on
exhaust side. The disassembly is also possible on the control side.
Starting position Crankcase is open. Cylinder head removed. Running gear is turned such
that piston is about 60° before/after TDC.
Work steps 1. Removing top land ring (see Work Card 050.01).

2. Removing piston (see Work Card 034.01).

3. Turn running gear, until crank pin is at BDC.
4. Release big-end bearing bolts (2) (see Work Card 030.02).
5. Fasten two supports (030.195) on big-end bearing cap (7) and connect-
ing rod shank (4) by means of hexagon bolts (9 and 10). See Fig. 2.
Work Cards, classified into sub-assemblies

6. Unscrew and remove the nuts (3). See Fig. 2.

7. Unscrew by hand and remove big-end bearing bolts (2). See Fig. 3.
8. Fasten the rope guide (030.512-11) between the balance weights (1).
See Fig. 4.

The pins (11) of the rope guide must be screwed in until they abut against
the balance weights.

The running gear must no longer be turned after attaching the cable
2009-02-11

guide!
L48/60B

9. Fasten the rope guide (030.512-5) with hexagon bolts (12) to the balance
weights (1). See Fig. 4.

2 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Fasten rope guide to balance weights such that rope guide is still

Connecting rod/Big-end bearing

movable!

10. Hook in the ratchet hoist (002.552) at a suitable place.

11. Lay a wire rope (030.512-22) over the rope guides. Fasten the ends of
the rope with shackles (002.452) to the supports. See Fig. 5.
12. Hook the wire rope into the ratchet hoist and secure it with a rope clamp
(030.512-23). Tension the wire rope. See Fig. 5.
13. Unscrew and remove the hexagon bolts (9). See Fig. 6.
14. Lower the big-end bearing cap (7) by actuating the ratchet hoist until it
reaches the oil sump (6). See Fig. 7.
15. Remove the rope clamp from the wire rope and unhook the wire rope
from the ratchet hoist.
16. Detach the wire rope from the supports and remove it.
17. Remove the ratchet hoist.
18. Detach the rope guides. See Fig. 8.
19. Fasten two holders (030.192) to connecting rod shank (4). See Fig. 9.

Holders are used for fixing the big-end bearing shell in the connecting
rod shank.

20. Insert carrier (030.507) into the connecting rod shank (4) on the control
side, mount washer (030.505-8) and washer (17) on carrier then screw
on and tighten hexagon nut (16). See Fig. 9.
21. Lay the strap (030.208) around the crank pin (14) and fasten it to the
connecting rod shank (4). See Fig. 9.

Work Cards, classified into sub-assemblies

Assembly of the strap secures the connecting rod shank against the
crank pin slipping while turning.

22. Turn the running gear until the connecting rod shank is 10° from the
horizontal. See Fig. 10.
23. Introduce carrier (030.506) into the crankcase from the exhaust-gas
side, making sure that the rollers (22) of the carrier (030.507) are resting
on the bottom flange of the carrier. See Fig. 11.
24. Fit carrier (030.506) on crank pin (14) and fasten to cylinder crankcase
(5) with hexagon bolt (19). It may be necessary to slightly turn the running
2009-02-11

gear carefully. See Fig. 11.

25. Check that the rollers (22) of the carrier (030.507) are resting on the bot-
L48/60B

tom flange of the carrier (030.506), slightly turn running gear carefully if
necessary.
26. Fix carrier (030.506) to balance weights (1) with two hexagon bolts (20).

6704 030.05-05 EN 3 (23)

030.05 MAN Diesel & Turbo

27. Attach guide piece (24) of suspension device (030.508) to carrier

Connecting rod/Big-end bearing

(030.506), insert suspension device into connecting rod shank (4), screw
on and tighten hexagon nuts (25). See Fig. 12.
28. Remove locating clamp (030.207) and fitting strap (030.208). See Fig.
17.
29. Fasten the rope (23) with shackle (002.453) to the suspension device.
Attach rope to lifting tackle. See Fig. 12.
30. Pull connecting rod shank (4) out towards the exhaust-gas side until it
reaches the stop of the guide piece (24) at the end of the carrier. See
Fig. 13.
31. Detach the guide piece (24) from the carrier (030.506), then pull con-
necting rod shank (4) out parallel to the carrier until the carrier (030.507)
makes contact with the end of this carrier. See Fig. 14.
32. Screw two hexagon bolts (27) into the carrier (030.506). See Fig. 15.

If the two hexagon bolts are not screwed in, the connecting rod shank
cannot be swivelled for the remaining disassembly!

33. Pull connecting rod shank (4) upwards, detach carrier (030.507) from
carrier (030.506). See Fig. 16.
34. Detach the carrier (030.507).
35. Set the connecting rod shank (4) down carefully on a wooden support,
taking holders (030.192) into account.
36. Remove/detach tools (030.506 and 030.508).

Work sequence 2 - Installing the connecting rod shank

Preliminary remark Figures and text apply to the installation of the connecting rod shank on
exhaust side. The installation is also possible on the control side.
Work Cards, classified into sub-assemblies

Starting position Turn running gear such that crank pin / balance weight is 10° to the hori-
zontal. Big-end bearing shell is inserted in connecting rod shank and
secured by two holders (030.192).
Work steps 1. Guide carrier (030.506) into the crankcase from the exhaust-gas side
and fasten with hexagon bolt (19) to cylinder crankcase (5). See Fig. 11.
2. Check that the carrier (030.506) is resting on the crank pin (14), slightly
turn the running gear carefully if necessary. See Fig. 11.
3. Fix carrier (030.506) to balance weights (1) with two hexagon bolts (20).
See Fig. 11.
4. Screw two hexagon bolts (27) into the carrier (030.506). See Fig. 15.

If the two hexagon bolts are not screwed in, the connecting rod shank
2009-02-11

installation cannot be swivelled for the installation and impacts on the

cylinder crankcase!
L48/60B

5. Insert suspension device (030.508) into the connecting rod shank (4),
screw on and tighten hexagon nuts (25). See Fig. 12.

4 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Ensure correct installation position of the suspension device, guide piece

Connecting rod/Big-end bearing

(24) must be on the control side of the connecting rod shank (see
identification on connecting rod shank)!

6. Fasten the rope (23) with shackle (002.453) to the suspension device.
Attach rope to lifting tackle.
7. Lift the connecting rod shank (4).
8. Insert carrier (030.507) into the connecting rod shank (4) on the control
side, mount washer (030.505-8) and washer (17) on carrier then screw
on and tighten hexagon nut (16). See Fig. 9.

Ensure correct installation position of the beam, it must be installed on

the control side of the connecting rod shank (see identification on
connecting rod shank)!

9. Thoroughly oil the running surface of the big-end bearing shell.

10. Drive connecting rod shank (4) over carrier (030.506), lower and suspend
carrier (030.507) in carrier. See Fig. 15.
11. Lower connecting rod shank (4) further, until it is parallel to the carrier
(030.506). See Fig. 14.
12. Unscrew two hexagon bolts (27) and let connecting rod shank (4) slide
slowly and carefully onto carrier (030.506) in crankcase, until the guide
piece (24) is at the end of carrier.
13. Suspend guide pieces (24) in carrier (030.506). See Fig. 13.
14. Let connecting rod shank (4) slide on slowly on carrier (030.506) in
crankcase, until connecting rod shank /big-end bearing shell rests
against crank pin (14). See Fig. 12.
15. Lay the strap (030.208) around the crank pin (14) and fasten it to the
connecting rod shank (4). See Fig. 12.

Work Cards, classified into sub-assemblies

16. Fit bracket (030.207-1) around connecting rod shank (4) and fasten to
balance weight (1) with two hexagon bolts (26). See Figs. 12 and 13.
17. Screw two hexagon bolts (28) into the bracket until they make contact
with the connecting rod shank (4).
18. Fit thrust piece (030.207-3) on bracket, turn hexagon bolt (29) until it
makes contact with the balance weight (1) and thrust piece on the con-
necting rod shank (4). See Fig. 13.
19. Remove rope (23) from suspension fixture.
20. Detach suspension device (030.508) from connecting rod shank (4).
21. Remove carrier (030.506) carefully from crankcase.
2009-02-11

22. Turn the running gear until the crank pin (14) is at BDC. See Fig. 9.
23. Detach the strap (030.208) and the holders (030.192).
L48/60B

24. Fasten the rope guide (030.512-11) between the balance weights (1).
See Figs. 2 and 8.

6704 030.05-05 EN 5 (23)

030.05 MAN Diesel & Turbo

The pins (11) of the rope guide must be screwed in until they abut against
Connecting rod/Big-end bearing

the balance weights.

The running gear must no longer be turned after attaching the cable
guide!

25. Fasten the rope guide (030.512-5) with hexagon bolts (12) to the balance
weights (1). See Figs. 2 and 8.

Fasten rope guide to balance weights such that rope guide is still
movable!

26. Hook in the ratchet hoist (002.552) at a suitable place.

27. Lay a wire rope (030.512-22) over the rope guides. Fasten the ends of
the rope with shackles (002.452) to the supports (030.195). See Fig. 7.
28. Hook the wire rope into the ratchet hoist and secure it with a rope clamp
(030.512-23). Tension the wire rope.
29. Thoroughly oil the running surface of the big-end bearing shell.
30. Lift up the big-end bearing cap (7) by operating the ratchet hoist
(002.552) until contact is made on the connecting rod shank (4).

When joining together the big-end bearing cap with the connecting rod
shank, note the locating pins (8)! See Figs. 1 and 7.

31. Screw the hexagon bolts (9) into the holders (030.195) in the connecting
Work Cards, classified into sub-assemblies

rod shank (4) and tighten. See Figs. 5 and 6.

32. Remove the rope clamp (030.512-23) from the wire rope (030.512-22)
and unhook the wire rope from the ratchet hoist.
33. Detach the wire rope from the supports and remove it.
34. Remove the ratchet hoist.
35. Detach rope routings (030.512-5 and 030.512-11). See Fig. 4.
36. Install big-end bearing bolts (2) from above, through the connecting rod
shank (4), screw into big-end bearing cap (7) and tighten them hand-
tight until the collar of the big-end bearing bolt come into contact. See
Fig. 3.
37. Tighten the nuts (3) hand-tight until contact is made. See Fig. 2.
2009-02-11

38. Detach the supports (030.195).

L48/60B

39. Tighten the big-end bearing bolts (2) (see Work Card 030.02).

6 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

40. Check the bearing clearance with thickness gauges (000.454); in doing

Connecting rod/Big-end bearing

so, insert the thickness gauge approx. 10 mm deep from the coupling
side and from the free engine end.
41. Install the piston (see Work Card 034.01).
42. Install the top land ring (see Work Card 050.01).

Work Cards, classified into sub-assemblies

1 Balance weight 4 Connecting rod shank 7 Big-end bearing cap
2 Big-end bearing bolt 5 Cylinder crankcase 8 Locating pin
3 Nut 6 Oil sump
Figure 1: Connecting rod shank - Big-end bearing
2009-02-11

L48/60B

6704 030.05-05 EN 7 (23)

030.05 MAN Diesel & Turbo
Connecting rod/Big-end bearing
Work Cards, classified into sub-assemblies

2 Big-end bearing bolt 4 Connecting rod shank 9 Hexagon bolt M16x25

3 Nut 7 Big-end bearing cap 10 Hexagon bolt M16x25
Figure 2: Big-end bearing - attaching/detaching the retaining brackets / screwing the nuts off/on
2009-02-11
L48/60B

8 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Connecting rod/Big-end bearing

2 Big-end bearing bolt 4 Connecting rod shank 7 Big-end bearing cap

Work Cards, classified into sub-assemblies

Figure 3: Big-end bearing - removing/fitting the big-end bearing bolts
2009-02-11

L48/60B

6704 030.05-05 EN 9 (23)

030.05 MAN Diesel & Turbo
Connecting rod/Big-end bearing
Work Cards, classified into sub-assemblies

2009-02-11

1 Balance weight 7 Big-end bearing cap 12 Hexagon bolt M20x30

L48/60B

4 Connecting rod shank 11 Pin

Figure 4: Big-end bearing - attaching/detaching the rope guides

10 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Connecting rod/Big-end bearing

13 Suspension point
Figure 5: Big-end bearing - attaching/detaching the wire rope

Work Cards, classified into sub-assemblies

2009-02-11

L48/60B

6704 030.05-05 EN 11 (23)

030.05 MAN Diesel & Turbo
Connecting rod/Big-end bearing

4 Connecting rod shank 9 Hexagon bolt M16x25

Figure 6: Big-end bearing - Removing/fitting the hexagon bolts (connection between connecting rod shank
and support)
Work Cards, classified into sub-assemblies

2009-02-11
L48/60B

12 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Connecting rod/Big-end bearing

6 Oil sump 7 Big-end bearing cap 8 Locating pin
Figure 7: Big-end bearing - lowering/lifting the big-end bearing cap

Work Cards, classified into sub-assemblies

2009-02-11

L48/60B

6704 030.05-05 EN 13 (23)

030.05 MAN Diesel & Turbo
Connecting rod/Big-end bearing

1 Balance weight 11 Pin 14 Crankshaft/crank pin

4 Connecting rod shank 12 Hexagon bolt M20x30
Work Cards, classified into sub-assemblies

Figure 8: Connecting rod shank - detaching/attaching the rope guides

2009-02-11
L48/60B

14 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Connecting rod/Big-end bearing

Work Cards, classified into sub-assemblies

4 Connecting rod shank 15 Hexagon bolt M16x25 17 Washer

14 Crankshaft/crank pin 16 Hexagon nut M16 18 Hexagon bolt M10x20
Figure 9: Connecting rod shank - attaching/detaching the holders, carrier and strap
2009-02-11

L48/60B

6704 030.05-05 EN 15 (23)

030.05 MAN Diesel & Turbo
Connecting rod/Big-end bearing

14 Crankshaft/crank pin
Work Cards, classified into sub-assemblies

Figure 10: Connecting rod shank - crank pin turned 10° from horizontal

2009-02-11
L48/60B

16 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Connecting rod/Big-end bearing

Work Cards, classified into sub-assemblies
2009-02-11

1 Balance weight 14 Crankshaft/crank pin 21 Support

L48/60B

4 Connecting rod shank 19 Hexagon bolt M20x40 22 Roller

5 Cylinder crankcase 20 Hexagon bolt M20x40
Figure 11: Connecting rod shank - installation/removal of carrier

6704 030.05-05 EN 17 (23)

030.05 MAN Diesel & Turbo
Connecting rod/Big-end bearing
Work Cards, classified into sub-assemblies

1 Balance weight 15 Hexagon bolt M16x25 25 Hexagon nut M30

4 Connecting rod shank 23 Rope 26 Hexagon bolt M20x30
14 Crankshaft/crank pin 24 Guide piece
2009-02-11

Figure 12: Connecting rod shank - attaching/detaching the suspension device

L48/60B

18 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Connecting rod/Big-end bearing

4 Connecting rod shank 24 Guide piece

Work Cards, classified into sub-assemblies

Figure 13: Connecting rod shank - removal/installation
2009-02-11

L48/60B

6704 030.05-05 EN 19 (23)

030.05 MAN Diesel & Turbo
Connecting rod/Big-end bearing

4 Connecting rod shank

Figure 14: Connecting rod shank - removal/installation
Work Cards, classified into sub-assemblies

2009-02-11
L48/60B

20 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Connecting rod/Big-end bearing

Work Cards, classified into sub-assemblies

4 Connecting rod shank 27 Hexagon bolt M16x40

Figure 15: Connecting rod shank - screwing the hexagon bolts on or off / swivelling the connecting rod shank
2009-02-11

L48/60B

6704 030.05-05 EN 21 (23)

030.05 MAN Diesel & Turbo
Connecting rod/Big-end bearing
Work Cards, classified into sub-assemblies

1 Balance weight 5 Cylinder crankcase 14 Crankshaft/crank pin

4 Connecting rod shank
Figure 16: Connecting rod shank - removal/installation
2009-02-11
L48/60B

22 (23) 6704 030.05-05 EN

 MAN Diesel & Turbo 030.05

Connecting rod/Big-end bearing

1 Balance weight 28 Hexagon bolt M12x45
4 Connecting rod shank 29 Hexagon bolt M12x45

Work Cards, classified into sub-assemblies

26 Hexagon bolt M20x30
Figure 17: Connecting rod shank - assembly of locating clamp
2009-02-11

L48/60B

6704 030.05-05 EN 23 (23)

 MAN Diesel & Turbo 030.08

Big-end bearing cap/connecting rod shank

Connecting rod/Big-end bearing

Clean and check contact surfaces of the big-end bearing shells

Summary
Ensure/ restore operational safety, ensure correct execution of work.
The contact surfaces of the big-end bearing shells shall be cleaned and
checked during every inspection of the big-end bearing shells.
The work sequence includes:
cleaning and checking components.
Safety requirements
- Driving shaft secured against turning
- Components secured against moving
- Engine secured against starting
Tools/aids required
Quantity Designation Number Status
1 Safety goggles - Inventory
1 Protective gloves - Inventory
1 Fibre mat with resin-bonded abrasive - Inventory
1 Diesel oil, clean - Inventory
1 Rust inhibitor - Inventory
1 Solvent cleaner - Inventory

Corresponding Work Cards

Work card Work card Work card
030.03 030.04 030.09

Work Cards, classified into sub-assemblies

Work sequence - Cleaning and checking the contact surface
Starting position Big-end bearing cap is lowered, connecting rod shank is secured, big-end
bearing shells are removed (see Work Card 030.03 and 030.04).
48/60;48/60B;48/60CR;51/60DF

Protection during cleaning work!

Wear safety goggles and protective gloves for cleaning work!
Follow instructions issued by the manufacturing companies!

Work steps 1. Cover crankcase using suitable equipment, especially at the sides, to
prevent the ingress of dirt.
2009-04-28

2. Apply slushing oil or clean diesel oil onto contact surface (F) on big-end
bearing cap (2) or connecting rod shank (1). Clean contact surface using
fibre mat (3) until it is absolutely dirt-free. To facilitate cleaning, wrap
fibre mat around a type of support (4). See figures 1 to 3.

6704 030.08-01 EN 1 (4)

030.08 MAN Diesel & Turbo

3. Check contact surface (F) on big-end bearing cap (2) or connecting rod
Connecting rod/Big-end bearing

shank (1) completely and thoroughly for fretting (G). Fretting can easily
be identified by running one's finger nail over suspicious surfaces.
Rough or uneven surfaces indicate fretting. For examples, see figures 4
and 5.

Fretting areas
If there is no fretting (G) on the cleaned contact surface (F), the big-end
bearing cap (2) or the connecting rod shank (1) can continue to be used.
If there are fretting areas, these must be reworked (see Work Card
030.09).

4. Clean contact surface (F) on the big-end bearing cap (2) or connecting
rod shank (1) with a solvent cleaner, the contact surface must be abso-
lutely free of dirt and oil residues.
5. Remove the cover from the crankcase.

Tool name Manufacturer (example).

Fibre mat with resin-bonded abrasive Scotch-BriteTM WR-RL, Type A medium
Rust inhibitor ANTICORIT 1
Solvent cleaner ARDROX 9PR88
Table 1: Required tools/manufacturers
Work Cards, classified into sub-assemblies

1 Connecting rod shank

2 Big-end bearing cap
F Contact area
48/60;48/60B;48/60CR;51/60DF

2009-04-28

Figure 1: Connecting rod shank and big-end bearing cap (illustration shows
48/60 B)

2 (4) 6704 030.08-01 EN

 MAN Diesel & Turbo 030.08

Connecting rod/Big-end bearing

2 Big-end bearing cap 4 Support (e.g. aluminium profile)
3 Fibre mat F Contact area
Figure 2: Big-end bearing cap - cleaning with fibre mat

Work Cards, classified into sub-assemblies

48/60;48/60B;48/60CR;51/60DF

Figure 3: Big-end bearing cap - illustration above: before cleaning / illustration

below: after cleaning
2009-04-28

6704 030.08-01 EN 3 (4)

030.08 MAN Diesel & Turbo
Connecting rod/Big-end bearing

G Fretting
Figure 4: Big-end bearing cap - fretting *
Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

G Fretting
Figure 5: Big-end bearing cap - fretting *
2009-04-28

* not all fretting areas are marked in the illustrations

4 (4) 6704 030.08-01 EN

 MAN Diesel & Turbo 030.09

Big-end bearing cap/connecting rod shank

Connecting rod/Big-end bearing

Rework contact surface for big-end bearing shells

Summary
Ensure / restore operational safety, ensure correct execution of work.
If fretting areas are identified during cleaning and inspection of the contact
surface for the big-end bearing shells, the contact surface must be
reworked.
The work sequence includes:
reworking the components.
Safety requirements
- Driving shaft secured against turning
- Components secured against moving
- Engine secured against starting
Tools/aids required
Quantity Designation Number Status
1 Hand grinder - Inventory
1 Oil stone - Inventory
1 Abrasive cap - Inventory
1 Abrasive cap holder - Inventory
1 Safety goggles - Inventory
1 Protective gloves - Inventory
1 Universal abrasive cleaner - Inventory
1 Solvent cleaner - Inventory

Corresponding Work Cards

Work Cards, classified into sub-assemblies

Work card Work card Work card
000.34 030.08

Work sequence - Reworking contact surfaces

48/60;48/60B;48/60CR;51/60DF

Starting position Contact surfaces for big-end bearing shells are cleaned and checked (see
Work Card 030.08).

Protection during cleaning work!

Wear safety goggles and protective gloves for cleaning work!
Follow instructions issued by the manufacturing companies!
2009-04-28

Work steps 1. Smooth all fretting areas (even the smallest ones) using the universal abrasive
cleaner. Areas which can not be smoothed with the universal abrasive
cleaner must be treated with the oil stone.

6704 030.09-01 EN 1 (3)

030.09 MAN Diesel & Turbo

2. With all smoothed/machined areas (even the smallest ones), carry out a
Connecting rod/Big-end bearing

crack test (magnetic particle inspection method) to detect potential

cracks (see Work Card 000.34).
Should no cracks be detected, continue with point 5.

Cracks in the contact face at the connecting rod shank

During the crack test, no cracks may be identified in the marked area (±
35° to the central axis) of the connecting rod shank! See figure 2.
If cracks are detected in this area, the connecting rod may no longer be
used and must be replaced!

3. Grind out all cracks identified during the crack test with a hand grinder
with abrasive cap holder and mounted abrasive cap, maximum machin-
ing depth 1 mm. Deburr sharp edges on the ground-out areas.
4. Continue crack test (magnetic particle inspection method) in the
ground-out areas (see Work Card 000.34).

Cracks in the ground-out areas

If during the crack test in the ground-out areas, cracks are still detected,
the connecting rod must be replaced.
If cracks are no longer present, the connecting rod can continue to be
used.

5. Clean contact surface (F) on the big-end bearing cap (2) or connecting
rod shank (1) with a solvent cleaner, the contact surfaces must be abso-
lutely free of grinding and oil residues.
6. Remove the cover from the crankcase.

Tool name Manufacturer (example).

Solvent cleaner ARDROX 9PR88
Universal abrasive cleaner HOLEX 55 7660, fine
Table 1: Required tools/manufacturers
Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

2009-04-28

2 (3) 6704 030.09-01 EN

 MAN Diesel & Turbo 030.09

Connecting rod/Big-end bearing

1 Connecting rod shank
2 Big-end bearing cap
F Contact area

Figure 1: Connecting rod shank and big-end bearing cap (illustration shows
48/60 B)

Work Cards, classified into sub-assemblies

1 Connecting rod shank
F Contact area
48/60;48/60B;48/60CR;51/60DF

Figure 2: Connecting rod shank - area in which no cracks are permissible

2009-04-28

6704 030.09-01 EN 3 (3)

MAN Diesel & Turbo 034

Piston/Piston rings
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.8-1 EN 1 (2)

 MAN Diesel & Turbo
Piston/Piston rings

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.8-1 EN

 MAN Diesel & Turbo 034.01

Piston

Piston/Piston rings
removal and installation

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for quality/wear condition.
Pistons are to be removed in the course of service and maintenance activ-
ities.
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Tap wrench 034.098 Standard
1 Tapered sleeve for inserting the piston rings 034.094 Standard
1 Suspension device 034.092 Standard
1 Carrier 034.092-1 Standard
1 Tap 034.080 Standard
1 Pilot rod 034.006 Standard
2 Guide tube 030.210 Standard
1 Locating clamp 030.207 Standard

Work Cards, classified into sub-assemblies

1 Bracket 030.207-1 Standard
1 Thrust piece 030.207-3 Standard
1 Hand rail 011.013 Standard
1 Foot board (for oil sump) 011.012 Standard
1 Foot board (for oil sump) 011.011 Standard
1 Tommy bar, 6 009.068 Standard
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
1 Shackle A1.0 002.453 Standard
1 Extension piece 12.5x250 001.912 Standard
2009-02-11

1 Socket spanner insert 24x12.5 001.757 Standard

1 Thickness gauges 0.05-1 000.451 Option
L48/60B

1 Combination spanner (set) - Inventory

1 Lifting tackle - Inventory
1 Rope - Inventory

6704 034.01-02 EN 1 (15)

034.01 MAN Diesel & Turbo

Quantity Designation Number Status

Piston/Piston rings

1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
030.01 034.02 050.01

Technical data
Designation Information
Piston with con rod small end 597,5 kg

Work sequence 1 - Removing the piston

The top land ring must be removed before removing the piston, as its
diameter is smaller than that of the piston (see Work Card 050.01)!

Starting position Top land ring removed.

Work steps 1. Turn the running gear until the piston (6) is at TDC.

2. Clean the threaded bores on the upper side of the piston with tap
(034.080).
3. Place carrier (034.092-1) on piston (6). Screw two hexagon bolts (19)
into piston and tighten with a torque of 60 Nm. Fasten carrier with hexagon
nut (20). See Fig. 2.
4. Attach the rope (18) with the shackle (002.453) on the support.

Ensure correct suspension point for in-line engine! See Fig. 2.

Work Cards, classified into sub-assemblies

5. Turn the running gear until the piston (6) is exactly at BDC.
6. Attach rope (18) to lifting tackle.
7. Fasten handle (011.013) to cylinder crankcase (16).
8. Insert foot board (011.012 for normal oil sump or 011.011 for V oil sump)
in oil sump (15).
9. Loosen the conrod shank bolts (10) (see Work Card 030.01).
10. Fit bracket (030.207-1) around connecting rod shank (11) and fasten to
balance weight (14) with two hexagon bolts (23). See Figs. 3 and 4.
11. Screw two hexagon bolts (22) into the holder until they make contact
2009-02-11

with the connecting rod shank (11).

12. Fit thrust piece (030.207-3) on bracket, turn hexagon bolt (24) until it
L48/60B

makes contact with the balance weight (14) and thrust piece on the
connecting rod shank (11). See Fig. 4.

2 (15) 6704 034.01-02 EN

 MAN Diesel & Turbo 034.01

13. Unscrew and remove the nuts (12) from the conrod shank bolts (10).

Piston/Piston rings
14. Pull piston (6) upwards over cylinder liner (9) until the pilot rod (034.006)
can be screwed into carrier. See Fig. 5.
15. Carefully pull the piston (6) out of the cylinder liner (9), guiding it with the
pilot rod. See Fig. 6.

Do not damage cylinder head bolts (5) and conrod shank bolts (10) during
disassembly of the piston!

16. Set the piston (6) down on a clean support without damaging the conrod
shank bolts (10).
17. Detach the tool from the piston (6).
18. Seal the lubricating oil bore in the connecting rod shank (11) to prevent
the ingress of dirt.
19. Cover the opening which is now present in the cylinder liner (9) using
suitable equipment.
20. Clean and check the piston (6) (see Work Card 034.02).
21. Clean the connecting rod small end (7).

Work sequence 2 - Installing the piston

Starting position Piston is cleaned, checked, possibly overhauled and assembled with big-
end bearing head, cylinder liner and joint faces on big-end bearing head and
connecting rod shank are cleaned, connecting rod is fixed to balance weight
with a locating clamp. Handle fitted to cylinder crankcase casing, foot board
is fitted in oil sump.
Work steps 1. Remove the cover for the cylinder liner bore.

2. Fit guide bush (034.094) on cylinder liner (9) and oil liberally.
3. Place carrier (034.092-1) on piston (6). Screw two hexagon bolts (19)

Work Cards, classified into sub-assemblies

into piston and tighten with a torque of 60 Nm. Fasten carrier with hexagon
nut (20).
4. Fasten cable (18) with shackle (002.453) on carrier and suspend from
lifting tackle.

Ensure correct suspension point for in-line engine! See Fig. 8.

5. Carefully lift up the piston (6).

6. Screw on two guide tubes (030.210) until they make contact with the
conrod shank bolts (10). See Fig. 8.
2009-02-11

7. Screw the pilot rod (034.006) into the carrier.

L48/60B

8. Apply clean lubricating oil to piston rings and running surface of piston
(6).

6704 034.01-02 EN 3 (15)

034.01 MAN Diesel & Turbo

9. Arrange the position of the piston ring joints (1 to 4) for piston rings for
Piston/Piston rings

control side (ST) according to the figure. See Fig. 7.

10. Open the lubricating oil bore in the connecting rod shank (11).
11. Move piston (6) with lifting tackle over the cylinder liner (9) and carefully
lower it into the lead-in sleeve, guiding the piston with the pilot rod until
the lower section of the piston slides into the cylinder liner. See Fig. 9.

Turn piston such that marking (ST) on piston top side points to control
side.

Do not damage cylinder head bolts (5) and conrod shank bolts (10) during
assembly of the piston!

12. Unscrew and remove the pilot rod.

13. Lower the piston (6) carefully to allow the piston rings to slide through
the lead-in sleeve in the cylinder liner (9).

Align piston and small end at the right time such that guide tubes point
to the appropriate holes in connecting rod shank.

14. Continue to lower the piston (6) carefully until big-end bearing head (7)
fits on connecting rod shank (11). See Fig. 10.

Pay attention to locating pins (17) in the big-end bearing head! See Fig.
10.
Work Cards, classified into sub-assemblies

To be able to guide in the piston more easily, slacken the hexagon bolts
(22) on the bracket (030.207-1) to allow the connecting rod and
connecting rod small end to align with one another automatically.

15. Check by means of thickness gauges (000.451) that parting line thick-
ness is smaller than 0.05 mm over its entire periphery.
16. Unscrew and remove the guide tubes.
17. Check that the conrod shank bolts (10) are screwed in hand-tight so the
collar rests on the connecting rod small end (7). See Fig. 11.
18. Screw the nuts (12) finger-tight onto the conrod shank bolts (10).
2009-02-11

19. Detach the locating clamps (030.207).

20. Tighten the conrod shank bolts (10) (see Work Card 030.01).
L48/60B

21. Remove foot board (011.011 or 011.012) from the oil sump (15).
22. Remove handle (011.013).

4 (15) 6704 034.01-02 EN

 MAN Diesel & Turbo 034.01

23. Turn the running gear until the piston (6) is at TDC.

Piston/Piston rings
24. Unhook cable (18), remove carrier.
25. Detach the lead-in sleeve.

Work Cards, classified into sub-assemblies

2009-02-11

L48/60B

6704 034.01-02 EN 5 (15)

034.01 MAN Diesel & Turbo
Piston/Piston rings
Work Cards, classified into sub-assemblies

5 Cylinder head bolt 10 Conrod shank bolt 15 Oil sump

6 Piston 11 Connecting rod shank 16 Cylinder crankcase
7 Connecting rod small end 12 Nut 17 Locating pin
2009-02-11

8 Backing ring 13 Big-end bearing cap ST Control side

9 Cylinder liner 14 Balance weight
Figure 1: Piston and connecting rod - Illustration shows engine 48/60B with normal oil sump
L48/60B

6 (15) 6704 034.01-02 EN

 MAN Diesel & Turbo 034.01

Piston/Piston rings
6 Piston 19 Hexagon bolt M16x90
9 Cylinder liner 20 Hexagon nut M16
18 Rope ST Control side
Figure 2: Removing the piston

Work Cards, classified into sub-assemblies

2009-02-11

L48/60B

6704 034.01-02 EN 7 (15)

034.01 MAN Diesel & Turbo
Piston/Piston rings
Work Cards, classified into sub-assemblies

6 Piston 12 Nut 21 Hexagon bolt M20x40

2009-02-11

7 Connecting rod small end 14 Balance weight ST Control side

10 Conrod shank bolt 15 Oil sump
11 Connecting rod shank 16 Cylinder crankcase
L48/60B

Figure 3: Removal of piston - Illustration shows engine 48/60B with normal oil sump

8 (15) 6704 034.01-02 EN

 MAN Diesel & Turbo 034.01

Piston/Piston rings
11 Connecting rod shank 23 Hexagon bolt M20x30
14 Balance weight 24 Hexagon bolt M12x45

Work Cards, classified into sub-assemblies

22 Hexagon bolt M12x45
Figure 4: Removing the piston - detail of fig. 3
2009-02-11

L48/60B

6704 034.01-02 EN 9 (15)

034.01 MAN Diesel & Turbo
Piston/Piston rings
Work Cards, classified into sub-assemblies

5 Cylinder head bolt 9 Cylinder liner 18 Rope

2009-02-11

6 Piston 10 Conrod shank bolt ST Control side

7 Connecting rod small end 11 Connecting rod shank
L48/60B

Figure 5: Removal of piston - Illustration shows engine 48/60B with normal oil sump

10 (15) 6704 034.01-02 EN

 MAN Diesel & Turbo 034.01

Piston/Piston rings
Work Cards, classified into sub-assemblies

Figure 6: Removing the piston

1-4 Position of the piston ring joint

2009-02-11

ST Control side
L48/60B

Figure 7: Installation of the piston - Position of the piston ring (end) gaps

6704 034.01-02 EN 11 (15)

034.01 MAN Diesel & Turbo
Piston/Piston rings
Work Cards, classified into sub-assemblies

5 Cylinder head bolt 9 Cylinder liner 20 Hexagon nut M16

6 Piston 10 Conrod shank bolt ST Control side
7 Connecting rod small end 18 Rope
8 Backing ring 19 Hexagon bolt M16x90
Figure 8: Installing the piston
2009-02-11
L48/60B

12 (15) 6704 034.01-02 EN

 MAN Diesel & Turbo 034.01

Piston/Piston rings
6 Piston 11 Connecting rod shank
7 Connecting rod small end 18 Rope

Work Cards, classified into sub-assemblies

9 Cylinder liner ST Control side
10 Conrod shank bolt
Figure 9: Installing the piston
2009-02-11

L48/60B

6704 034.01-02 EN 13 (15)

034.01 MAN Diesel & Turbo
Piston/Piston rings
Work Cards, classified into sub-assemblies

6 Piston 10 Conrod shank bolt 17 Locating pin

2009-02-11

7 Connecting rod small end 11 Connecting rod shank ST Control side

Figure 10: Piston and big-end bearing - Illustration shows engine 48/60B with normal oil sump
L48/60B

14 (15) 6704 034.01-02 EN

 MAN Diesel & Turbo 034.01

Piston/Piston rings
7 Connecting rod small end
10 Conrod shank bolt
11 Connecting rod shank

Figure 11: Conrod shank bolt

Work Cards, classified into sub-assemblies

2009-02-11

L48/60B

6704 034.01-02 EN 15 (15)

 MAN Diesel & Turbo 034.02

Piston/Piston rings

Piston/Piston rings
inspecting

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the work is carried out correctly, check the components as to their
state / extent of their wear.
The pistons and piston rings are to be checked with regard to the appear-
ance of their contact faces as well as the lubricating and wear condition.
The work/work steps include:
Measuring components and
Assessing contact pattern /wear condition.
Tools/aids required
Quantity Designation Number Status
1 Piston ring expander 034.086 Standard
1 Thickness gauges 0.05-1 000.451 Option
1 Felt-tip pen/marker pen - Inventory
1 Dial gauge - Inventory

Corresponding Work Cards

Work card Work card Work card
034.01 034.05 034.07

Work sequence 1 - Checking the piston

Starting position Piston has been removed and placed on a suitable wooden support.

Work steps 1. Piston (1) and piston rings (17 to 20) are to be checked for condition.

Work Cards, classified into sub-assemblies

The piston running surface should have a uniform wear surface
appearance and be free of machining marks and other damage.
Deep grooves and seizure points indicate overloading of the engine,
faulty cooling, insufficient lubrication or impurities lodged between
piston and cylinder liner.

2. Clean piston (1) of carbon residues, without roughening the surface of

the piston floor. Clean the running surface carefully.

Graphitated layer on the piston skirt must not be damaged while

cleaning!
2008-10-22

3. Measure and note axial clearance of the piston rings (17 to 20) in its
piston ring grooves, compare with maximum permissible clearance and
48/60B

incorporate in operating log sheets.

6707 034.02-02 EN 1 (6)

034.02 MAN Diesel & Turbo

Determine the axial clearance at four places using thickness gauges

Piston/Piston rings

(000.451) (control /exhaust/coupling side /free engine end) in quarter

piston ring groove depth. See Fig. 2.

For assessment of piston rings see Work Card 034.05 and 034.07.
Work sequence 2 - Removing and installing the piston rings
Preliminary remark When checking the pistons, the piston rings are not usually to be removed, since they
are under heavy strain during removal and installation!
Work steps In the event that piston rings are removed because of their wear condition
or dirt:
1. Remove piston rings (17 to 20) individually by means of tensioner
(034.086), clean and label using a marker pen (cylinder number and
number of the piston ring groove).

Identification of the piston rings is necessary in order to prevent mixing

up of the piston rings (used piston rings must be installed again in the
same piston and same piston ring groove)!

Always use tensioners for removal and fitting of piston rings. See Fig. 3.

2. Clean piston ring grooves carefully and determine the wear.

Determine the height of piston ring grooves at four places using suitable
measuring gauge (3) (control /exhaust/coupling side /free engine end) in
quarter piston ring groove depth. See Fig. 4.
Work Cards, classified into sub-assemblies

3. Check piston rings (17 to 20) accurately, replace if necessary.

Conically deflected piston ring grooves indicate excessive wear of the

cylinder liners!
Deflected piston ring grooves can be reworked! We recommend
contacting MAN Diesel & Turbo SE! Install replacement piston rings
suitable for the reworked piston ring grooves and establish new piston
ring height in the operation descriptions!

4. Pull up piston rings (17 to 20) on piston (1) using tensioner. Pay attention
to the position according to the identification mark.
5. Measure axial clearance of the piston rings (17 to 20) in its piston ring
grooves and note in the operational records.
2008-10-22

Determine the axial clearance at four places using thickness gauges

(000.451) (control /exhaust/coupling side /free engine end) in quarter
48/60B

piston ring groove depth. See Fig. 2.

2 (6) 6707 034.02-02 EN

 MAN Diesel & Turbo 034.02

Observe the running-in guidelines

Piston/Piston rings
If an already used piston is installed in another cylinder liner, the
compression rings (17 to 19) and the oil control rings (20) must always
be replaced and the cylinder liner must be re-honed (see Work Card
050.05)! The engine should then be run-in again (see running-in
specifications in Engine - Operating Instructions Volume 010.005)!

For dimensions and clearances of piston rings see Volume 010.005 Engine - Operating
Instructions.
Arrangement of the piston rings (see figure 5):
▪ A chrome ceramic coated compression ring (17) is fitted into the top
piston ring groove (ring groove 1) in the piston crown. The ring flank with
the designation "TOP" is the top flank.
▪ Chrome plated compression rings (18 and 19) are installed in the second
and third piston ring groove from the top (ring groove 2 and 3). The ring
flank with the designation "TOP" is the top flank.
▪ An oil control ring (20) is installed in the fourth piston ring groove from
the top (ring groove 4). The oil control ring with tubular spring must
always be set such that the ring flank with the identification "TOP"
always faces up.

1 Piston
2 Connecting rod small end
17 Compression ring

Work Cards, classified into sub-assemblies

18 Compression ring
19 Compression ring
20 Oil control ring

Figure 1: Piston with con rod small end

2008-10-22

48/60B

6707 034.02-02 EN 3 (6)

034.02 MAN Diesel & Turbo
Piston/Piston rings

1 Piston 19 Compression ring A Piston ring groove depth

17 Compression ring 20 Oil control ring B Measuring location - 1/4 piston ring groove depth (A)
Work Cards, classified into sub-assemblies

18 Compression ring
Figure 2: Measuring the axial clearance of the piston rings

2008-10-22
48/60B

4 (6) 6707 034.02-02 EN

 MAN Diesel & Turbo 034.02

Piston/Piston rings
17 Compression ring
18 Compression ring
19 Compression ring
20 Oil control ring

Figure 3: Tensioner with inserted piston rings

1 Piston Work Cards, classified into sub-assemblies

3 Dial gauge
A Piston ring groove depth
B Measuring location - 1/4 piston ring groove depth (A)
Figure 4: Measuring the piston ring groove height (determine the wear)
2008-10-22

48/60B

6707 034.02-02 EN 5 (6)

034.02 MAN Diesel & Turbo
Piston/Piston rings

1 Piston
17 Compression ring
18 Compression ring
19 Compression ring
20 Oil control ring

Figure 5: Arrangement of the piston rings

Work Cards, classified into sub-assemblies

2008-10-22
48/60B

6 (6) 6707 034.02-02 EN

 MAN Diesel & Turbo 034.03

Piston pin and piston pin bush

Piston/Piston rings
removing and installing/checking

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the work is carried out correctly, check the components as to their
state / extent of their wear.
The piston pins and piston pin bushes are to be checked at regular intervals
and must therefore be dismantled.
The work/work steps include:
Disassembling components,
Checking parts/ components,
Assembling components.
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 034.144 Option
1 Shackle A1.0 002.453 Standard
1 Pliers for locking ring 002.165 Standard
1 Lifting eye bolt M20 000.155 Standard
1 Lifting tackle - Inventory
1 Wood (to support underneath) - Inventory
1 Rope - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card

Work Cards, classified into sub-assemblies

034.01

Technical data
Designation Information
Connecting rod small end 146,5 kg
Piston pin 101 kg

Work sequence 1 - Removing the piston pin

Starting position Piston is disassembled, cleaned externally and set down on wooden sup-
port (piston skirt / small end face up).
Work steps 1. Screw lifting eye bolt (000.155) into small end (6). See Fig. 2/I.
2008-10-22

2. Fasten cable (9) with shackle (002.453) on lifting eye bolt and suspend
from lifting tackle.
48/60B

3. Lift big-end bearing head (6) slightly, so that the piston pin (4) is unloa-
ded.

6707 034.03-02 EN 1 (7)

034.03 MAN Diesel & Turbo

4. Remove locking rings (3) using pliers (002.165).

Piston/Piston rings

5. Push out piston pin (4) until the big-end bearing head (6) can be
removed. In doing so, protect the piston (1) from tilting by the use of
wooden supports (8). See Fig. 2/I.

In the event of a temperature difference of 30 to 40°C as compared to

the piston, the piston pin is to be pulled out slightly. To do so, carefully
heat up the piston, for example by using a gas burner, around the piston
pin area by applying the torch in circular movements and ensuring that
the flame does not come too close to the piston.

6. Lift small end (6) carefully from the piston (1) and place on a clean sup-
port. See Fig. 2/II.

When putting down the connecting rod small end, make sure that the
conrod shank bolts (7) are not damaged!

7. Detach the tool.

8. Fasten cable (9) by means of a shackle (002.453) to removal and fitting
fixture (034.144) and suspend from lifting tackle.
9. Fit removal and fitting fixture in piston pin (4). See Fig. 3/I.
10. Dismantle piston pin (4) carefully from the piston (1) and place on a clean
support surface. See Fig. 3/II.
11. Detach the tool.
12. Clean piston pin (4) and piston pin bush (5) and check the wear (for
maximum permissible clearance see Engine - Operating Instructions
Volume 010.005).

If necessary, the piston pin bush should be replaced in a customer

service workshop, because it needs to be supercooled for fitting. Install
Work Cards, classified into sub-assemblies

a reserve small end in the meanwhile. No additional scraping should be

performed on either the running surface of the new piston pin bush or
the run-in bush.

13. Check all parts for damage, renew/replace if necessary.

Work sequence 2 - Installing the piston pin

Starting position Piston, small end and piston pin are cleaned.

Work steps 1. Check the movability of the guide shoe (2) in the piston (1).

2. Fasten cable (9) by means of a shackle (002.453) to removal and fitting

fixture (034.144) and suspend from lifting tackle.
2008-10-22

3. Fit removal and fitting fixture in piston pin (4). Raise piston pin. See Fig.
3/II.
4. Set piston pin (4) on piston (1) and push it carefully to the extent that
48/60B

big-end bearing head (6) can still be installed. See Fig. 3/I.

2 (7) 6707 034.03-02 EN

 MAN Diesel & Turbo 034.03

5. In doing so, protect the piston (1) from tilting by the use of wooden sup-

Piston/Piston rings
ports (8). See Fig. 3/I.
6. Detach the tool.
7. Screw lifting eye bolt (000.155) into small end (6).
8. Fasten cable (9) with shackle (002.453) on lifting eye bolt and suspend
from lifting tackle. Raise small end. See Fig. 2/II.
9. Apply clean lubricating oil to running surface of the piston pin bush (5).
10. Install small end (6) carefully in the piston (1). See Fig. 2/I.
11. Push piston pin (4) completely into the piston (1), raising or lowering the
small end (6) a little if necessary.
12. Insert locking rings (3) in their grooves using pliers (002.165).
13. Detach the tool.
14. Rotate locking rings (3) so that their gap points towards the piston crown
or piston skirt. See Fig. 4.

Work Cards, classified into sub-assemblies

2008-10-22

48/60B

6707 034.03-02 EN 3 (7)

034.03 MAN Diesel & Turbo
Piston/Piston rings

1 Piston 5 Piston pin bush

2 Guide shoe 6 Connecting rod small end
Work Cards, classified into sub-assemblies

3 Locking ring 7 Conrod shank bolt

4 Piston pin
Figure 1: Piston with con rod small end
2008-10-22
48/60B

4 (7) 6707 034.03-02 EN

 MAN Diesel & Turbo 034.03

1 Piston 6 Connecting rod small end 9 Rope

Piston/Piston rings
Work Cards, classified into sub-assemblies
4 Piston pin 8 Wooden support I - II Work steps
Figure 2: Removal of the small end
2008-10-22

48/60B

6707 034.03-02 EN 5 (7)

034.03 MAN Diesel & Turbo
Piston/Piston rings
Work Cards, classified into sub-assemblies

1 Piston 9 Rope
2008-10-22

4 Piston pin I - II Work steps

8 Wooden support
Figure 3: Disassembly of the piston pin
48/60B

6 (7) 6707 034.03-02 EN

 MAN Diesel & Turbo 034.03

Piston/Piston rings
1 Piston 3 Locking ring
Figure 4: Position of the gap of the locking rings (direction of gap: Piston crown
- Illustration at left or piston skirt - illustration at right)

Work Cards, classified into sub-assemblies

2008-10-22

48/60B

6707 034.03-02 EN 7 (7)

 MAN Diesel & Turbo 034.04

Piston

Piston/Piston rings
dismantling and assembling

Summary
Carry out the work in good time according to the maintenance schedule,
check the components as to their state / extent of their wear.
Pistons are to be dismantled within the scope of maintenance and repair
work.
The work/work steps include:
Dismantling components,
assembling components.
Tools/aids required
Quantity Designation Number Status
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.017 Standard
1 Torque wrench 008.011 Standard
1 Pliers for the locking rings C 19-60 002.162 Standard
1 Pliers for locking rings A 19-60 002.122 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 spanner insert 36x20 001.796 Standard
1 Socket spanner insert 14x12.5 001.753 Standard
1 Honing stone - Option
1 Lifting tackle - Inventory

Work Cards, classified into sub-assemblies

1 Wood (to support underneath) - Inventory
1 Oil stone - Inventory
1 Scriber - Inventory
1 Emery paper - Inventory
1 Hemp rope - Inventory
1 Nylon rope - Inventory
1 Side cutter - Inventory
1 Depth gauge - Inventory
1 Molykote HSC - Inventory
1 Lubricant (Copa Slip) - Inventory
2007-12-07

1 Lubricating oil, clean - Inventory

Corresponding Work Cards

48/60B

Work card Work card Work card

034.03

6707 034.04-04 EN 1 (6)

034.04 MAN Diesel & Turbo

Technical data
Piston/Piston rings

Designation Information
Piston crown 180,5 kg
Piston skirt 223 kg

Work sequence 1 - Dismantling the piston

Starting position Piston is disassembled, cleaned externally and set down on wooden sup-
port (piston skirt / small end face up).
Work steps 1. Remove piston pin and small end (see Work Card 034.03).

2. Loosen and unscrew four nuts (5), remove thrust pieces (6).
3. Suspend piston skirt (10) from lifting tackle through piston pin bores by
means of cable, lift carefully and place on a clean wooden supports.

Do not damage studs (7) when lifting the piston skirt! Do not place piston
skirt on guide shoe (9)!

4. Remove the locking ring (21), while doing so, hold the guide shoe (9)
with your hand.

If the guide shoe is not held, it will fall out of the guide once the locking
ring is removed!

5. Push the guide shoe (9) out of the guide.

6. Detach supporting ring (11 and 13) and compression spring (12).
7. Remove locking ring (14) from piston skirt (10).
8. Unscrew the studs (7) from the piston crown (16).
Work Cards, classified into sub-assemblies

9. Remove O-ring seal (22).

10. Clean piston crown (16) and skirt (10) carefully.
Clean the cooling chamber (internally) to a polished metal condition
using wire brushes or emery belts. Blow the oil bores out using com-
pressed air. Check the parts for damage (cracks).
11. Check the contact surface between the piston crown (16) and skirt (10),
and smooth out any lifting of the material (see work sequence 2).

Work sequence 2 - Smoothing out the contact surface between the piston crown and the
piston skirt
Preliminary remark There may be local, point welds between piston crown and skirt during
2007-12-07

engine operation, which cause material bumps on the contact faces during
the dismantling of the piston.
As the exact starting position can no longer be reached during assembly of
48/60B

the piston, the material bumps must be removed or smoothened.

Starting position The piston is dismantled and has been cleaned.

2 (6) 6707 034.04-04 EN

 MAN Diesel & Turbo 034.04

Work steps 1. Check the contact surface of the piston crown (16) and the piston skirt

Piston/Piston rings
(10) for raised points in the material.
2. Remove any raised points in the material using several work steps, using
emery paper with increasingly fine grain size (100 - 180).
3. Smooth the contact surfaces using oil stone or a honing stone.

In doing so, ensure in particular that the raised points in the material are
completely removed from the contact surfaces of the piston crown and
the piston skirt, since any remaining raised points can lead to high
selective point compressive stress.

Work sequence 3 - Assembling the piston

Starting position Piston components are cleaned, checked and replaced if required, piston
crown is placed on wooden supports.

Carry out points 1 to 18 if the parts have been replaced, points 1 to 12

and 16 to 18 generally after dismantling the piston.

Work steps 1. Install locking ring (14) in piston skirt (10) using pliers (002.162).

2. Fit supporting ring (11) and compression spring (12) on guide shoe (9).
3. Place supporting ring (13) over guide shoe (9) and rest on compression
spring (12).
4. Slightly lubricate the guide shoe (9) running surface using clean lubri-
cating oil.
5. Insert guide shoe (9) in piston skirt (10) and install locking ring (21) in the
groove using pliers (002.122).
6. Screw studs (7) into piston crown (16) with tightening torque 50 Nm.

Work Cards, classified into sub-assemblies

7. Determine and note thread projection (A) of all studs (7). See Fig. 2.

If the determined thread projection (A) of a stud (7) is greater than 280.5
mm, it should be replaced!

8. Insert new O-ring seals (22), lubricated with new, clean lubricating oil
into the ring groove. In doing so ensure that the entire circumference of
the O-ring seals seal is tightened equally and that it is not twisted.
9. Check resting surface of piston crown (16) and skirt (10), they must be
absolutely clean and dry.
10. Suspend piston skirt (10) from lifting tackle through piston pin bores by
2007-12-07

means of cable, lift and carefully place on piston crown (16).

Before fitting the piston skirt, ensure the correct location of the bore in
48/60B

the piston skirt to the dowel pin (15) in the piston crown!
Do not damage studs (7) when fitting the piston skirt on the piston crown!

6707 034.04-04 EN 3 (6)

034.04 MAN Diesel & Turbo

11. Insert thrust pieces (6) in holes by means of studs (7).

Piston/Piston rings

12. Apply Molykote HSC or lubricant "Copa Slip" to the threads and resting
surface of the nuts (5) and screw on until they come to rest.
13. Tighten nuts (5) with tightening torque 350 Nm, in the order 1-2-3-4. See
Fig. 3.
14. Loosen the nuts (5) again.
15. Check the tightening of the studs (7) with torque 50 Nm.
16. Final tightening in two stages:
● Nuts (5) with tightening torque 80 Nm, sequence 1-2-3-4 pre-tensioning,
● Nuts (5) with rotation angle 180°, sequence 4-3-2-1 to be turned on
further.
Check: It must not be possible to further rotate the nuts at torque 300 Nm!
17. Check the guide shoe (9) mobility.
18. Install piston pin and small end (see Work Card 034.03).
Work Cards, classified into sub-assemblies

2007-12-07
48/60B

4 (6) 6707 034.04-04 EN

 MAN Diesel & Turbo 034.04

Piston/Piston rings
5 Nut 11 Supporting ring 17 Compression ring
6 Thrust piece 12 Compression spring 18 Compression ring
7 Stud 13 Supporting ring 19 Compression ring
8 Sleeve 14 Locking ring 20 Oil control ring

Work Cards, classified into sub-assemblies

9 Guide shoe 15 Dowel pin 21 Locking ring
10 Piston skirt 16 Piston crown 22 O-ring seal
Figure 1: Piston
2007-12-07

48/60B

6707 034.04-04 EN 5 (6)

034.04 MAN Diesel & Turbo
Piston/Piston rings

7 Stud
16 Piston crown
A Bolt projection

Figure 2: Piston - thread projection of the stud

1-4 Tightening sequence

Work Cards, classified into sub-assemblies

Figure 3: Piston - Tightening sequence of the studs/nuts

2007-12-07
48/60B

6 (6) 6707 034.04-04 EN

 MAN Diesel & Turbo 034.05

Piston rings

Piston/Piston rings
assessing

Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components dimensionally, evaluate contact pattern/wear
condition.
Asses the piston rings at regular intervals on the basis of the wear pattern.
The work includes:
Checking parts/components.
Corresponding Work Cards
Work card Work card Work card
034.07

Preliminary remarks
The piston rings must be replaced after the operating hours listed in the
maintenance schedule. They are also to be replaced if, during intermediate
checks, damage to the running surface is detected or there is too much
clearance.
Compression rings are in use with chrome coated or chrome ceramic
coated running surfaces and chrome plated oil control rings. See Table 1.
Ring Running surface Appearance
Compression rings
Groove 1 Chrome-ceramic coated net of cracks later
Groove 2/3 chrome coated uniformly grey
Oil control ring

Work Cards, classified into sub-assemblies

Groove 4 chrome coated uniformly grey
Table 1: Piston rings/Surface coating
In the case of chrome plated rings, the appearance of the coating only
shows minor or slight change during continuous wear. This is not the case
for chrome ceramic coated rings. The running surface of these rings when
not worn has a smooth metallic appearance and has a uniform grey colour.
After several hundred operating hours, a net of cracks becomes visible. This
is normal. This is the result of hard metal-oxide ceramic particles burying
themselves into the network structure of the chrome coat.
The ring version can be identified by the item number stamped on the upper
side of the piston rings.
Wear patterns of chrome or chrome ceramic coated piston rings
2007-03-28

As a result of the shape of the running surface, new compressing rings do

not wear along the entire running surface, but only along running pattern
General

area A. As the wear increases, the running pattern area becomes wider and
wider.

6682 034.05-02 EN 1 (3)

034.05 MAN Diesel & Turbo
Piston/Piston rings

A Running pattern height B Ring height

Figure 1: Running surface of chrome plated piston rings (operating hours >
1000 h)

Figure 2: Network of cracks in chrome ceramic coated piston rings (operating

hours > 8,000 h)
At the end of its working life the running pattern reaches up to the chamfers
or radii of the ring flanks. (figure 3).

Figure 3: Piston ring with a well-formed running pattern at the end of its working
life
The piston ring shown in figure 3 shows chamfers or radii, which can still be
clearly identified. Coated compression rings must be replaced once the
running pattern height extends to cover the entire height of the piston ring,
i.e. the chamfers or radii are barely visible. In this condition, the next sched-
uled maintenance interval cannot be completed safely given the remaining
Work Cards, classified into sub-assemblies

coating thickness.
Burn marks (C) can be identified by local discolouration on the running sur-
face. Rings in this condition must be replaced. Figure 4.

Figure 4: Piston ring with burn marks in the running surface

Coated compression rings and oil control rings must also be replaced once
2007-03-28

the coating has been worn off in one location.

General

2 (3) 6682 034.05-02 EN

 MAN Diesel & Turbo 034.05

Piston/Piston rings
Figure 5: Piston ring with coating worn away
Figure 5 shows a chrome plated compression ring. The layer of chrome has
been partially worn away at (D).
Once spallings or cracks are visible in the coating of a piston ring it also
should be replaced.
Chrome ceramic coated compression rings must be replaced once the
closed surface, traversed by microcracks, has dissolved into a structure that
looks similar to a cobblestone surface. At this point, the cracks have
reached the base material and there is a risk of breakaways.

Work Cards, classified into sub-assemblies

2007-03-28

General

6682 034.05-02 EN 3 (3)

 MAN Diesel & Turbo 034.07

Piston rings with chrome ceramic coating

Piston/Piston rings
assessing

Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/wear condition.
Asses the piston rings at regular intervals on the basis of the wear pattern.
The work includes:
Checking parts/components.
Corresponding Work Cards
Work card Work card Work card
034.05

Preliminary remarks
The piston rings must be replaced after the operating hours listed in the
maintenance schedule. They are also to be replaced if, during intermediate
checks, damage to the running surface is detected or there is too much
clearance.
In groove 1, piston rings with the chrome ceramic coated running surface
are in use. The ring version can be identified by the item number stamped
on the upper side of the piston rings.
As opposed to plasma coated or chrome plated rings, the appearance of
the coating of chrome ceramic coated rings changes significantly with
increased wear. The running surface of these rings when still new has a
smooth metallic appearance and is uniformly silver grey in colour. After
several hundred hours in operation, a network of cracks or individual lon-
gitudinal and transverse cracks becomes visible. This is normal and is the
result of hard metal-oxide ceramic particles burying themselves into the

Work Cards, classified into sub-assemblies

network structure of the chrome coat. This leads to very high levels of wear
resistance and a significantly improved thermal load capacity with minimal
wear on the cylinder liners. The characteristic network of cracks in this case
serves the purpose of providing a reservoir of lube oil.
The following sequence of images shows the piston rings, magnified
approx. five times. The sequence of images is provided to facilitate the
assessment of coated piston rings and supplements the Work Card 034.05.
2007-04-23

General

6682 034.07-01 EN 1 (4)

034.07 MAN Diesel & Turbo

1. Normal wear pattern. Piston ring can be used without reservations

Piston/Piston rings

Figure 1: Wide network of cracks

This running surface appearance shows the normal state of wear for a
chrome ceramic coated ring.
Assessing: The piston ring can be used without restrictions and can continue
to be used.
Work Cards, classified into sub-assemblies

Figure 2: Tight network of cracks

This running surface appearance also shows a normal state of wear. The
entire surface is smooth. Wave-forms in the running layer in the direction of
the cracks are not visible. This pattern will not result in any flaking of the
coating.
Assessment: The piston ring can be used without restrictions and can con-
tinue to be used.
2007-04-23
General

2 (4) 6682 034.07-01 EN

 MAN Diesel & Turbo 034.07

Piston/Piston rings
Figure 3: Narrow longitudinal cracks in the running direction
This running surface appearance also shows a normal state of wear. The
entire surface is smooth.
Assessment: If the crack width is < approx. 0.1 mm, the piston ring can be
used without any restrictions and can continue to be used.
2. Critical wear - the piston ring must be replaced

Work Cards, classified into sub-assemblies

Figure 4: Burn spot
The appearance of this running surface shows a normal state of wear how-
ever, in this case, it shows a burn spot, which cannot be rectified. In addition,
there is risk of a so-called blow-by.
Assessing: The piston ring can no longer be used and must be replaced.
2007-04-23

General

6682 034.07-01 EN 3 (4)

034.07 MAN Diesel & Turbo
Piston/Piston rings

Figure 5: Severe cobblestone formation

This running surface shows pronounced cobblestone formation with a wide
area of cracks. The surface is no longer smooth throughout, but instead
shows bulging around the cracks.
Assessment: The piston ring can no longer be used and must be replaced.

Figure 6: Wide longitudinal cracks in the running direction

This running surface shows an extensive formation of longitudinal cracks
with the risk of the coating flaking off, even though the surface may be
entirely smooth.
Assessment: Since the crack width is approx. > 0.1 mm, the piston ring can
Work Cards, classified into sub-assemblies

no longer be used and must be replaced.

3. Terminal damage. The piston ring must be replaced.
If the piston ring shows terminal damage, for example:
▪ Ring fracture
▪ Flaking of the running layer
▪ Spallings, etc.
the piston ring must be replaced. Check the adjoining parts, such as the
cylinder liner, piston, cylinder head, for damage.
2007-04-23
General

4 (4) 6682 034.07-01 EN

MAN Diesel & Turbo 050

Top land ring/cylinder liner

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.9-1 EN 1 (2)

 MAN Diesel & Turbo
Top land ring/cylinder liner

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.9-1 EN

 MAN Diesel & Turbo 050.01

Top land ring

Top land ring/cylinder liner

removal and installation

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the work is carried out correctly, check the components as to their
state / extent of their wear.
The top land ring must always be removed when the corresponding piston
is to be removed.
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 050.116 Standard
1 Carrier 050.116-1 Standard
3 Hexagon bolt 050.116-14 Standard
1 Removal and fitting fixture 050.085 Standard
1 Carrier 050.085-1 Standard
1 Pilot rod 034.006 Standard

Work Cards, classified into sub-assemblies

1 Shackle A1.0 002.453 Standard
1 Combination spanner (set) - Inventory
1 Lifting tackle - Inventory
1 Rope - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
055.02

Technical data
2007-12-05

Designation Information
Top land ring 117,5 kg
L48/60B

6704 050.01-01 EN 1 (10)

050.01 MAN Diesel & Turbo

Work sequence 1 - Disassembling the top land ring

Top land ring/cylinder liner

Starting position Cooling water has been drained off completely.

Cooling water must not be pumped into the bilges or into the sewage
system! Cooling water must be pumped into its own individual tank and
be reused (cooling water treatment agent)!

Cylinder head removed.

Work steps 1. Turn running gear, until piston (6) is about 60° before/after TDC.

2. Remove carbon residue on the top land ring (3) and from the upper area
of the cylinder liner (7).

Cover the gap between the piston and the cylinder liner to prevent foreign
substances from falling into it!

3. Tightly screw three hexagon bolts (050.116-14) into the tapped blind
hole in the top land ring (3) by hand. See Fig. 2.
4. Screw-in four hexagon bolts (9) until they abut on the backing ring (4).
5. Fasten cable (8) with shackle (002.453) on carrier and suspend from
lifting tackle.

Centring bolt (10) on the carrier must engage with fixing hole (C) on
backing ring (4)! See Fig. 2.

6. Tightly screw three hexagon bolts (050.116-14) into the tapped blind
hole in the top land ring (3) by hand. See Fig. 2.
7. Screw-in four hexagon bolts (9) until they abut on the backing ring (4).
Work Cards, classified into sub-assemblies

8. Fasten cable (8) with shackle (002.453) on carrier and suspend from
lifting tackle.

Ensure correct suspension point for in-line engine! See Fig. 2.

9. Screw the pilot rod (034.006) into the carrier.

10. Press top land ring (3) down by even, alternate rotation of the hexagon
bolts (9). See Fig. 3.
11. Carefully pull the top land ring (3) out upwards, using the pilot rod as a
2007-12-05

guide. See Fig. 4.

12. Place top land ring (3) on a clean support.
L48/60B

13. Detach the tool.

14. Remove the O-ring seals (2).

2 (10) 6704 050.01-01 EN

 MAN Diesel & Turbo 050.01

15. Clean the top land ring (3).

Top land ring/cylinder liner

Work sequence 2 - Fitting the top land ring
Starting position Piston is fitted, top land ring is cleaned.

Work steps 1. Insert new O-ring seals (2), lubricated with new, clean lubricating oil into
the ring grooves. In doing so ensure that the O-ring seals are tightened
equally and are not twisted around the entire circumference.
2. Screw the hexagon bolts (9 and 050.116-14) back.
3. Attach the carrier (050.116-1) to the top land ring (3).

Note the position of the carrier to the mark (M) on the top land ring. See
Fig. 5.

4. Tightly screw three hexagon bolts (050.116-14) into the tapped blind
hole in the top land ring (3) by hand. See Fig. 2.
5. Screw the pilot rod (034.006) into the carrier.
6. Fasten cable (8) with shackle (002.453) on carrier and suspend from
lifting tackle.

Ensure correct suspension point for in-line engine! See Fig. 5.

7. Lift the top land ring (3), guide it over the cylinder liner (7) and carefully
insert it into the backing ring (4), in doing so guide it with the pilot rod.

When installing the top land ring, ensure the correct placement of the
marking (M) on the top land ring / backing ring! Centring bolt (10) on the
carrier must engage with fixing hole (C) on support ring (4)! See Fig. 2.

Work Cards, classified into sub-assemblies

8. Detach the tool.
9. Screw thrust screws (11) back in the carrier (050.085-1).
10. Place the carrier onto the backing ring (4) and fasten with the hexagon
bolts (12). See Fig. 6.
11. Screw in the thrust screws (11) up to top edge of the top land ring (3).
12. Using even, alternating turns of the thrust screws (11), press the top land
ring (3) down, until it abuts the cylinder liner (7).

Ensure that when the top land ring is being pressed down that it does
not get tilted in the backing ring!
2007-12-05

L48/60B

13. Detach the tool.

14. After removing all of the engine parts (cylinder head, etc.) fill cooling
water into the engine, vent the cooling water pipe.

6704 050.01-01 EN 3 (10)

050.01 MAN Diesel & Turbo

15. After completing the installation/assembly work and re-establishing the

Top land ring/cylinder liner

cooling water pressure, check whether the O-ring seals (2) are OK -
water must not emerge from the check bores (A and B). See Fig. 1.
16. With the engine running, check the cylinders at the check bores (A) for
gas leakages. See Fig. 1.
Work Cards, classified into sub-assemblies

2007-12-05
L48/60B

4 (10) 6704 050.01-01 EN

 MAN Diesel & Turbo 050.01

Top land ring/cylinder liner

Work Cards, classified into sub-assemblies

1 Cylinder head bolt 5 Cylinder crankcase B Check bore

2 O-ring seal 6 Piston C Fixing hole in backing ring
3 Top land ring 7 Cylinder liner M Mark
2007-12-05

4 Backing ring A Check bore ST Control side

Figure 1: Backing ring/cylinder liner with top land ring
L48/60B

6704 050.01-01 EN 5 (10)

050.01 MAN Diesel & Turbo
Top land ring/cylinder liner
Work Cards, classified into sub-assemblies

3 Top land ring 8 Rope C Fixing hole in backing ring

4 Backing ring 9 Hexagon bolt M20x140 ST Control side
7 Cylinder liner 10 Centring pin
Figure 2: Removing/fitting the top land ring
2007-12-05
L48/60B

6 (10) 6704 050.01-01 EN

 MAN Diesel & Turbo 050.01

Top land ring/cylinder liner

3 Top land ring 9 Hexagon bolt M20x140
4 Backing ring ST Control side
7 Cylinder liner
Figure 3: Removing the top land ring

Work Cards, classified into sub-assemblies

2007-12-05

L48/60B

6704 050.01-01 EN 7 (10)

050.01 MAN Diesel & Turbo
Top land ring/cylinder liner

Figure 4: Removing the top land ring

Work Cards, classified into sub-assemblies

2007-12-05
L48/60B

8 (10) 6704 050.01-01 EN

 MAN Diesel & Turbo 050.01

Top land ring/cylinder liner

3 Top land ring M Mark
Figure 5: Fitting the top land ring - Position of carrier for marking on the top
land ring

Work Cards, classified into sub-assemblies

2007-12-05

L48/60B

6704 050.01-01 EN 9 (10)

050.01 MAN Diesel & Turbo
Top land ring/cylinder liner
Work Cards, classified into sub-assemblies

3 Top land ring 11 Thrust screw

4 Backing ring 12 Hexagon bolt M24x50
7 Cylinder liner ST Control side
Figure 6: Installing the top land ring
2007-12-05
L48/60B

10 (10) 6704 050.01-01 EN

 MAN Diesel & Turbo 050.02

Cylinder liner

Top land ring/cylinder liner

measure

Summary
Check the components as to their state / extent of their wear, prevent
operational problems / damage.
The cylinder liners are to be checked within the scope of maintenance and
repair work.
The work/work steps include:
Measuring components and
Assessing contact pattern /wear condition.
Tools/aids required
Quantity Designation Number Status
1 Gauge bar 32/40 050.164 Option
1 Gauge bar 48/60 050.162 Option
1 Micrometer (Internal) 48/60 050.062 Option
1 Micrometer (Internal) 32/40 050.038 Option

Preliminary remarks
Cylinder liners are not evenly worn all the way around their surface or along
the running surface. The wear values are limited both with regard to ovality
as well as to the maximum wear. This way, any sealing problems and over-
loads on the piston rings may be avoided.
Regular inspection will provide ideas for optimising the operating conditions
and will be decision-making factors for any necessary cylinder liner replace-
ment.
Work sequence 1 - measuring the cylinder liner

Work Cards, classified into sub-assemblies

Starting position Cylinder head is detached, top land ring is disassembled, piston and con-
necting rod (in engine 32/40) or small end (in engine 48/60 B) are disas-
sembled. Cylinder liner thoroughly cleaned, particularly in the upper area
and on top (in the contact area of the gauge bar).
Work steps 1. Insert gauge bar (050.162 or 050.164) in cylinder liner (8). See Fig. 2.
The measuring bar is held magnetically to the running surface and the
upper side of the collar. The quantity and location of the measuring
points (1 to 5) are defined by the bores in the gauge bar.
32/40;48/60B;V48/60CR

2. Bring internal micrometer (050.038 or 050.062) up to the temperature of

the cylinder liner (8)
3. Insert the internal micrometer into each of the bores in the gauge bar,
2008-10-22

take measurements and make a note of the measured values. See Fig.
3.

6682 050.02-02 EN 1 (5)

050.02 MAN Diesel & Turbo

Type and source of danger

Top land ring/cylinder liner

Measure the dimensions in the transverse and longitudinal direction of

the engine.

4. Determine the temperature of the cylinder liner (8) during the measure-
ment and make a note of the value.
5. Record the dimensions in the operating log sheet and compare them to
the maximum permitted values (see Volume 010.005 Engine - Operating
Instructions).

If the measured values exceed the maximum permitted values for wear
or out-of-roundness then the cylinder liner must be replaced!

The wear is calculated by subtracting the nominal dimension from the

measured values. The out-of-roundness is the difference between the
measured values (in the transverse and longitudinal direction of the engine)
in one plane.
Work Cards, classified into sub-assemblies
32/40;48/60B;V48/60CR

2008-10-22

2 (5) 6682 050.02-02 EN

 MAN Diesel & Turbo 050.02

Top land ring/cylinder liner

6 Cylinder head bolt 9 Cylinder crankcase
7 Backing ring ST Control side

Work Cards, classified into sub-assemblies

8 Cylinder liner
Figure 1: Cylinder liner
32/40;48/60B;V48/60CR
2008-10-22

6682 050.02-02 EN 3 (5)

050.02 MAN Diesel & Turbo
Top land ring/cylinder liner

1-5 Measuring point 8 Cylinder liner

Figure 2: Cylinder liner - inserted gauge bar
Work Cards, classified into sub-assemblies
32/40;48/60B;V48/60CR

2008-10-22

4 (5) 6682 050.02-02 EN

 MAN Diesel & Turbo 050.02

Top land ring/cylinder liner

8 Cylinder liner
Figure 3: Measuring the cylinder liner
Measuring plane Cylinder diameter (mm)
Cyl. 1 Cyl. 2 Cyl. 3 etc.
trans- longitudi- trans- longitudi- trans- longitudi-

Work Cards, classified into sub-assemblies

verse nal verse nal verse nal
1 480,36 480,28
2 480,52 480,45
3 480,24 480,16
4 480,18 480,15
5 480,07 480,05
Temperature of cylinder liner during 30 °C
measurement
Running surface condition perfect
32/40;48/60B;V48/60CR

Table 1: Measurement report - Example for engine 48/60 B

2008-10-22

6682 050.02-02 EN 5 (5)

 MAN Diesel & Turbo 050.03

Cylinder liner with backing ring

Top land ring/cylinder liner

removal and installation

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the work is carried out correctly, check the components as to their
state / extent of their wear.
The cylinder liners must be removed at regular intervals to be cleaned.
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Transport device 050.209 Standard
1 Stop piece 050.209-1 Standard
1 Carrier 050.209-2 Standard
1 Removal and fitting fixture 050.085 Standard
1 Carrier 050.085-1 Standard
1 Pilot rod 034.006 Standard
1 Shackle A2.0 002.455 Standard

Work Cards, classified into sub-assemblies

2 Shackle A1.6 002.454 Standard
1 Socket spanner insert 24x12.5 001.757 Standard
1 Ratchet tool 001.521 Standard
2 Lifting eye bolt M30x2 000.146 Standard
4 Wooden support - Inventory
1 Lifting tackle - Inventory
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
2 Rope - Inventory
1 Lubricating oil, clean - Inventory
2008-10-22

Corresponding Work Cards

L48/60B

Work card Work card Work card

034.01 050.01 050.02
055.02

6704 050.03-02 EN 1 (12)

050.03 MAN Diesel & Turbo

Technical data
Top land ring/cylinder liner

Designation Information
Backing ring 830 kg
Cylinder liner 690 kg
Cylinder liner with backing ring 1520 kg

Work sequence 1 - Removing the cylinder liner with backing ring

Starting position Cooling water has been drained off completely.

Cooling water must not be pumped into the bilges or into the sewage
system! Cooling water must be pumped into its own individual tank and
be reused (cooling water treatment agent)!

Cylinder head detached, piston top land ring and piston removed with con-
necting rod small end, connecting rod shank fastened to balance weight
with locating clamp.
Work steps 1. Clean the cylinder liner (6).

2. Measure the cylinder liner (6) (see Work Card 050.02).

3. Remove all pipes and pipe unions from the backing ring (2).
4. Unscrew and remove two hexagon socket bolts (8) from the backing
ring (2). See Fig. 1.
5. Screw thrust screws (10) back in the carrier (050.085-1).
6. Fit carrier on backing ring (2) and fasten with hexagon bolts (9), making
sure that the branch socket for the pilot rod (034.006) is on the control
side (ST). See Fig. 2/I.
7. Screw in thrust screws (10) until they reach the top edge of the cylinder
liner (6). See Fig. 2/I.
Work Cards, classified into sub-assemblies

This avoids the potentially loose backing ring from falling down when
removing the drawn cylinder liner.

8. Fasten cable (11) with shackle (002.455) onto carrier and suspend from
lifting tackle.

Ensure correct suspension point for in-line engine! See Fig. 2.

2008-10-22

9. Screw pilot rod into branch socket on carrier. See Fig. 2/I.
10. Cover crankcase using suitable equipment, especially at the sides, to
prevent dirt entering from the cooling chambers in the connecting rod
L48/60B

and main bearings.

2 (12) 6704 050.03-02 EN

 MAN Diesel & Turbo 050.03

11. Pull cylinder liner (6) and backing ring (2) parallel to the centre axis of

Top land ring/cylinder liner

the cylinder up and out of the cylinder crankcase (5), using the pilot rod
to guide the cylinder liner. See figure 2/II and 3.

When removing the cylinder liner, see that the cylinder head bolts (1) are
not damaged!

12. Set cylinder liner (6) and backing ring (2) down on wooden supports (12,
approx. 140 mm high). See Fig. 4/I.
13. Screw two lifting eye bolts (000.146) into the backing ring (2). See Fig.
4/I.
14. Remove cable (11) from carrier.
15. Fasten two ropes (11) with shackle (002.454) to the lifting eye bolts and
attach to lifting tackle. Tension rope.
16. Turn thrust screws (10) back several revolutions, slacken the lifting
tackle slightly and tap backing ring (2) carefully to release it (use wooden
or copper base).
17. Detach carrier and lower backing ring (2) onto wooden supports (13).
See Fig. 4/II.

Secure the cylinder liner to keep it from tilting!

18. Detach the tool.

19. Slide the carrier (050.209-2) under the cylinder liner (6). See Fig. 5/I.
20. Place Stop (050.209-1) on the cylinder liner (6).
21. Plug carrier onto threaded rod (16), screw hexagon nut (17) onto threa-
ded rod and tighten. See Fig. 5/II.

Work Cards, classified into sub-assemblies

Ensure that the carrier is inserted correctly into the cylinder liner while
screwing the hexagon nut on!

22. Attach lifting tackle (14) to swivel eye bolt (15). See Fig. 5/II.
23. Lift cylinder liner (6) out of backing ring (2) and set down on wooden
support. See Fig. 5/III.

Secure the cylinder liner to keep it from tilting!

2008-10-22

24. Detach the tool.

L48/60B

25. Remove all O-ring seals (3 and 7).

26. Clean the cylinder liner (6).

6704 050.03-02 EN 3 (12)

050.03 MAN Diesel & Turbo

27. Blow out oil bores with compressed air.

Top land ring/cylinder liner

Work sequence 2 - Installing the cylinder liner with backing ring

Starting position Cylinder liner has been thoroughly cleaned internally and externally. The
cylinder liner has been measured (see Work Card 050.02).

Type and source of danger

Deep scoring in the piston running surface or too much wear requires
the cylinder liner to be replaced, especially if the maximum permitted
wear has been reached around the upper compression ring area in TDC
or if the ovality is excessive (see Volume 010.005 Engine - Operating
Instructions)!

Lubricating oil bores have been blown out, sealing faces have been thor-
oughly cleaned and are undamaged. Cylinder liner is set on wooden sup-
ports (about 140 mm high). Crankcase has been covered using suitable
equipment.
Work steps 1. Slide the carrier (050.209-2) under the cylinder liner (6).

2. Place stop piece (050.209-1) on the cylinder liner (6).

3. Plug carrier onto threaded rod (16), screw hexagon nut (17) onto threa-
ded rod and tighten.

Ensure that the carrier is inserted correctly into the cylinder liner while
screwing the hexagon nut on!

4. Attach lifting tackle (14) to swivel eye bolt (15).

5. Lift up the cylinder liner (6).
6. Insert new O-ring seals (3 and 7) which have been oiled with clean lubri-
cating oil in the ring grooves; in doing so, make sure that they are evenly
tensioned all around the circumference and that they are not twisted.
Work Cards, classified into sub-assemblies

7. Place the cylinder liner (6) into the backing ring (2). See Fig. 5.

Even when inserting the cylinder liner into the backing ring ensure that
the marks (M) on the cylinder liner and backing ring are exactly opposite
each other. See Fig. 6.

Secure the cylinder liner to keep it from tilting!

8. Detach transport fixture (050.209).

2008-10-22

9. Screw lifting eye bolts (000.146) into the backing ring (2). See Fig. 4.
10. Fasten two ropes (11) with shackle (002.454) to the lifting eye bolts and
L48/60B

attach to lifting tackle.

4 (12) 6704 050.03-02 EN

 MAN Diesel & Turbo 050.03

11. Pull backing ring (2) over the cylinder liner (6) from below, taking the O-

Top land ring/cylinder liner

ring seals (3 and 7) into consideration.

See that the marks (M) on backing ring and cylinder liner match up! See
Fig. 6.

12. Screw thrust screws (10) back in the carrier (050.085-1).

13. Fit carrier on backing ring (2) and fasten with hexagon bolts (9), making
sure that the branch socket for the pilot rod (034.006) is on the control
side (ST). See Fig. 4.
14. Screw in thrust screws (10) until they reach the top edge of the cylinder
liner (6). See Fig. 4.
15. Separate ropes (11) from lifting eye bolts, unscrew lifting eye bolts.
16. Fasten cable (11) with shackle (002.455) onto carrier and suspend from
lifting tackle.

Ensure correct suspension point for in-line engine! See Fig. 3.

17. Screw pilot rod into branch socket on carrier. See Fig. 3.
18. Lift and move backing ring (2) with cylinder liner (6) until it is above the
locating hole in the cylinder crankcase (5).
19. Insert backing ring (2) with cylinder liner (6) carefully into the cylinder
crankcase (5), using the pilot rod to guide the cylinder liner.

Ensure correct position of the locating pin (4) to the hole in the cylinder
crankcase! Do not damage cylinder head bolts (1) during assembly!

Work Cards, classified into sub-assemblies

20. Detach the tool.
21. Insert two hexagon socket bolts (8) through backing ring (2), screw into
cylinder crankcase (5) and tighten.
22. Remove the cover from the crankcase.
23. Measure the cylinder liner (6) (see Work Card 050.02).
24. Attach all pipes and pipe unions.
25. Once all engine parts have been installed/attached (piston, cylinder
head, etc.), fill cooling water in engine and vent cooling water pipe.
26. After completing the installation/assembly work and re-establishing the
cooling water pressure, check whether the O-ring seals (3) are OK -
2008-10-22

water must not emerge from the check bores (A and B). See Fig. 1.
27. With the engine running, check the cylinders at the check bores (A) for
L48/60B

gas leakages. See Fig. 1.

6704 050.03-02 EN 5 (12)

050.03 MAN Diesel & Turbo

Observe the running-in guidelines

Top land ring/cylinder liner

If a new cylinder liner was installed, it should be run-in according to

specifications (see Volume 010.005 Engine - Operating Instructions)!
Work Cards, classified into sub-assemblies

2008-10-22
L48/60B

6 (12) 6704 050.03-02 EN

 MAN Diesel & Turbo 050.03

Top land ring/cylinder liner

Work Cards, classified into sub-assemblies

1 Cylinder head bolt 5 Cylinder crankcase A Check bore

2 Backing ring 6 Cylinder liner B Check bore
3 O-ring seal 7 O-ring seal M Mark
2008-10-22

4 Locating pin 8 Hexagon socket bolt ST Control side

Figure 1: Cylinder liner with backing ring
L48/60B

6704 050.03-02 EN 7 (12)

050.03 MAN Diesel & Turbo
Top land ring/cylinder liner
Work Cards, classified into sub-assemblies

1 Cylinder head bolt 6 Cylinder liner ST Control side

2008-10-22

2 Backing ring 9 Hexagon bolt M24x50 I - II Work steps

4 Locating pin 10 Thrust screw
5 Cylinder crankcase 11 Rope
L48/60B

Figure 2: Removal/installation of cylinder liner with backing ring

8 (12) 6704 050.03-02 EN

 MAN Diesel & Turbo 050.03

Top land ring/cylinder liner

Work Cards, classified into sub-assemblies
2008-10-22

L48/60B

Figure 3: Removal/installation of cylinder liner with backing ring

6704 050.03-02 EN 9 (12)

050.03 MAN Diesel & Turbo
Top land ring/cylinder liner
Work Cards, classified into sub-assemblies

2 Backing ring 10 Thrust screw ST Control side

2008-10-22

4 Locating pin 11 Rope I - II Work steps

6 Cylinder liner 12 Wooden support
9 Hexagon bolt M24x50 13 Wooden support
L48/60B

Figure 4: Setting down the cylinder liner with backing ring / lowering the backing ring

10 (12) 6704 050.03-02 EN

 MAN Diesel & Turbo 050.03

Top land ring/cylinder liner

Work Cards, classified into sub-assemblies

2 Backing ring 12 Wooden support 16 Threaded rod

2008-10-22

3 O-ring seal 13 Wooden support 17 Hexagon nut M16

6 Cylinder liner 14 Lifting tackle I-III Work steps
7 O-ring seal 15 Swivel eye bolt
L48/60B

Figure 5: Removal/fitting of the cylinder liner from the backing ring

6704 050.03-02 EN 11 (12)

050.03 MAN Diesel & Turbo
Top land ring/cylinder liner
Work Cards, classified into sub-assemblies

2 Backing ring M Mark

6 Cylinder liner
Figure 6: Inserting the cylinder liner in the backing ring - Position of the markings
on backing ring and cylinder liner
2008-10-22
L48/60B

12 (12) 6704 050.03-02 EN

 MAN Diesel & Turbo 050.04

Cylinder liner

Top land ring/cylinder liner

removal and installation

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the work is carried out correctly, check the components as to their
state / extent of their wear.
The cylinder liners must be removed at regular intervals to be cleaned.
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Transport device 050.209 Standard
1 Stop piece 050.209-1 Standard
1 Carrier 050.209-2 Standard
1 Forcing-out fixture 050.205 Standard
2 Threaded rod 050.205-15 Standard
1 Carrier (lower) 050.184 Standard
1 Carrier (upper) 050.183 Standard

Work Cards, classified into sub-assemblies

1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
2 Hydraulic tensioner (hollow piston) 009.022 Standard
1 Shackle A1.6 002.454 Standard
1 Socket spanner insert 24x12.5 001.757 Standard
1 Ratchet tool 001.521 Standard
1 Lifting tackle - Inventory
1 Combination spanner (set) - Inventory
1 Rope - Inventory
1 Lubricating oil, clean - Inventory
2008-10-22

Corresponding Work Cards

L48/60B

Work card Work card Work card

009.03 009.05 034.01
050.01 050.02 055.02

6704 050.04-03 EN 1 (15)

050.04 MAN Diesel & Turbo

Technical data
Top land ring/cylinder liner

Designation Information
Cylinder liner 690 kg

Work sequence 1 - Removing the cylinder liner

Starting position Cooling water has been drained off completely.

Cooling water must not be pumped into the bilges or into the sewage
system! Cooling water must be pumped into its own individual tank and
be reused (cooling water treatment agent)!

Cylinder head detached, piston top land ring and piston removed with con-
necting rod small end, connecting rod shank fastened to balance weight
with locating clamp. Running gear is turned such that cylinder liner can be
easily accessed from below.
Work steps 1. Clean the cylinder liner (5).

2. Measure the cylinder liner (5) (see Work Card 050.02).

3. Fasten cable (7) with shackle (002.454) on lifting eye bolt of the lower
carrier (050.184). Direct the rope through the cylinder liner (5) and hook
onto lifting tackle.
4. Introduce lower carrier carefully through the drive casing opening, pull
up and insert in the cylinder liner (5). Hold the carrier in this position. See
Fig. 2.
5. Screw threaded rods (050.205-15) into the lower carrier until they abut.
See Fig. 2.
6. Insert upper carrier (050.183) over threaded rods and place on backing
ring (2). See Fig. 3.
7. Insert hydraulic hollow piston tensioners (009.022) through threaded
Work Cards, classified into sub-assemblies

rods and place on the upper carrier. See Fig. 3.

8. Screw hexagon nuts (8) hand-tight onto threaded rods until they come
to rest on hydraulic hollow piston tensioners.
9. Unhook cable (7) from bottom carrier and from lifting tackle and remove
from drive chamber.
10. Cover crankcase using suitable equipment, especially at the sides, to
prevent dirt entering from the cooling chambers in the connecting rod
and main bearings.
11. Connect high-pressure hoses (009.306) to hydraulic hollow piston ten-
sioners and to high-pressure pump (009.341). Connect an oil pressure
gauge (0 - 400 bar) to the high-pressure pump.
2008-10-22

12. Set high-pressure pump in operation (see Work Card 009.03) and pump
hydraulic hollow piston tensioners slowly until the cylinder liner (5) relea-
ses from cylinder crankcase (4). See Fig. 4.
L48/60B

2 (15) 6704 050.04-03 EN

 MAN Diesel & Turbo 050.04

Observe the oil pressure gauge during the pumping (max. working

Top land ring/cylinder liner

pressure: 700 bar)!

13. Release the pressure.

14. Separate high-pressure hose from hydraulic hollow piston tensioner and
high-pressure pump.
15. Detach or remove tool.
16. Place stop piece (050.209-1) on the cylinder liner (5). See Fig. 5/I.
17. Introduce carrier (050.209-2) carefully through opening in drive chamber
and fit onto threaded rod (9). Screw the hexagon nuts (10) onto the
threaded rod and tighten them. See Fig. 5/II.

Ensure that the carrier is inserted correctly into the cylinder liner while
screwing the hexagon nut on!

18. Attach lifting tackle (11) to swivel eye bolt (12). See Fig. 6/I.
19. Pull the cylinder liner (5) parallel to the cylinder centre axis upwards out
the cylinder crankcase (4). See Fig. 6/II.

When removing the cylinder liner, see that the cylinder head bolts (1) are
not damaged!

20. Set aside cylinder liner (5) on wooden supports (13, about 140 mm high).
See Fig. 7.

Secure the cylinder liner to keep it from tilting!

21. Detach the tool. Work Cards, classified into sub-assemblies

22. Remove all O-ring seals (3 and 6).
23. Clean the cylinder liner (5).
24. Blow out oil bores with compressed air.

Work sequence 2 - Installing the cylinder liner

Starting position Cylinder liner has been thoroughly cleaned internally and externally. The
cylinder liner has been measured (see Work Card 050.02).
2008-10-22

L48/60B

6704 050.04-03 EN 3 (15)

050.04 MAN Diesel & Turbo

Type and source of danger

Top land ring/cylinder liner

Deep scoring in the piston running surface or too much wear requires
the cylinder liner to be replaced, especially if the maximum permitted
wear has been reached around the upper compression ring area in TDC
or if the ovality is excessive (see Volume 010.005 Engine - Operating
Instructions)!

Lubricating oil bores have been blown out, sealing faces have been thor-
oughly cleaned and are undamaged. Cylinder liner is set on wooden sup-
ports (about 140 mm high).
Crankcase has been covered using suitable equipment.
Work steps 1. Slide the carrier (050.209-2) under the cylinder liner (5).

2. Place stop piece (050.209-1) on the cylinder liner (5).

3. Plug carrier onto threaded rod (9), screw hexagon nut (10) onto threaded
rod and tighten. See Fig. 8.

Ensure that the carrier is inserted correctly into the cylinder liner while
screwing the hexagon nut on!

4. Attach lifting tackle (11) to swivel eye bolt (12).

5. Lift up the cylinder liner (5).
6. Insert new O-ring seals (3 and 6) which have been oiled with clean lubri-
cating oil in the ring grooves; in doing so, make sure that they are evenly
tensioned all around the circumference and that they are not twisted.
7. Guide the cylinder liner (5) over the locating hole in the cylinder crank-
case (4). See Fig. 6/II.
8. Insert the cylinder liner (5) carefully parallel to the cylinder centre axis
into the backing ring (2) and the cylinder crankcase (4). See Fig. 9.
Work Cards, classified into sub-assemblies

See that the marks (M) on backing ring and cylinder liner match up! See
figure 9.
Do not damage cylinder head bolts (1) during assembly!

9. Detach or remove transport fixture (050.209).

10. Remove the cover from the crankcase.
11. Measure the cylinder liner (5) (see Work Card 050.02).
12. Once all engine parts have been installed/attached (piston, cylinder
head, etc.), fill cooling water in engine and vent cooling water pipe.
13. After completing the installation/assembly work and re-establishing the
cooling water pressure, check whether the O-ring seals (3) are OK -
2008-10-22

water must not emerge from the check bores (A and B). See Fig. 1.
14. With the engine running, check the cylinders at the check bores (A) for
L48/60B

gas leakages. See Fig. 1.

4 (15) 6704 050.04-03 EN

 MAN Diesel & Turbo 050.04

Observe the running-in guidelines

Top land ring/cylinder liner

If a new cylinder liner was installed, it should be run-in according to
specifications (see Volume 010.005 Engine - Operating Instructions)!

Work Cards, classified into sub-assemblies

2008-10-22

L48/60B

6704 050.04-03 EN 5 (15)

050.04 MAN Diesel & Turbo
Top land ring/cylinder liner
Work Cards, classified into sub-assemblies

1 Cylinder head bolt 6 O-ring seal

2 Backing ring A Check bore
3 O-ring seal B Check bore
2008-10-22

4 Cylinder crankcase M Mark

5 Cylinder liner ST Control side
Figure 1: Cylinder liner
L48/60B

6 (15) 6704 050.04-03 EN

 MAN Diesel & Turbo 050.04

Top land ring/cylinder liner

2 Backing ring 7 Rope
5 Cylinder liner ST Control side

Work Cards, classified into sub-assemblies

Figure 2: Removing the cylinder liner
2008-10-22

L48/60B

6704 050.04-03 EN 7 (15)

050.04 MAN Diesel & Turbo
Top land ring/cylinder liner

2 Backing ring 8 Hexagon nut M30

4 Cylinder crankcase ST Control side
Work Cards, classified into sub-assemblies

5 Cylinder head
Figure 3: Removing the cylinder liner

2008-10-22
L48/60B

8 (15) 6704 050.04-03 EN

 MAN Diesel & Turbo 050.04

Top land ring/cylinder liner

2 Backing ring 8 Hexagon nut M30
4 Cylinder crankcase ST Control side

Work Cards, classified into sub-assemblies

5 Cylinder liner
Figure 4: Removing the cylinder liner
2008-10-22

L48/60B

6704 050.04-03 EN 9 (15)

050.04 MAN Diesel & Turbo
Top land ring/cylinder liner

5 Cylinder liner ST Control side

9 Threaded rod I - II Work steps
10 Hexagon nut M16
Figure 5: Removing the cylinder liner
Work Cards, classified into sub-assemblies

2008-10-22
L48/60B

10 (15) 6704 050.04-03 EN

 MAN Diesel & Turbo 050.04

Top land ring/cylinder liner

Work Cards, classified into sub-assemblies

1 Cylinder head bolt 11 Lifting tackle

2008-10-22

2 Backing ring 12 Swivel eye bolt

4 Cylinder crankcase ST Control side
5 Cylinder liner I - II Work steps
L48/60B

Figure 6: Removing / installing the cylinder liner

6704 050.04-03 EN 11 (15)

050.04 MAN Diesel & Turbo
Top land ring/cylinder liner

3 O-ring seal 10 Hexagon nut M16

5 Cylinder liner 11 Lifting tackle
6 O-ring seal 12 Swivel eye bolt
9 Threaded rod 13 Wooden support
Figure 7: Setting the cylinder liner down
Work Cards, classified into sub-assemblies

2008-10-22
L48/60B

12 (15) 6704 050.04-03 EN

 MAN Diesel & Turbo 050.04

Top land ring/cylinder liner

Work Cards, classified into sub-assemblies

3 O-ring seal 11 Lifting tackle

5 Cylinder liner 12 Swivel eye bolt
6 O-ring seal 13 Wooden support
9 Threaded rod M Mark
10 Hexagon nut M16
2008-10-22

Figure 8: Installation of the cylinder liner - Position of the stop piece for marking
on the cylinder liner
L48/60B

6704 050.04-03 EN 13 (15)

050.04 MAN Diesel & Turbo
Top land ring/cylinder liner
Work Cards, classified into sub-assemblies

1 Cylinder head bolt 9 Threaded rod

2008-10-22

2 Backing ring 10 Hexagon nut M16

3 O-ring seal 11 Lifting tackle
4 Cylinder crankcase M Mark
L48/60B

5 Cylinder liner ST Control side

6 O-ring seal
Figure 9: Installation of the cylinder liner

14 (15) 6704 050.04-03 EN

 Top land ring/cylinder liner
050.04

15 (15)
Work Cards, classified into sub-assemblies
L48/60B

6704 050.04-03 EN
MAN Diesel & Turbo
2008-10-22
 MAN Diesel & Turbo 050.05

Cylinder liner

Top land ring/cylinder liner

honing

Summary
Carry out the work in good time according to the maintenance schedule,
check the components as to their state / extent of their wear, restore running
surface to operational state, ensure the tasks are carried out correctly.
The cylinder liners are to be checked at regular intervals and the original
running surface geometry is to be restored to how it was.
The work/work steps include:
Honing the reversing area of the piston rings,
Honing the entire running surface.
Tools/aids required
Quantity Designation Number Status
1 Honing device 050.087 Option
1 Rope pull with remote control 050.087-1 Option
1 Cross tie 050.087-2 Option
2 Extension pipe 050.087-3 Option
2 Extension pipe 050.087-4 Option
2 Intermediate piece 050.087-5 Option
4 Stop for stroke limiter 050.087-6 Option
1 Guide arm with control valve 050.087-7 Option
1 Extension 050.087-8 Option
1 Drive unit 050.087-9 Option
1 Air connection with universal joint 050.087-10 Option
1 Honing head 050.087-11 Option

Work Cards, classified into sub-assemblies

1 Tank 050.087-12 Option
1 Funnel 050.087-13 Option
1 Additional mass 050.087-14 Option
2 Spring strap 050.087-16 Option
1 Air supply station 050.087-17 Option
1 injection nozzle 050.087-20 Option
3 Cleaning brush 050.087-21 Option
2 Threaded piece 050.087-22 Option
1 Oil for air oiler 050.087-23 Option
L48/60;L51/60DF

1 Support 050.087-24 Option

2008-07-23

1 Honing stone (set) for laser-hardened cylinder lin- - Option

ers
1 Honing stone (set) for unhardened cylinder liners - Option
1 Collecting tank - Inventory
1 Lift gear with rope - Inventory

6644 050.05-01 EN 1 (10)

050.05 MAN Diesel & Turbo

Quantity Designation Number Status

Top land ring/cylinder liner

1 Cleaning agent (diesel oil / kerosene) - Inventory

Corresponding Work Cards

Work card Work card Work card
034.01 050.02

Preliminary remark
Cylinder liners must be rehoned when the piston rings are replaced or once
the maintenance interval has elapsed. Honing restores the original surface
finish of the running surface of the liner. This roughness is necessary to
ensure a sufficiently thick and adhesive lubricating film. While for the most
part the microgeometry can be returned to its original state, it is not possible
to influence the wear profile, i.e. the macrogeometry of the cylinder liner.
Typically during the first work step the TDC area of the piston rings is honed.
In the second work step, work is performed to the entire piston ring running
surface.
The honing of the cylinder liner is not very time-consuming. Operating the
device and the work itself, as well as correctly assessing the results, how-
ever, does require concentration and a certain amount of experience. We
thus recommend having this task performed at least once for instruction
purposes by MAN Diesel & Turbo SE staff.
Structure and mode of operation
In essence, the honing device consists of:
▪ the rope pull (1) - see figure 1
▪ the drive unit (15)
▪ the honing head (20)
▪ the lubrication installation (17 and 24)
Work Cards, classified into sub-assemblies

▪ the guide elements (2 to 4, 6 to 8 and 10) and

▪ the portable air supply station (23).
Drive and control of the fixture are operated on compressed air (pmax = 18
bar).
The fittings of the air supply station (23) serve for air filtering and water
removal as well as the addition of oil. See Fig. 2.
Use the control valves on the compressed air outlets to make a pre-setting
of the hoisting speed and of the honing head speed (20) as well as pre-
setting of the pressure of the grinding element (18). The rope pull contol
engine is activated for lifting and lowering movements using the buttons on
L48/60;L51/60DF

the remote control (5).

2008-07-23

Using the ball cock on the guide arm (7) the drive unit (15) is switched on
and off. The pressing power of the grinding element is regulated by means
of the slide valve located next to it.
Using the lubrication installation, consisting of tank (24) and injection noz-
zles (17) the grinding area can be lubricated and cleansed of abrasion par-
ticles. The lubricating -/cleaning medium is collected in a funnel (22), fixed

2 (10) 6644 050.05-01 EN

 MAN Diesel & Turbo 050.05

to the lower edge of the cylinder liner (14), and transported to the outside

Top land ring/cylinder liner

from there. When switching from grinding strips to cleaning brushes (19), it
is possible to mechanically clean the cylinder liner (14).
The fixture can be set for various diameters and adapted to suit various
stroke lengths by using extension pipes and intermediate pieces.

Work Cards, classified into sub-assemblies

L48/60;L51/60DF
2008-07-23

6644 050.05-01 EN 3 (10)

050.05 MAN Diesel & Turbo
Top land ring/cylinder liner
Work Cards, classified into sub-assemblies

1 Rope pull 13 Cylinder head bolt

2 Cross tie 14 Cylinder liner
3 Extension pipe 15 Drive unit
4 Stop for stroke limiter 16 Air connection with universal joint
5 Remote control 17 injection nozzles
6 Extension pipe 18 Grinding element with honing
stones
7 Guide arm with control valves 19 Cleaning brushes
L48/60;L51/60DF

8 Threaded piece 20 Honing head

9 Additional mass 21 Spring strap
2008-07-23

10 Intermediate piece 22 Funnel

11 Extension 23 Air supply station
12 Support 24 Tank
Figure 1: Pneumatic honing device when mounted

4 (10) 6644 050.05-01 EN

 MAN Diesel & Turbo 050.05

Top land ring/cylinder liner

23 Air supply station A Compressed air supply
26 Filter/water separator B Compressed air to rope-pull motor
(hoisting speed)
27 Oiler C Compressed air to drive unit (rotational
speed)
28 Pressure regulating valve D Compressed air to guide arm/honing
head (contact pressure)
29 Pressure gauge
Figure 2: Air supply station (side view and view from above)

Work sequence 1 - Honing the piston ring reversal point in the top dead centre (nip area)
Starting position Cylinder head removed. Piston with small end removed. Connecting rod
shank fastened on balance weight by means of locating clamp and turned
to side so that funnel (22) can be mounted. See figure 3, Cylinder liner

Work Cards, classified into sub-assemblies

cleaned (carbon residue and lubricant free) and measured accurately (cyl-
inder liner has not yet reached maximum wear, for threshold values see
Operating Instructions /Technical Data). Exits of channels for cylinder lubri-
cant closed off with kneadable compound (plasticine) or heavy grease.
Crank mechanism covered with suitable material. Funnel fastened to bot-
tom of cylinder liner and hose (31) directed outwards into collector (32).
Honing device set up and adjusted according to separate description.

The honing of the reversing range of the piston rings is to be executed

as the first operation using the short honing sticks before the later honing
of the entire running surface of the piston rings.
L48/60;L51/60DF

Work steps 1. Clamp honing stones, about 20 mm long, in each grinding element (18)
2008-07-23

at the same height in the area of centre of grinding element.

6644 050.05-01 EN 5 (10)

050.05 MAN Diesel & Turbo

The short honing stones can be produced by breaking long honing

Top land ring/cylinder liner

elements: Notch using a steel hacksaw blade, clamp in vice and break
off.

2. Guide honing head (20) carefully into cylinder liner (14).

3. Adjust the stroke movement of the honing head in cylinder liner with
stops (4) so that the top edge of the honing stones is about 10 mm above
the top dead centre of the first piston ring and the resultant stroke is
60-80 mm.
4. Align spray nozzles (17) so that lubricant coats the honing area on exit-
ing.
5. Close the shut-off cock for the tank (24) and fill it with lubricant (diesel
oil, gas oil or petroleum).

No smoking, do not use an open flame - fire hazard!

6. Open the tank's shut-off cock. Check that lubricant is discharged from
the spray nozzles and is coating the honing area. Check that lubricant
is reaching the collecting tank (32) via the funnel (22) without leaking.

Honing a cylinder liner needs about 4-6 litres of lubricant. Always make
sure a sufficient quantity of lubricant is used when performing the honing
process. It is advantageous to wash away abraded material immediately.
The lubricant may be used several times if it flows into the collecting tank
through a fleece mat.
Clean lubricant/cleaning agent must be used for subsequent cleaning of
the cylinder liner following the actual honing process.

7. Bring the honing device into operation using a tried-and-tested setting.

Work Cards, classified into sub-assemblies

Bring the honing stones into contact. Hone with short up and down
strokes (each about 20-30 double strokes) until the short honing stones
are consumed. This lasts about 1-1.5 minutes. Speed of the honing head
should be about 35 1/min, contact pressure 2.5 bar. Due to the short
stroke, only a shallow honing angle is achieved. If honing marks start to
appear in the TDC area of the first piston ring, cancel the honing proc-
ess. If a rounded ledge is still present at the reversal point of the first
piston ring, this is permissible. If required, the operation must be repea-
ted using a second set of short honing stones.
8. As soon as a satisfactory surface condition has been established, stop
the honing process and cut off the lubricant inlet.
9. Move the honing head out of the cylinder liner and secure in the upper
L48/60;L51/60DF

position.
2008-07-23

Work sequence 2 - Honing the entire running surface of the cylinder liner
Starting position Reversal area of piston rings at TDC honed, or cylinder liner available with
low wear shoulders in the TDC area.

6 (10) 6644 050.05-01 EN

 MAN Diesel & Turbo 050.05

This task is intended to roughen up the upper area of the cylinder liner

Top land ring/cylinder liner

on which no further honing grooves are visible after many operating
hours. The lower section should be honed as little as possible, but two
double strokes must be directed along the entire running surface of the
piston rings once this operation is complete. In case of laser-hardened
cylinder liners, pay attention to a fluent transition of the hardened running
surfaces to the underlying soft part of the cylinder liner.

Work steps 1. Mount six long honing stones on honing head (20).

2. Insert the honing head carefully into the cylinder liner (14).
3. Set stroke movement of the honing head with stops (4) such that the
honing stones move in their upper half of the stroke range of the piston
(running range of the piston rings) i.e. the upper and lower edges of the
stone overrun about 100 mm over it.
4. Align spray nozzles (17) so that lubricant coats the honing area on exit-
ing. Fill the tank (24) with lubricant (diesel oil, gas oil or petroleum).

No smoking, do not use an open flame - fire hazard!

5. Open the tank's shut-off cock. Check that lubricant is discharged from
the spray nozzles and is coating the honing area. Check that lubricant
is reaching the collecting tank (32) via the funnel (22) without leaking.

Honing a cylinder liner needs about 10 litres of lubricant.

Always make sure a sufficient quantity of lubricant is used when
performing the honing process. It is advantageous to wash away
abraded material immediately.

6. Bring the honing device into operation using a tried-and-tested setting.

Bring the honing stones into contact. Honing a cylinder liner needs

Work Cards, classified into sub-assemblies

about 75-80 up and down movements each at a hoisting speed of about
10 double strokes per minute. The total honing time for a cylinder liner
is normally about 4-8 minutes, where the higher values are valid for the
laser hardened cylinder liners.
Speed of the honing head - see Table 2, contact pressure 2.5 bar. Con-
trol the stroke movement so that a honing angle (α) of 45-60° (22.5-30°
to the horizontal) is achieved. See template in figure 4, A depth of surface
Rz of 10-15 µm for laser-hardened cylinder liners and for normal cylinder
liners is to be aimed at.
7. Stop fixture. Evaluate roughness, honing angle and honing pattern. See
Table 1.
L48/60;L51/60DF

If the evaluation proves to be satisfactory, execute two double strokes

over the entire running surface of piston rings. In doing so, adjust the
2008-07-23

stops (4) so that the honing stones run partially out of the cylinder liner.
The honing head must however not collide with the funnel(22).
8. After honing, measure the cylinder liner (see Work Card 050.02). If the
maximum wear is exceeded in the top dead centre of the first piston ring
or the maximum allowable radial out-of-roundness is exceeded (for lim-

6644 050.05-01 EN 7 (10)

050.05 MAN Diesel & Turbo

its see Operating instructions /Technical data) the cylinder liner must be
Top land ring/cylinder liner

renewed.
9. Change grinding element for hard cleaning brushes (19).
10. Run in honing head and, with reduced contact pressure of 0.5-1 bar and with
unchanged speed and hoisting speed, carefully remove all grinding res-
idues carefully (loosen/flush). Repeat the procedure using soft cleaning
brushes if necessary. Use plenty of lubricant when carrying out the
cleaning. Perform roughly 50 double strokes in total. Perform the last
cycle using fresh lubricant. No grinding residues should be left behind.
Check with the finger tips!
11. Remove the honing device. Move to next cylinder or clean the device
and store it safely, or stow it away in a packing box.
12. Remove kneading compounds or grease plugs from the outlets for cyl-
inder lubrication.
13. Separate lube oil pipes of the cylinder lubrication from cylinder crank-
case, blow bores for cylinder lubrication free using compressed air.
Connect lube oil pipes again.
14. Detach funnel (22), ensuring that no impurities enter the running gear.
15. Then clean the cylinder liner manually.

After the installation of the piston and the fitting of the cylinder cover,
pay attention to the instructions for comissioning the engine (see
Operating Instructions) at the time of the start-up.
Work Cards, classified into sub-assemblies
L48/60;L51/60DF

2008-07-23

8 (10) 6644 050.05-01 EN

 MAN Diesel & Turbo 050.05

Top land ring/cylinder liner

14 Cylinder liner 32 Collecting tank
22 Funnel α Honing angle
31 Hose
Figure 3: Honing of cylinder liner (starting position)

Work Cards, classified into sub-assemblies

As an alternative
Characteristic Test/measurement
1 2
Roughness Rz, measured at Measuring device Technovit imprint Finger nail test and visual
the TDC and mid-stroke (hardened plastic) - allows assessment
ranges of piston ring 1 subsequent assessment of
all the three parameters
Honing angle Protractor Angle template
Honing pattern, i.e. groove Judging fax film Observation with a magni-
profile and distribution, occur- imprints fier,
rence of "metal jackets" (lubri- (Cellulose acetate film) visual assessment/
cation and breakouts along the under the microscope Experience necessary
L48/60;L51/60DF

honing marks), (50-times magnification)

Unhoned "holes" remain
2008-07-23

Table 1: Assessment of running surface of cylinder liners following honing

Number of double Time per double
Lifting height Speed Number of double
Type strokes stroke *
(mm) (RPM) strokes required
per min (s)
48/60 700 23 10 6 70-75

6644 050.05-01 EN 9 (10)

050.05 MAN Diesel & Turbo

Number of double Time per double

Lifting height Speed Number of double
Top land ring/cylinder liner

Type strokes stroke *

(mm) (RPM) strokes required
per min (s)
* Valid for a honing angle (α) of 45°
Table 2: Processing parameters for the honing of cylinder liners
Work Cards, classified into sub-assemblies
L48/60;L51/60DF

2008-07-23

X 135° ≙ 45° honing angle Y 120° ≙ 60° honing angle

Figure 4: Auxiliary material required to manufacture a honing angle template

10 (10) 6644 050.05-01 EN

 MAN Diesel & Turbo 050.06

Sealing groove in the top land ring

Top land ring/cylinder liner

grinding

Summary
Check components for condition/wear condition, prevent operating prob-
lems/damage.
The sealing groove in the top land ring must be checked every time the
cylinder head is removed, and, if necessary, re-worked.
The work includes:
Grinding the sealing groove.
Tools/aids required
Quantity Designation Number Status
1 Grinding-in fixture 050.163 Option
1 Bracket 050.163-1 Option
1 Grinding wheel 050.163-2 Option
1 Sliding calliper - Inventory
1 Depth gauge - Inventory
1 Grinding paste, silicon-free - Inventory

Corresponding Work Cards

Work card Work card Work card
055.06

Work sequence - Grinding the sealing groove in the top land ring
Starting position Cylinder head and sealing ring are removed.

Work Cards, classified into sub-assemblies

Work steps 1. Clean the sealing groove (B) in the top land ring (3). See Fig. 2.

2. Fasten holder (050.163-1) to grinding wheel (050.163-2). See Fig. 3.

The grinding wheel can be used for the top land ring and cylinder head!
The correct side of the grinding wheel can be seen in figure 3!

3. Apply grinding paste to the grinding wheel.

Do not apply too much grinding paste.

48/60B;V48/60CR
2007-05-07

4. Fit grinding tool (050.163) on top land ring (3). See Fig. 3.
5. Move grinding tool up and down, lift occasionally, so that the grinding
paste can be redistributed.

6704 050.06-01 EN 1 (5)

050.06 MAN Diesel & Turbo

Grind as little as possible, because a flat surface is difficult to produce

Top land ring/cylinder liner

by grinding! If necessary, the top land ring should be machined on a

lathe!

6. Remove the grinding tool after the grinding is over.

7. Clean sealing groove (B) and top land ring (3) thoroughly of grinding
residues.
8. Dismantle grinding tool and clean it.
9. Measure top land ring (3), sealing ring (2) and cylinder head (1) and
determine Clearance (A). See Fig. 1.

For reground sealing groove (B) the clearance (A) between top land ring
and cylinder head must be at least 0.5 mm!
Work Cards, classified into sub-assemblies
48/60B;V48/60CR

2007-05-07

2 (5) 6704 050.06-01 EN

 MAN Diesel & Turbo 050.06

Top land ring/cylinder liner

Work Cards, classified into sub-assemblies
48/60B;V48/60CR
2007-05-07

1 Cylinder head 3 Top land ring

2 Sealing ring A Clearance
Figure 1: Cylinder head and top land ring

6704 050.06-01 EN 3 (5)

050.06 MAN Diesel & Turbo
Top land ring/cylinder liner

3 Top land ring 6 Backing ring

4 Cylinder head bolt B Sealing groove
5 Cylinder liner
Figure 2: Sealing groove in the top land ring
Work Cards, classified into sub-assemblies
48/60B;V48/60CR

2007-05-07

4 (5) 6704 050.06-01 EN

 MAN Diesel & Turbo 050.06

Top land ring/cylinder liner

3 Top land ring 6 Backing ring
4 Cylinder head bolt 7 Wing screw M10x50
Figure 3: Top land ring - Grinding the sealing groove

Work Cards, classified into sub-assemblies

48/60B;V48/60CR
2007-05-07

6704 050.06-01 EN 5 (5)

MAN Diesel & Turbo 055

Cylinder head/Valve seat rings/Safety valve

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.10-1 EN 1 (2)

 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.10-1 EN

 MAN Diesel & Turbo 055.01

Cylinder head bolts

Cylinder head/Valve seat rings/Safety valve

inspection, loosening and tightening

Summary
Clamp and release important threaded connections with the correct values,
ensure correct execution of work.
Cylinder head bolts should be inspected at regular intervals by using
hydraulic tensioners.
The work/work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Tension screw 055.127 Standard
2 Thrust piece 055.126 Standard
2 Thrust piece 055.125 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
1 Combination spanner (set) 009.231 Option
2 Hydraulic tensioner 009.063 Standard
2 Hydraulic tensioner 009.062 Standard
1 Tommy bar, 8 000.262 Option

Work Cards, classified into sub-assemblies

Corresponding Work Cards
Work card Work card Work card
000.30 000.32 000.33
009.03 009.05 009.13
112.01

Work sequence 1 - Checking the cylinder head bolts

48/60B;48/60CR;51/60DF

Starting position Rocker arm casing is detached.

Work steps 1. Remove protection caps (9) for cylinder head bolts (11).
2010-03-24

2. Clean the threads of the cylinder head bolts (11).

3. Screw tension bolts (055.127) in until they fit on cylinder head bolts (bolts
4 and 8). See Figs. 2 and 4.
4. Place the thrust pieces (055.126) over the tension screws and nuts (10).
5. Screw hydraulic tensioners (009.063) onto tension screws.

6707 055.01-01 EN 1 (9)

 055.01 MAN Diesel & Turbo

6. Insert pressure pieces (055.125) over cylinder head bolts (bolts 2 and 6) and
Cylinder head/Valve seat rings/Safety valve

nuts (10). See Figs. 2 and 4.

7. Screw hydraulic tensioner onto cylinder head bolts (009.062), ensuring
that pressure pieces are centred by the hydraulic tensioner.
8. Turn back hydraulic tensioners (009.063 and 009.062) by turn-back
angle (see Work Card 000.30).
9. Connect high pressure hoses (009.306) to hydraulic tensioners and to
high pressure pump (009.342).
10. Set the high pressure pump in operation (see Work Card 009.03) and
close the gap resulting from unscrewing.

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

11. Pump the hydraulic tensioners until the nuts (10) can be released.

Release pressure
The pressure may be max. 7% below or max. 5% above the control
pressure (850 bar) (see Work Card 000.30)!
If the release pressure is more than 7 % less than the reference pressure,
release all cylinder head bolts and re-tension subsequently (see work
sequence 2 and 3)!

Do not damage hydraulic tensioners!

While pumping up, watch the stroke controls (13) of the hydraulic
tightening devices! The hydraulic tensioners must only be pumped up to
the point where the markings (M) on the stroke controls reach the upper
edge of the threaded stop ring (14)! Otherwise the hydraulic tightening
Work Cards, classified into sub-assemblies

devices will be damaged! See Fig. 4.

12. Note releasing pressure and compare with control pressure (850 bar).
13. Regulate high pressure pump to specified pressure (850 bar).
14. Hand-tighten nuts (10) using Tommy bar (000.262) through cut-out in
the pressure pieces.
15. Release the pressure, uncouple the high pressure hoses from the
48/60B;48/60CR;51/60DF

hydraulic tensioners.

Resetting the hydraulic tensioners

The hydraulic tensioners return to the zero position automatically by the
compression springs (resetting duration about 2 to 3 minutes). However,
2010-03-24

the high-pressure pump must be connected, and its pressure-relief valve

must be open (see Work Card 009.03).

16. Detach the tightening devices.

2 (9) 6707 055.01-01 EN

 MAN Diesel & Turbo 055.01

17. Reset tension screws (055.127), pressure pieces (055.126) and

Cylinder head/Valve seat rings/Safety valve

hydraulic tensioners (009.063) to cylinder head bolts (bolts 1 and 5). See
points 3 to 5 / see figures 3 and 4.
18. Reset pressure pieces (055.125) and hydraulic tensioners (009.062) on
cylinder head bolts (bolts 3, and 7). See point 6 and 7 / see figure 3 and 4.
19. Check cylinder head bolts (bolts 1, 3, 5 and 7) in the same manner. See
point 8 to 14.
20. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.
21. Detach the tightening devices.
22. Fit protection caps (9) on cylinder head bolts (11).

Work sequence 2- Releasing the cylinder head bolts

Starting position Rocker arm casing is detached.

Work steps 1. Removing push rods (see Work Card 112.01).

2. Remove protection caps (9) for cylinder head bolts (11).

3. Clean the threads of the cylinder head bolts (11).
4. Screw tension bolts (055.127) in until they fit on cylinder head bolts (bolts
4 and 8). See figures 2 and 4.
5. Place the thrust pieces (055.126) over the tension screws and nuts (10).
6. Screw hydraulic tensioners (009.063) onto tension screws.
7. Insert pressure pieces (055.125) over cylinder head bolts (bolts 2 and 6) and
nuts (10). See Figs. 2 and 4.
8. Screw hydraulic tensioner onto cylinder head bolts (009.062), ensuring
that pressure pieces are centred by the hydraulic tensioner.
9. Turn back hydraulic tensioners (009.063 and 009.062) by turn-back
angle (see Work Card 000.30).

Work Cards, classified into sub-assemblies

10. Connect high pressure hoses (009.306) to hydraulic tensioners and to
high pressure pump (009.342).
11. Set the high pressure pump in operation (see Work Card 009.03) and
close the gap resulting from unscrewing.

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
48/60B;48/60CR;51/60DF

hydraulic tightening devices are damaged. This could inflict personal

injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

12. Pump the hydraulic tensioners until the nuts (10) can be released.
2010-03-24

Release pressure
The pressure may be max. 7% below or max. 5% above the control
pressure (850 bar) (see Work Card 000.30)!

6707 055.01-01 EN 3 (9)

 055.01 MAN Diesel & Turbo

Do not damage hydraulic tensioners!

Cylinder head/Valve seat rings/Safety valve

While pumping up, watch the stroke controls (13) of the hydraulic
tightening devices! The hydraulic tensioners must only be pumped up to
the point where the markings (M) on the stroke controls reach the upper
edge of the threaded stop ring (14)! Otherwise the hydraulic tightening
devices will be damaged! See Fig. 4.

13. Note releasing pressure and compare with control pressure (850 bar).
14. Turn back nuts (10) by using Tommy bar (000.262) through cut-out in
the pressure pieces (for turn-back angle see Work Card 000.30).
15. Release the pressure, uncouple the high pressure hoses from the
hydraulic tensioners.

Resetting the hydraulic tensioners

The hydraulic tensioners return to the zero position automatically by the
compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its pressure-relief valve
must be open (see Work Card 009.03).

16. Detach the tightening devices.

17. Reset tension screws (055.127), pressure pieces (055.126) and
hydraulic tensioners (009.063) to cylinder head bolts (bolts 1 and 5). See
points 4 to 6 / see figures 3 and 4.
18. Reset pressure pieces (055.125) and hydraulic tensioners (009.062) on
cylinder head bolts (bolts 3, and 7). See point 7 and 8 / see figure 3 and 4.
19. Release cylinder head bolts (bolts 1, 3, 5 and 7) in the same manner.
See point 9 to 14.
20. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.
21. Detach the tightening devices.
Work Cards, classified into sub-assemblies

Work sequence 3 - Tightening the cylinder head bolts

Starting position Nuts are screwed on and tightened by hand. Threads of the cylinder head
bolts are cleaned.

Prerequisite for correct tightening of a bolted connection

Prerequisite for correct tightening of a bolted connection is a pressure
gauge with an accurate read-out! If in doubt, test the pressure gauge
48/60B;48/60CR;51/60DF

with an equivalent pressure gauge!

Work steps 1. Screw tension bolts (055.127) in until they fit on cylinder head bolts (bolts
1 and 5). See Figs. 3 and 4.
2. Place the thrust pieces (055.126) over the tension screws and nuts (10).
2010-03-24

3. Screw hydraulic tensioners (009.063) onto tension screws.

4. Insert pressure pieces (055.125) over cylinder head bolts (bolts 3 and 7) and
nuts (10). See Figs. 3 and 4.

4 (9) 6707 055.01-01 EN

 MAN Diesel & Turbo 055.01

5. Screw hydraulic tensioner onto cylinder head bolts (009.062), ensuring

Cylinder head/Valve seat rings/Safety valve

that pressure pieces are centred by the hydraulic tensioner.
6. Connect high pressure hoses (009.306) to hydraulic tensioners and to
high pressure pump (009.342).
7. Put high pressure pump in operation (see Work Card 009.03) and clamp
cylinder head bolts with clamping pressure (900 bar).

Danger area in axial direction!

Powerful forces can be released in the axial direction if the high-pressure
hydraulic tightening devices are damaged. This could inflict personal
injury and cause material damage. You should therefore make sure when
working with hydraulic tightening devices that all persons stay clear of
the extended axis of the tightening device.

Do not damage hydraulic tensioners!

While pumping up, watch the stroke controls (13) of the hydraulic
tightening devices! The hydraulic tensioners must only be pumped up to
the point where the markings (M) on the stroke controls reach the upper
edge of the threaded stop ring (14)! Otherwise the hydraulic tightening
devices will be damaged! See Fig. 4.

8. Hand-tighten nuts (10) using Tommy bar (000.262) through cut-out in

the pressure pieces.
9. Release the pressure, uncouple the high pressure hoses from the
hydraulic tensioners.

Resetting the hydraulic tensioners

The hydraulic tensioners return to the zero position automatically by the
compression springs (resetting duration about 2 to 3 minutes). However,
the high-pressure pump must be connected, and its pressure-relief valve
must be open (see Work Card 009.03).

Work Cards, classified into sub-assemblies

10. Detach the tightening devices.
11. Reset tension screws (055.127), pressure pieces (055.126) and
hydraulic tensioners (009.063) to cylinder head bolts (bolts 4 and 8). See
points 1 to 3 / see figures 3 and 4.
12. Reset pressure pieces (055.125) and hydraulic tensioners (009.062) on
cylinder head bolts (bolts 2, and 6). See point 4 and 5 / see figure 3 and 4.
13. Connect high pressure hoses to hydraulic tensioners.
48/60B;48/60CR;51/60DF

14. Put high pressure pump in operation (see Work Card 009.03) and clamp
cylinder head bolts with clamping pressure (850 bar).

Tensioning the cylinder head bolts

The cylinder head bolts (bolts 1, 3, 5 and 7) need not be tensioned again.
2010-03-24

By tensioning the cylinder head bolt (bolts 2, 4, 6 and 8) they are relieved
to such an extent that all cylinder head bolts are equally tensioned.

15. Hand-tighten nuts (10) through cut-out in the pressure pieces using a
Tommy bar.

6707 055.01-01 EN 5 (9)

 055.01 MAN Diesel & Turbo

16. Release pressure, uncouple high pressure hoses from hydraulic ten-
Cylinder head/Valve seat rings/Safety valve

sioners and high pressure pump.

17. Detach the tightening devices.
18. Fit protection caps (9) on cylinder head bolts (11).
19. Attaching push rods (see Work Card 112.01).

1-8 Bolt number/Tightening order 11 Cylinder head bolt

9 Protection cap 12 Cylinder head
10 Nut
Figure 1: Cylinder head and cylinder head bolts
Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2010-03-24

6 (9) 6707 055.01-01 EN

 MAN Diesel & Turbo 055.01

Cylinder head/Valve seat rings/Safety valve

2 Bolt number/Tightening order 8 Bolt number/Tightening order
4 Bolt number/Tightening order 12 Cylinder head
6 Bolt number/Tightening order
Figure 2: Cylinder head bolts with attached tensioners - Illustration shows
tightening sequence 2 – -4 -6-8

Work Cards, classified into sub-assemblies

48/60B;48/60CR;51/60DF
2010-03-24

6707 055.01-01 EN 7 (9)

 055.01 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve

1 Bolt number/Tightening order 7 Bolt number/Tightening order

3 Bolt number/Tightening order 12 Cylinder head
5 Bolt number/Tightening order
Figure 3: Cylinder head bolts with attached tensioners - Illustration shows
tightening sequence 1 – -3 -5-7
Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2010-03-24

8 (9) 6707 055.01-01 EN

 MAN Diesel & Turbo 055.01

Cylinder head/Valve seat rings/Safety valve

1-8 Bolt number/Tightening order 12 Cylinder head M Marking on the stroke control
10 Nut 13 Stroke control
11 Cylinder head bolt 14 Threaded stop ring
Figure 4: Cylinder head with attached tensioner - left illustration shows arrangement for bolt numbers 2-3-6-7/
right illustration shows arrangement for bolts -numbers 1-4-5-8

Work Cards, classified into sub-assemblies

48/60B;48/60CR;51/60DF
2010-03-24

6707 055.01-01 EN 9 (9)

 MAN Diesel & Turbo 055.02

Cylinder head

Cylinder head/Valve seat rings/Safety valve

removing and refitting

Summary
Check components for condition/wear condition, prevent operating prob-
lems/damage.
Cylinder heads are to be dismantled within the scope of maintenance and
repair work.
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Carrier 055.207-1 Standard
1 Offset screwdriver 050.120 Standard
1 Pilot rod 034.006 Standard
1 Combination spanner (set) 009.231 Option
1 Shackle A2.0 002.455 Standard
1 Lifting tackle - Inventory
1 Hexagon screwdriver (set) - Inventory

Work Cards, classified into sub-assemblies

1 Rope - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.08 055.01 111.02
113.01 114.01 289.01
434.01
48/60B;V48/60CR

Technical data
2009-09-14

Designation Information
Cylinder head with valves 1200 kg

6704 055.02-01 EN 1 (9)

 055.02 MAN Diesel & Turbo

Work sequence 1 - Removing the cylinder head

Cylinder head/Valve seat rings/Safety valve

Starting position Cooling water is drained completely, coolant for injector cooling (if any) is
drained.

Cooling water must not be pumped into the bilges or into the sewage
system! Cooling water must be pumped into its own individual tank and
be reused (cooling water treatment agent)!

Running gear is turned such that piston of the relevant cylinder is at ignition
TDC (all valves closed). Rocker arm housing is detached, push rods are
removed.

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work steps 1. Release and detach all pipes and pipe fittings from relevant cylinder
head (5).
2. Detach casing of the exhaust pipe partially.
3. Open clamp (on in-line engine) or quick-fit coupling (on V-engine) on the
exhaust pipe connection (see Work Card 289.01).
4. Remove fuel injection line (see Work Card 434.01).
5. Release the cylinder head bolts (1) (see Work Card 055.01).
6. Unscrew and remove the nuts (2).
7. Place the carrier (055.207-1) onto the cylinder head (5) and fasten it with
the hexagon socket bolts (22 and 23). See Fig. 2.
8. Screw the pilot rod (034.006) into the carrier.
9. Fasten cable (24) with shackle (002.455) onto carrier and suspend from
Work Cards, classified into sub-assemblies

lifting tackle.

Ensure correct suspension point for in-line engine! See Fig. 3.

10. Carefully remove the cylinder head (5), using the pilot rod as a guide.
See Fig. 4.

Do not damage cylinder head bolts (1) and cylinder head sealing face
when detaching!
48/60B;V48/60CR

2009-09-14

11. Place the cylinder head (5) onto a clean surface.

12. Detach the tool.
13. Remove sealing ring (8) with offset screwdriver (050.120). See Fig. 5.

2 (9) 6704 055.02-01 EN

 MAN Diesel & Turbo 055.02

14. Remove O-rings (18 and 21) from sleeves (19 and 20).

Cylinder head/Valve seat rings/Safety valve

15. Cover all openings on engine by suitable means, even openings of the
push rod casing (11).
16. Block exhaust pipe connection to exhaust pipe with cover lid.
17. Remove O-rings (4, 6 and 7).
18. Clean cylinder head (5) (see work sequence 2).

Work sequence 2 - Cleaning the cylinder head

Starting position Cylinder head removed.

Work steps 1. Disassemble intake and exhaust valves (see Work Card 113.01 and
114.01).
2. Check intake and exhaust channels as well as the side opposite the
combustion chamber in terms of deposits and clean them of adhering
deposits, without damaging the surface.
3. Check cooling chambers for deposits, if needed, remove coating (see
Work Card 000.08).
4. Clean cylinder head top of oil sludge.
5. Assemble intake and exhaust valves (see Work Card 113.01 and
114.01).

Work sequence 3 - Installing the cylinder head

Starting position Cylinder head is cleaned, sealing faces between cylinder head and top land
ring, as well as between cylinder head and exhaust pipe piece are cleaned.

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work Cards, classified into sub-assemblies

Work steps 1. Insert a new sealing ring (8) in the groove.

2. Insert new O-rings (18 and 21) that have been oiled with clean lubricating
oil into the ring grooves; in doing so, make sure that they are evenly
tensioned all around the circumference and that they are not twisted.
See Fig. 1.
3. Place the carrier (055.207-1) onto the cylinder head (5) and fasten it with
the hexagon socket bolts (22 and 23). See Fig. 2.
4. Screw the pilot rod (034.006) into the carrier.
5. Fasten cable (24) with shackle (002.455) onto carrier and suspend from
48/60B;V48/60CR

lifting tackle.
2009-09-14

Ensure correct suspension point for in-line engine! See Fig. 3.

6. Lift up the cylinder head (5).

6704 055.02-01 EN 3 (9)

 055.02 MAN Diesel & Turbo

7. Insert new O-rings (4, 6 and 7), lubricated with clean lubricating oil, into
Cylinder head/Valve seat rings/Safety valve

the ring grooves, ensuring that they are tensioned equally along the
entire circumference and are not twisted. See Figs. 1 and 4.
8. Move the cylinder head (5) over the middle of the cylinders. See Fig. 4.
9. Loosen hexagon socket bolts (12) on push rod casings (11).

The push rod coverings can then also align to the cylinder head.

10. Carefully attach the cylinder head (5), guiding it in with the pilot rod.

When fitting the cylinder head observe the following points:

●Do not damage cylinder head bolts (1),
● Pay attention to parallel pin (16) and sleeves (19 and 20),
● Pay attention to flush fit of flange (3)/push rod coverings (11),
● Pay attention to flush fit of pipe section (17)/Quick-fitting coupling (on
in-line engine) or axial-compensator (25)/pipe clamp (on V-engine)!

11. Detach the tool.

12. Screw the nuts (2) onto the cylinder head bolts (1) and tighten them
fingertight. See Fig. 1.
13. Tighten the cylinder head bolts (1) (see Work Card 055.01).
14. Tighten hexagon socket bolts (12) of the push rod casings (11). See Fig.
1.
15. Attach the fuel-injection line (see Work Card 434.01).
16. Connect exhaust line to cylinder head (5) (see Work Card 289.01).
17. Attach the casing of the exhaust gas pipe.
18. Fit all pipes and pipe fittings to the cylinder head in question.
Work Cards, classified into sub-assemblies

19. After installation/attachment of all engine parts (push rods, rocker arm
housing, etc.), fill cooling water into engine, bleed coolant pipe.
20. After completing the assembly work, check, with the existing cooling
water pressure, whether O-rings are OK, and that there is no water
escaping from inspection bore (A and B). See Fig. 1.
21. With the engine running, check the cylinders at the inspection bores (A)
for gas leaks. See Fig. 1.

If the cylinder head is leaking in spite of tightened cylinder head bolts, it

must be removed again and the sealing ring (8) should be checked!
48/60B;V48/60CR

2009-09-14

4 (9) 6704 055.02-01 EN

 MAN Diesel & Turbo 055.02

Cylinder head/Valve seat rings/Safety valve

Work Cards, classified into sub-assemblies

1 Cylinder head bolt 9 Top land ring 17 Pipe section

2 Nut 10 Supporting ring 18 O-ring
48/60B;V48/60CR

3 Flange 11 Push rod casing 19 Sleeve

2009-09-14

4 O-ring 12 Hexagon socket bolt 20 Sleeve

5 Cylinder head 13 Cylinder crankcase 21 O-ring
6 O-ring 14 Piston A Inspection bore
7 O-ring 15 Cylinder liner B Inspection bore
8 Sealing ring 16 Cylinder pin ST Control side
Figure 1: Cylinder head - Illustration shows in-line engine

6704 055.02-01 EN 5 (9)

 055.02 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve
Work Cards, classified into sub-assemblies

5 Cylinder head 23 Hexagon socket bolt M24x150

22 Hexagon socket bolt M30x160 ST Control side
Figure 2: Cylinder head - Attaching the suspension device
48/60B;V48/60CR

2009-09-14

6 (9) 6704 055.02-01 EN

 MAN Diesel & Turbo 055.02

Cylinder head/Valve seat rings/Safety valve

5 Cylinder head 25 Axial compensator ST Control side
17 Pipe section A Illustration for in-line engine
24 Rope B Illustration for V engine
Figure 3: Detaching/attaching the cylinder head - suspension point for in-line engine and V-engine

Work Cards, classified into sub-assemblies

48/60B;V48/60CR
2009-09-14

6704 055.02-01 EN 7 (9)

 055.02 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve
Work Cards, classified into sub-assemblies

1 Cylinder head bolt 9 Top land ring

4 O-ring 10 Supporting ring
5 Cylinder head 15 Cylinder liner
6 O-ring 24 Rope
7 O-ring ST Control side
8 Sealing ring
Figure 4: Detaching/attaching the cylinder head
48/60B;V48/60CR

2009-09-14

8 (9) 6704 055.02-01 EN

 MAN Diesel & Turbo 055.02

Cylinder head/Valve seat rings/Safety valve

Work Cards, classified into sub-assemblies
48/60B;V48/60CR

8 Sealing ring ST Control side

2009-09-14

9 Top land ring I-II Work steps

Figure 5: Removing the sealing ring

6704 055.02-01 EN 9 (9)

 MAN Diesel & Turbo 055.03

Cylinder head

Cylinder head/Valve seat rings/Safety valve

Grind seats

Summary
Ensure correct execution of work, evaluate contact pattern /wear state,
restore contact pattern.
If the contact pattern of a valve seat is incorrect, regenerate it by grinding
(closed, bearing surface).
The work includes:
Creating a correct contact pattern.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Milling and grinding tool 055.202 Standard
1 Tool bar 055.202-1 Standard
1 Guide tube 055.202-2 Standard
1 Bearing retainer 055.202-3 Standard
1 Guide bush 055.202-5 Standard
1 Extension 055.202-6 Standard
1 Grinding wheel 055.202-9 Standard
1 Grinding wheel 055.202-10 Standard

Work Cards, classified into sub-assemblies

1 Tap wrench 055.202-15 Standard
1 Guide bush 055.202-18 Standard
1 Small grinding plates (Set) 055.202-34 Standard
1 Pliers for locking rings 055.202-36 Standard
1 Cleaning tool 055.133 Standard
1 Combination spanner (set) - Inventory
48/60B;48/60CR;51/60DF

1 Sliding calliper - Inventory

1 Torch - Inventory
1 Depth gauge - Inventory
1 Quick-acting cleanser Loctite 7061 - Option
2007-05-07

1 Touching-test ink - Inventory

Corresponding Work Cards

Work card Work card Work card
055.02 161.01 221.01

6704 055.03-01 EN 1 (7)

 055.03 MAN Diesel & Turbo

Preliminary remark
Cylinder head/Valve seat rings/Safety valve

Inspect the valve seating surface in question in the cylinder head by

using a touching test every time there is a removal of starter and injection
valves. A closed, bearing surface should be seen on the valve seat in this
touching test. If not, the valve seating surface must be reground.

Work sequence - Grinding the valve seating surface

Identifying the tool parts To facilitate the assigning of the bearing retainers, guide bushes and grind-
ing wheels to the individual valves, they are identified as follows:
AS .... Starting valve
E ...... Injection valve

Starting position Corresponding valve (starter or injection valve) or both valves are disas-
sembled.
Work steps 1. Check small grinding plates (055.202-34) on grinding wheel (055.202-9
or 055.202-10).
Important!
Pull out used small grinding plates from grinding wheel. Remove any adhe-
sive residue with Loctite 7061 quick-acting cleaner. Stick new small grinding
plates to the grinding wheel.
Number of small grinding plates:
Grinding wheel for starting valve 10 pieces (see figure 3)
Grinding wheel for injection valve 9 pieces (see figure 7)

1. Insert feather key (6) in groove and fit the required grinding wheel on tool
bar (055.202-1). See figure 2 or 6.
2. Fit washer (5), screw-on hexagon nut (4) on tool bar and tighten.
3. Fit required guide bush (055.202-5 or 055.202-18) until it rests on lock-
Work Cards, classified into sub-assemblies

ing ring (8) on guide tube (055.202-2) and lock with a second locking
ring (7). See figure 2 or 6.
4. Place tool bars with attached grinding wheel in valve bore or insert (2)
and fit it on valve seating surface (A).
5. Insert guide tube with attached guide bush over tool bar and place it in
valve bore or insert (2) until it rests.
6. Insert bearing retainer (055.202-3) over guide tube and place on cylinder
48/60B;48/60CR;51/60DF

head (1) or insert (3). See figure 2 or 6.

Ensure correct installation of the bearing retainer (diameter of the guide/

identification marks made on bearing retainer).
2007-05-07

7. Fit extension (055.202-6) and tap wrench (055.202-15) on tool bar.

8. Move grinding wheel to and fro by a rotary movement of the tap wrench.

2 (7) 6704 055.03-01 EN

 MAN Diesel & Turbo 055.03

Grind off only so much material that valve seating surface (A) is bright

Cylinder head/Valve seat rings/Safety valve

and without damage over the entire width! Therefore remove the tool
often and check valve seating surface!

9. Remove tool after the grinding process is complete.

10. Valve seating surface (A) to be cleaned with cleaning device (055.133).
See figure 4 or 8.
11. Dismantle tool, clean and store in wooden box.
12. After grinding a valve seating surface (A) many times, detach cylinder
head (1) (see Work Card 055.02) and determine dimension (B) and note.
See figure 5 or 9
Important!
If a measured dimension is smaller than the allowable dimension, the cyl-
inder head (1) or insert (2) must be changed.
Minimum allowable dimension:
Starting valve 77.6 mm
Injection valve 51.5 mm

Work Cards, classified into sub-assemblies

48/60B;48/60CR;51/60DF
2007-05-07

1 Cylinder head 3 Insert

2 Insert A Valve seating surface
Figure 1: Cylinder head - Valve bore for starting valve (illustration left) and use
for injection valve (illustration right)

6704 055.03-01 EN 3 (7)

 055.03 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve

1 Cylinder head 6 Feather key

4 Hexagon nut M10 7 Locking ring
5 Washer 8 Locking ring
Figure 2: Valve bore for starting valve - Grinding the valve seating surface
Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2007-05-07

Figure 3: Grinding wheel for starting valve seating surface - Number and
arrangement of the small grinding plates

4 (7) 6704 055.03-01 EN

 MAN Diesel & Turbo 055.03

Cylinder head/Valve seat rings/Safety valve

1 Cylinder head

Figure 4: Valve bore for starting valve - Cleaning the valve seating surface

Work Cards, classified into sub-assemblies

1 Cylinder head
B Dimension
C Bottom edge cylinder head
48/60B;48/60CR;51/60DF

Figure 5: Valve bore for starting valve - Dimension to be determined (lower edge
cylinder head /valve seating surface) after multiple grinding of the valve seating
surface
2007-05-07

6704 055.03-01 EN 5 (7)

 055.03 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve

1 Cylinder head 5 Washer

2 Insert 6 Feather key
3 Insert 7 Locking ring
4 Hexagon nut M10 8 Locking ring
Work Cards, classified into sub-assemblies

Figure 6: Valve bore for injection valve - Grinding the valve seating surface
48/60B;48/60CR;51/60DF

2007-05-07

Figure 7: Grinding wheel for injection valve seat - Number and arrangement of
the small grinding plates

6 (7) 6704 055.03-01 EN

 MAN Diesel & Turbo 055.03

Cylinder head/Valve seat rings/Safety valve

1 Cylinder head
2 Insert
3 Insert

Figure 8: Valve bore for injection valve - Cleaning the valve seating surface

Work Cards, classified into sub-assemblies

1 Cylinder head
2 Insert
B Dimension
C Bottom edge cylinder head
48/60B;48/60CR;51/60DF

Figure 9: Valve bore for injection valve - Dimension to be determined (lower

edge cylinder head /valve seating surface) after multiple grinding of the valve
seating surface
2007-05-07

6704 055.03-01 EN 7 (7)

 MAN Diesel & Turbo 055.04

Valve seat rings

Cylinder head/Valve seat rings/Safety valve

removal and installation

Summary
Impart necessary knowledge, ensure correct execution of work.
The removal and fitting of valve seat rings is not among the activities speci-
fied in the service schedule.
The work/work steps include:
Removing components,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Mounting device 113.287 Standard
1 Thrust piece 113.287-1 Standard
1 Guide piece 113.205-2 Standard
1 Handle 113.205-3 Standard
1 Clamping piece 113.205-4 Standard
1 Extractor 113.207 Standard
1 Counter support 002.525 Standard
1 Extractor 002.513 Standard
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Hydraulic tensioner (hollow piston) 009.022 Standard
1 Combination spanner (set) - Inventory
1 Inside micrometer - Inventory
1 Sliding calliper - Inventory

Work Cards, classified into sub-assemblies

1 Autogenic welding unit - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.19 009.03 009.05
055.02 113.01 113.03
113.04 114.01

Preliminary remark
2008-10-29

Intake or exhaust valve seat rings must be removed and replaced

▪ if there are corrosion and impact places, which cannot be removed by
turning,
48/60B

▪ if breakaway or burn-through or tension cracks are present and

6704 055.04-03 EN 1 (12)

 055.04 MAN Diesel & Turbo

▪ if rework limit (see Work Card 113.04) has been reached.

Cylinder head/Valve seat rings/Safety valve

Work sequence 1 - Removal of an intake or exhaust valve seat ring

Starting position Cylinder head is removed, loaded in cylinder head-turnover stand and
cleaned carefully of oil and fuel. Corresponding valve is removed. Combus-
tion chamber side faces upwards.

Type and source of danger

Removal of an exhaust valve seat ring (4):
If the work instructions are not followed severe heating can give rise to
very poisonous and corrosive vapours (hydrofluoric acid) caused by
decomposition of the O-ring seals (5 and 6) (see Work Card 000.21)!

Work steps 1. Heat the intake valve seat ring (3) or exhaust valve seat ring (4) with
welding torch (8) at four points on the valve seat roughly 90° apart until
the material melts. See Fig. 2.

Type and source of danger

It is not possible to remove the intake or exhaust valve seat rings without
heating them or allowing them to cool down first!

2. Let cylinder head (2) and valve seat ring cool down.

Type and source of danger

The tangential stress is reduced in the heating zone as a result of
exceeding the yield point.

3. Screw back expanding solid (9) until extractor (002.513) can be intro-
duced into the intake or exhaust valve seat ring (3 or 4). See figure 3/I
or 4/I.
4. Set complete extractor (113.207, consisting of counter support and
extractors) over valve seat ring.
Work Cards, classified into sub-assemblies

5. Align bolts (12) after releasing the hexagon nuts (13) such that they fit
on the cylinder head (2) in a supporting position. Then retighten the
hexagon nuts.
6. Lower shells (10) by rotating the spindle (15), until they are in front of the
gap (D) between the intake or exhaust valve seat ring (3 or 4) and cylinder
head (2). See figure 3/II or 4/II.
7. Hold the crown (11) and open the extractor as far as possible by turning
the spindle (15). See figure 3/III or 4/III.

Type and source of danger

Make sure that shells engage in the gap between valve seat ring and
cylinder head!
2008-10-29

8. Extract the intake or exhaust valve seat ring (3 or 4) by uniformly turning

the adjusting nut (14). See figure 3/IV or 4/IV.
48/60B

2 (12) 6704 055.04-03 EN

 MAN Diesel & Turbo 055.04

Type and source of danger

Cylinder head/Valve seat rings/Safety valve

Make sure that the valve seat ring is extracted uniformly, i.e. is not tilted!

9. Remove valve seat ring including tool from cylinder head (2).
10. Detach the tool.
11. Remove O-ring seals (5 and 6) during removal of an exhaust valve seat
ring (4).

Type and source of danger

If the O-ring seals are decomposed or have brown discolouration,
neoprene gloves must be worn!

12. Check locating hole in the cylinder head (2) for damage and dimension
(B) at several places. See figure 5 or 6.
Maximum Inlet valve 178,026 mm
allowable dimension (B):
Exhaust valve 181.530 mm

Type and source of danger

If the dimension (B) is exceeded, over-size valve seat rings are available
from MAN Diesel & Turbo SE! In this case the locating hole will have to
be reworked!

Work sequence 2 - Fitting an intake valve seat ring

Starting position Cylinder head is loaded in cylinder head turnover stand (combustion cham-
ber side facing upwards). Locating hole in the cylinder head is cleaned and
measured.

Work Cards, classified into sub-assemblies

Work steps 1. Slide guide piece (113.205-2) into valve guide (1). Fit clamping piece
(113.205-4) and screw on the hexagon nut (16) by hand (without open-
ended or ring spanners) until it comes to a rest.
2. Screw the handle (113.205-3) into thrust piece (113.287-1) until it abuts.
3. Place thrust piece on new inlet valve seat ring (3), insert together over
guide piece and centre it by hand in the locating hole. See Fig. 7/I.
4. Unscrew handle from thrust piece.
5. Fit hydraulic hollow piston tensioner (009.022) over guide piece and
tighten hexagon nut (17) by hand. See Fig. 7/II.
6. Connect high-pressure hose (009.306) to hydraulic hollow piston ten-
sioner and high-pressure pump (009.342). Connect an oil pressure
2008-10-29

gauge (0 - 400 bar) to the high-pressure pump.

7. Put high-pressure pump in operation (see Work Card 009.03) and pump
hydraulic hollow piston tensioner slowly.
48/60B

6704 055.04-03 EN 3 (12)

 055.04 MAN Diesel & Turbo

Watch the oil pressure gauge whilst pumping! Sudden rise in pressure
Cylinder head/Valve seat rings/Safety valve

during the pressing indicates tilting of the inlet valve seat ring!

8. Pump up hydraulic hollow piston tensioner, until inlet valve seat ring (3)
fits. See Fig. 7/III.

Observe oil pressure gauge carefully shortly before the fitting of the inlet
valve seat ring! End point location is indicated by a severe rise in
pressure!

9. Release the pressure.

10. Separate high-pressure hose from hydraulic hollow piston tensioner and
high-pressure pump.
11. Detach or remove tool.
12. Check gap (D) at several places for uniform width.
13. Turn down inlet valve seat ring (3) with valve seat lathe and touch up
with new valve cone (see Work Card 113.03 and 113.04).
14. Install inlet valve with new or reground valve tapers (see Work Card
113.01).

Work sequence 3 - Fitting an exhaust valve seat ring

Starting position Cylinder head is loaded in cylinder head turnover stand (combustion cham-
ber side facing upwards). Locating hole in the cylinder head and bush is
cleaned. Locating hole is measured.
Work steps 1. Slide guide piece (113.205-2) into valve guide (1). Fit clamping piece
(113.205-4) and screw on the hexagon nut (16) by hand (without open-
ended or ring spanners) until it comes to a rest.
Work Cards, classified into sub-assemblies

2. Place new O-ring seal (5) oiled with clean lubricating oil in ring groove,
ensuring that it is not twisted.
3. Insert a new O-ring seal (6) oiled with clean lubricating oil in the ring
groove, making sure that it is evenly tensioned all around the circum-
ference and is not twisted.
4. Screw the handle (113.205-3) into thrust piece (113.287-1) until it abuts.
5. Place thrust piece on new exhaust valve seat ring (4), insert these
together over guide piece and centre by hand in the locating hole. See
Fig. 8/I.
6. Unscrew handle from thrust piece.
7. Fit hydraulic hollow piston tensioner (009.022) over guide piece and
2008-10-29

tighten hexagon nut (17) by hand. See Fig. 8/II.

8. Connect high-pressure hose (009.306) to hydraulic hollow piston ten-
sioner and high-pressure pump (009.342). Connect an oil pressure
48/60B

gauge (0 - 400 bar) to the high-pressure pump.

4 (12) 6704 055.04-03 EN

 MAN Diesel & Turbo 055.04

9. Put high-pressure pump in operation (see Work Card 009.03) and pump

Cylinder head/Valve seat rings/Safety valve

hydraulic hollow piston tensioner slowly.

Watch the oil pressure gauge whilst pumping! Sudden rise in pressure
during the pressing indicates tilting of the exhaust valve seat ring!

10. Pump up hydraulic hollow piston tensioner, until exhaust valve seat ring
(4) fits. See Fig. 8/III.

Observe oil pressure gauge carefully shortly before the fitting of the
exhaust valve seat ring! End point location is indicated by a severe rise
in pressure!

11. Release the pressure.

12. Separate high-pressure hose from hydraulic hollow piston tensioner and
high-pressure pump.
13. Detach or remove tool.
14. Check gap (D) at several places for uniform width.
15. Turn down exhaust valve seat ring (4) with valve seat lathe and touch up
with new valve taper (see Work Card 113.03 and 113.04).
16. Install exhaust valve with new or reground valve tapers (see Work Card
114.01).

Work Cards, classified into sub-assemblies

2008-10-29

48/60B

6704 055.04-03 EN 5 (12)

 055.04 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve

1 Valve guide 5 O-ring seal

2 Cylinder head 6 O-ring seal
3 Inlet valve seat ring 7 Sleeve
4 Exhaust valve seat ring
Figure 1: Intake and exhaust valve seat ring in the cylinder head
Work Cards, classified into sub-assemblies

2008-10-29
48/60B

6 (12) 6704 055.04-03 EN

 MAN Diesel & Turbo 055.04

Cylinder head/Valve seat rings/Safety valve

2 Cylinder head 7 Sleeve
3 Inlet valve seat ring 8 Welding torch
4 Exhaust valve seat ring A Heating locations
5 O-ring seal ST Control side
6 O-ring seal
Figure 2: Heating the valve seat ring

Work Cards, classified into sub-assemblies

Note regarding illustration on top left: The illustration of the cylinder head and of the installed inlet valve seat
ring does not correspond to the actual appearance of the cylinder head
and of the inlet valve seat ring in the engine 48/60 B and is a schematic
diagram only.
2008-10-29

48/60B

6704 055.04-03 EN 7 (12)

 055.04 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve
Work Cards, classified into sub-assemblies

2 Cylinder head 13 Hexagon nut

3 Inlet valve seat ring 14 Adjusting nut
9 Expanding solid 15 Spindle
2008-10-29

10 Shell D Gap between cylinder head and intake valve seat ring
11 Crown I-IV Work steps
12 Pin
48/60B

Figure 3: Removal of an inlet valve seat ring

8 (12) 6704 055.04-03 EN

 MAN Diesel & Turbo 055.04

Cylinder head/Valve seat rings/Safety valve

Work Cards, classified into sub-assemblies

2 Cylinder head 12 Pin

4 Exhaust valve seat ring 13 Hexagon nut
7 Sleeve 14 Adjusting nut
2008-10-29

9 Expanding solid 15 Spindle

10 Shell D Gap between cylinder head and exhaust valve seat ring
11 Crown I-IV Work steps
48/60B

Figure 4: Removal of an exhaust valve seat ring

6704 055.04-03 EN 9 (12)

 055.04 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve

2 Cylinder head
Dimension (diameter of locating
B
hole)

Figure 5: Intake valve seat ring - locating hole in cylinder head

2 Cylinder head
Dimension (diameter of locating
B
hole)

Figure 6: Exhaust valve seat ring - locating hole in cylinder head

Work Cards, classified into sub-assemblies

2008-10-29
48/60B

10 (12) 6704 055.04-03 EN

 MAN Diesel & Turbo 055.04

Cylinder head/Valve seat rings/Safety valve

Work Cards, classified into sub-assemblies

1 Valve guide 17 Hexagon nut M30

2 Cylinder head C Contact face on cylinder head
3 Inlet valve seat ring D Gap between cylinder head and intake valve seat ring
2008-10-29

16 Hexagon nut M30 I-III Work steps

Figure 7: Installation of an inlet valve seat ring
48/60B

6704 055.04-03 EN 11 (12)

 055.04 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve
Work Cards, classified into sub-assemblies

1 Valve guide 16 Hexagon nut M30

2 Cylinder head 17 Hexagon nut M30
4 Exhaust valve seat ring C Contact face on cylinder head
2008-10-29

5 O-ring seal D Gap between cylinder head and exhaust valve seat ring
6 O-ring seal I-III Work steps
7 Sleeve
48/60B

Figure 8: Installation of an exhaust valve seat ring

12 (12) 6704 055.04-03 EN

 MAN Diesel & Turbo 055.05

Cylinder head with reversing device

Cylinder head/Valve seat rings/Safety valve

working/machining

Summary
Impart the necessary knowledge, ensure adequate application.
Various tasks must be performed on the cylinder heads at regular intervals.
The turnover stand is used to do this.
The work includes:
Chucking components.
Tools/aids required
Quantity Designation Number Status
1 Turnover stand 055.130 Option
1 Combination spanner (set) - Inventory

Preliminary remark
The turnover stand is suitable for:
▪ thorough cleaning and checking of the cylinder heads,
▪ grinding the valve seating surfaces in the cylinder head (see Work Card
055.03),
▪ For removal and fitting of the valve seat rings (see Work Card 055.04),
▪ Checking the valve seating surfaces (see Work Card 113.03),
▪ Machining the valve seating surface (see Work Card 113.04),

Work sequence - Mounting the cylinder head

Starting position Cylinder head with suspension device in the lifting tackle.

Work Cards, classified into sub-assemblies

Work steps 1. Fasten fixing plates (7) with hexagon bolts (5) to cylinder head (9). In
doing so ensure that marking "AS" points to the exhaust side.
2. Lift cylinder head (9) into turning device and secure with the intended
equipment.
3. Remove the suspension device.
4. With the locking lever (10) flipped upward, the cylinder head (9) may now
be brought into any desired position by turning the handwheel (3).

Note_Fixing the cylinder head

Fixing the cylinder head (9) is possible by inserting the locking lever (10)
in the groove in the raster disc (11) every 45°.
2008-10-29

When working on the clamped cylinder head always insert the locking
L48/60B

lever in a groove in the raster disc.

6704 055.05-01 EN 1 (2)

 055.05 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve

1 Collecting trough 5 Hexagon bolt 10 Locking lever

2 Frame 6 Circumscribed circle 11 Ratchet disc
3 Handwheel for shuttle gearbox 7 Fixing plate
4 Reversing shaft axis 9 Cylinder head
Figure 1: Turning fixture for cylinder head
Work Cards, classified into sub-assemblies

2008-10-29
L48/60B

2 (2) 6704 055.05-01 EN

 MAN Diesel & Turbo 055.06

Sealing face on cylinder head

Cylinder head/Valve seat rings/Safety valve

grinding

Summary
Check components for quality/wear condition, prevent operating problems/
damages.
The sealing face on cylinder head is to be checked every time the cylinder
head is removed and reworked if necessary.
The work extends to:
Grinding the sealing face.
Tools/aids required
Quantity Designation Number Status
1 Grinding-in fixture 050.163 Option
1 Bracket 050.163-1 Option
1 Grinding wheel 050.163-2 Option
1 Sliding calliper - Inventory
1 Depth gauge - Inventory
1 Grinding paste, silicon-free - Inventory

Corresponding Work Cards

Work card Work card Work card
050.06 055.05

Work sequence - Grinding the sealing face on the cylinder head

Starting position Cylinder head is removed and clamped in the turnover stand.

Work Cards, classified into sub-assemblies

Work steps 1. Clean the sealing face (B) on the cylinder head (1). See Fig. 2.

2. Fasten holder (050.163-1) to grinding wheel (050.163-2). See Fig. 3.

The grinding wheel can be used for the top land ring and cylinder head!
The correct side of the grinding wheel can be seen in figure 3!

3. Apply grinding paste to the grinding wheel.

Do not apply too much grinding paste.

48/60B;V48/60CR
2007-05-07

4. Place grinding device (050.163) on cylinder head (1). See Fig. 3.

5. Move grinding tool up and down, lift occasionally, so that the grinding
paste can be redistributed.

6704 055.06-01 EN 1 (5)

 055.06 MAN Diesel & Turbo

Grind as little as possible, because a flat surface is difficult to produce

Cylinder head/Valve seat rings/Safety valve

by grinding! If necessary, the cylinder head should be machined on a

lathe!

6. Remove the grinding tool after the grinding is over.

7. Clean sealing face (B) and cylinder head (1) thoroughly of grinding res-
idues.
8. Dismantle grinding tool and clean it.
9. Measure cylinder head (1), sealing ring (2) and top land ring (3) and
determine Clearance (A). See Fig. 1.

For reground sealing face (B) the clearance (A) between cylinder head
and top land ring must be at least 0.5 mm!
Work Cards, classified into sub-assemblies
48/60B;V48/60CR

2007-05-07

2 (5) 6704 055.06-01 EN

 MAN Diesel & Turbo 055.06

Cylinder head/Valve seat rings/Safety valve

Work Cards, classified into sub-assemblies
1 Cylinder head 3 Top land ring
2 Sealing ring A Clearance
Figure 1: Cylinder head and top land ring
48/60B;V48/60CR
2007-05-07

6704 055.06-01 EN 3 (5)

 055.06 MAN Diesel & Turbo
Cylinder head/Valve seat rings/Safety valve

1 Cylinder head B Sealing face

Figure 2: Sealing face on cylinder head
Work Cards, classified into sub-assemblies
48/60B;V48/60CR

2007-05-07

4 (5) 6704 055.06-01 EN

 MAN Diesel & Turbo 055.06

Cylinder head/Valve seat rings/Safety valve

Work Cards, classified into sub-assemblies
1 Cylinder head 7 Wing screw M10x50
Figure 3: Cylinder head - Grinding the sealing face 48/60B;V48/60CR
2007-05-07

6704 055.06-01 EN 5 (5)

MAN Diesel & Turbo 073

Covering/Crankcase cover
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.11-1 EN 1 (2)

 MAN Diesel & Turbo
Covering/Crankcase cover

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.11-1 EN

 MAN Diesel & Turbo 071.01

Casings on coupling side

Covering/Crankcase cover
removing and refitting

Summary
Insert/replace components, machine properly and mount them.
The casing on the coupling side is to be dismounted only for disassembly
of the outer crankshaft bearing cover.
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Torque wrench 008.017 Standard
2 Shackle A1.0 002.453 Standard
1 Adapter 12.5x20 001.927 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Screwdriver insert 14x12.5 001.858 Standard
1 Ratchet tool 001.521 Standard
2 Lifting eye bolt M16 000.143 Standard
1 Combination spanner (set) - Inventory

Work Cards, classified into sub-assemblies

1 Lifting tackle with rope - Inventory
1 Wood (to support underneath) - Inventory
1 Hexagon nut M10 - Inventory
1 Securing compound, Loctite 243 - Inventory
48/60;48/60CR;L40/54;51/60DF

1 Sealing compound (Silicone) - Inventory

Corresponding Work Cards

Work card Work card Work card
000.19 000.30

Technical data
2007-06-15

Designation Information
Covering lower part L 40/54: 27 kg, L 48/60: 24,5 kg, V 48/60: 27,5 kg
Splash ring half L 40/54: 16 kg, L 48/60: 10,5 kg, V 48/60: 12,5 kg
Covering half L 40/54: 60 kg, L 48/60: 73,5 kg, V 48/60: 84 kg

6701 071.01-01 EN 1 (5)

071.01 MAN Diesel & Turbo

Designation Information
Covering/Crankcase cover

Covering upper part L 40/54: 25 kg, L 48/60: 24,5 kg, V 48/60: 27,5 kg

Work sequence 1 - Removing

Work steps 1. Remove all pipes obstructing the removal of the casing.

2. Remove drain pipe (17) including seals (18).

3. Screw two lifting eye bolts (000.143) into casing upper part (4), fasten
rope with shackle (002.453) to lifting eye bolts and suspend from lifting
tackle.
4. Remove two taper pins (9).
5. Unscrew hexagon nuts (1) and hexagon bolts (3) and remove hexagon
bolts (2). Remove covering upper section.
6. Detach the tool.
7. Screw two lifting eye bolts (000.143) into casing lower part (21), fasten
rope with shackle (002.453) to lifting eye bolts and suspend from lifting
tackle. Tension rope.
8. Remove two taper pins (11).
9. Unscrew hexagon bolts (3) and remove casing lower part.
10. Detach the tool.
11. Screw two lifting eye bolts (000.143) into right hand covering half (22),
fasten rope with shackle (002.453) to lifting eye bolts and suspend from
lifting tackle.
12. Remove taper pins (10, 20 and 23).
13. Unscrew hexagon nuts (5) and hexagon bolts (12 and 15) for right casing
half and remove hexagon bolts (6 and 19). Remove right hand casing
half.
14. Detach the tool.
Work Cards, classified into sub-assemblies

15. Screw two lifting eye bolts (000.143) into left hand covering half (13),
fasten rope with shackle (002.453) to lifting eye bolts and suspend from
lifting tackle.
16. Unscrew hexagon bolts (12 and 15) for left casing half and dismantle left
casing half.
48/60;48/60CR;L40/54;51/60DF

17. Support splash ring lower part by suitable means (e.g. wooden block).
18. Unscrew hexagon socket bolts (26) and remove splash ring upper part
(24).
19. Remove the lower part of the splash ring (25), in doing so, pay attention
to the parallel pin (27).
20. Clean all individual parts, check splash ring upper and lower part for
2007-06-15

damages.

2 (5) 6701 071.01-01 EN

 MAN Diesel & Turbo 071.01

Covering/Crankcase cover
1 Hexagon nut 10 Taper pin 19 Hexagon bolt
2 Hexagon bolt 11 Taper pin 20 Taper pin
3 Hexagon bolt 12 Hexagon bolt 21 Covering lower part
4 Covering upper part 13 left casing half 22 right casing half
5 Hexagon nut 14 Oil sump 23 Taper pin
6 Hexagon bolt 15 Hexagon bolt 24 Splash ring upper part
7 Crankshaft 16 Hexagon bolt 25 Splash ring lower part
8 Cylinder crankcase 17 Drain pipe
9 Taper pin 18 Seal
Figure 1: Casing on coupling side (illustration shows in-line engine 40/54)

Work Cards, classified into sub-assemblies

7 Crankshaft
48/60;48/60CR;L40/54;51/60DF

24 Splash ring upper part

25 Splash ring lower part
26 Hexagon socket bolt
27 Parallel pin
2007-06-15

Figure 2: Splash ring (illustration shows in-line engine 40/54)

6701 071.01-01 EN 3 (5)

071.01 MAN Diesel & Turbo

Work sequence 2 - Fitting

Covering/Crankcase cover

Work steps 1. Clean the contact face on cylinder crankcase (8).

2. Clean the crankshaft (7) around the splash ring area.

3. Place splash ring lower part (25) on the crankshaft and support by suit-
able means (e.g. wooden block).

When placing the splash ring lower part, pay attention to the position of
the parallel pin (27)!

4. Fit splash ring upper part (24) on crankshaft and splash ring lower part.
5. Apply securing compound Loctite 243 on threads of hexagon socket
bolts (26), screw-on and tighten hexagon socket bolts alternately with
the specified torque (see Work Card 000.30).
6. Remove support for splash ring lower part.
7. Screw lifting eye bolts (000.143) into left hand covering half (13), fasten
cable with shackle (002.453) to lifting eye bolts and suspend from lifting
tackle.
8. Apply sealing compound Silicone Rhodorsil to contact faces of the left
half of the covering.
9. Attach left casing half, screw hexagon bolts (12 and 15) in until they rest.

In the installation of the casing halves (13 and 21) ensure that splash ring
is not damaged!

10. Detach the tool.

11. Attach right casing half (22) in the same manner. See point 7 to 10.
Work Cards, classified into sub-assemblies

12. Loosely connect right and left casing halves by means of hexagon nuts
(5) and hexagon bolts (6 and 19).
13. Fix right and left casing halves by inserting two taper pins (20 and 23).
Tighten hexagon nuts.
48/60;48/60CR;L40/54;51/60DF

14. Fix covering halves by two taper pins (10) with cylinder crankcase (8),
tighten hexagon bolts (12 and 15).
15. Screw lifting eye bolts (000.143) into covering lower part (21), fasten
rope with shackle (002.453) to lifting eye bolts and suspend from lifting
tackle.
16. Paint contact faces on casing bottom part with sealing compound Sili-
cone Rhodorsil.
2007-06-15

17. Attach casing lower part, screw hexagon bolts (3) in loosely until they
rest.
18. Detach the tool.
19. Attach casing upper part (4) in the same manner. See points 15 to 18).

4 (5) 6701 071.01-01 EN

 MAN Diesel & Turbo 071.01

20. Insert hexagon bolts (2) and loosely screw in hexagon nuts (1) until they

Covering/Crankcase cover
rest.
21. Fix casing upper and lower part by inserting two taper pins (9). Tighten
hexagon nuts.
22. Fix casing upper and lower part with cylinder crankcase by inserting two
taper pins (11). Tighten hexagon bolts.
23. Attach drain pipe (17) including seals (18) and align. Screw in the hex-
agon bolts (16) and tighten them.

Work Cards, classified into sub-assemblies

48/60;48/60CR;L40/54;51/60DF
2007-06-15

6701 071.01-01 EN 5 (5)

 MAN Diesel & Turbo 073.01

Safety valve on crankcase cover

Covering/Crankcase cover
checking, detaching and attaching

Summary
Execute work on time according to the maintenance schedule, ensure /
restore operating reliability again.
Examine safety valves on crankcase covers at regular intervals for their easy
movement.
The work / work steps extend to:
Inspection of parts/ components,
Detaching and attaching parts/ components.
Safety requirements
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) 009.231 Option
1 Torque wrench 10-60 Nm 008.029 Standard
1 Adapter 12.5x10 001.922 Standard
1 Extension piece 12.5x125 001.911 Option
1 Cross handle 001.891 Option
1 Socket spanner insert 24x12.5 001.757 Option
1 Socket spanner insert 19x12.5 001.755 Option
1 Sliding calliper - Inventory
1 Depth gauge - Inventory
1 Metal adhesive (Loctite Adhaesiv 307) - Inventory

Work Cards, classified into sub-assemblies

1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.19 000.30

Technical data
Designation Information
Crankcase cover with safety valve V 48/60B: 58,5 kg
Crankcase cover with safety valve L 48/60B: 44 kg
2009-03-31

Safety valve 24,5 kg

Control dimension (L) V 48/60B: 14,8 mm
Control dimension (L) L 48/60B: 17,6 mm
48/60B

6707 073.01-04 EN 1 (6)

073.01 MAN Diesel & Turbo

Preliminary remarks
Covering/Crankcase cover

The purpose of checking the ease of movement of all safety valves mounted
on the crankcase is to ensure that increases in pressure/pressure waves,
e.g. following an explosion, can be safely reduced.

As the temperature of the bearings or the oil mist concentration is higher

following an alarm or engine stop, open the crankcase once 10 minutes
have elapsed at the earliest! A danger of explosion exists due to the
inflow of oxygen as overheated components and the surrounding fuel
may be at ignition temperature!

Work sequence 1 - Checking the safety valves

Work steps 1. Remove the resistance thermometer (6) and place safely to one side.

2. Slacken the hexagon nuts (3) and twist the retaining bow (2).
3. Remove the crankcase cover (5).
4. Check that safety valve (1) is in good condition and check for ease of
movement, detach if necessary and replace with new safety valve (see
work sequence 2).
5. Check valve plate (15), compression spring (16) and O-ring seal (14) for
damage, detach safety valve (1) if necessary and replace with new safety
valve (see work sequence 2). See Fig. 4.
6. Check sealing ring (13) for damage, replace if necessary.

Before installing a new sealing ring, clean the groove in the crankcase
cover to remove any adhesive residue that may still be attached. Glue in
the new sealing ring using metal adhesive (Loctite 307) (see Work Card
000.19).

7. Oil thread of stud bolts (4) and contact surface of hexagon nuts (3) with
clean lubricating oil.
Work Cards, classified into sub-assemblies

8. Place crankcase cover (5) on dowel pins (7) and attach to cylinder
crankcase (9).
9. Turn back retaining bow (2).
10. Tighten hexagon nuts (3) to the prescribed torque (see Work Card
000.30).
11. Determine control dimension (L).

Undercutting of control dimension

If the control dimension is undercut, repeat the tightening operation,
replace the cup springs (12) if necessary. Observe the correct
arrangement when installing new cup springs. See Fig. 3.
2009-03-31

12. Install resistance thermometer (6). See Fig. 1.

13. Check the other safety valves (1) in the same manner.
48/60B

2 (6) 6707 073.01-04 EN

 MAN Diesel & Turbo 073.01

Work sequence 2 - Detaching and attaching the safety valve

Covering/Crankcase cover
Starting position Crankcase cover is removed with safety valve.

Work steps 1. Unscrew and remove hexagon bolts (17) and safety valve (1) from crank-
case cover (5).
2. Remove the seal (19).
3. Mount new seal (19).
4. Check new safety valve (1) for ease of movement.
5. Position new safety valve (1) on the crankcase cover (5), insert hexagon
bolts (17) including new lockwashers (18) through safety valve, screw
into crankcase cover and tighten applying a maximum torque of 44 Nm.

Work Cards, classified into sub-assemblies

2009-03-31

48/60B

6707 073.01-04 EN 3 (6)

073.01 MAN Diesel & Turbo
Covering/Crankcase cover
Work Cards, classified into sub-assemblies

1 Safety valve 5 Crankcase cover 9 Cylinder crankcase

2009-03-31

2 Retaining bow 6 Resistance thermometer 10 Sealing ring

3 Hexagon nut 7 Dowel pin 11 Bolt
4 Stud 8 Cable
48/60B

Figure 1: Crankcase cover with safety valve and splash oil attached (illustration shows V-engine)

4 (6) 6707 073.01-04 EN

 MAN Diesel & Turbo 073.01

Covering/Crankcase cover
Work Cards, classified into sub-assemblies
1 Safety valve 7 Dowel pin
2 Retaining bow 9 Cylinder crankcase
3 Hexagon nut 12 Cup spring
4 Stud 13 Sealing ring
5 Crankcase cover L Control length
Figure 2: Crankcase cover with attached safety valve and splash oil
2009-03-31

48/60B

6707 073.01-04 EN 5 (6)

073.01 MAN Diesel & Turbo
Covering/Crankcase cover

2 Retaining bow 12 Cup spring

3 Hexagon nut 20 Washer
4 Stud 21 Sleeve
Figure 3: Crankcase cover

5 Crankcase cover
Work Cards, classified into sub-assemblies

14 O-ring seal
15 Valve plate
16 Compression spring
17 Hexagon bolt
18 Lockwasher
19 Seal
2009-03-31
48/60B

Figure 4: Crankcase cover with attached safety valve

6 (6) 6707 073.01-04 EN

MAN Diesel & Turbo 100

Control device operating mechanism

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.12-1 EN 1 (2)

 MAN Diesel & Turbo
Control device operating mechanism

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.12-1 EN

 MAN Diesel & Turbo 100.01

Control device operating mechanism

Control device operating mechanism

inspecting

Summary
Carry out tasks in due time according to the maintenance schedule, check
the components for their quality / wear condition
The camshaft drive must be checked at regular intervals for any variances,
the contact pattern is to be analysed so that any source for disturbances
can be recognised in due time and if needed can be removed.
The work includes:
Checking parts/components.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Torque wrench 008.016 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Extension piece 12.5x125 001.911 Standard
1 Socket spanner insert 24x12.5 001.757 Standard
1 Thickness gauges 0.05-1 000.451 Standard
1 Combination spanner (set) - Inventory

Corresponding Work Cards

Work card Work card Work card

Work Cards, classified into sub-assemblies

000.30 020.03

Work sequence 1 - Checking the camshaft drive

Starting position The covering cap on the camshaft drive has been removed.

Work steps 1. Carry out a visual inspection of all gear wheels (1, 6 and 7).

2. Measure clearances of the rotating shoulder with thickness gauges

(000.451), note and compare with required target values (see Volume
010.005 Engine - Operating Instructions).
L48/60B;L51/60DF

3. Determine bearing and axial clearance of the double spur wheel (6), note
and compare with specified required values (see Volume 010.005
2008-10-22

Engine - Operating Instructions).

4. Check that hexagon bolts (3 and 5) are tightened firmly with specified
torque (see Work Card 000.30).
5. Check all injection nozzles for smooth operation.

6704 100.01-01 EN 1 (4)

100.01 MAN Diesel & Turbo

Blow compressed air through blocked injection nozzles.

Control device operating mechanism

6. Check all threaded connections for firm seating.

Work sequence 2 - Overhaul work on the camshaft drive

Recommendation We recommend having overhaul work to the camshaft drive performed at a
customer service support location or by a MAN Diesel & Turbo staff mem-
ber.

While performing overhaul work, which requires a drive disconnection

from the crankshaft to the camshaft, only turn the running gear if all push
rods of the inlet and exhaust valves have been removed (otherwise the
open inlet and exhaust valves may be damaged by the pistons as they
ascend)!

Crankshaft gearwheel Check the crankshaft gearwheel (7) see Work Card 020.03.
Work Cards, classified into sub-assemblies
L48/60B;L51/60DF

2008-10-22

2 (4) 6704 100.01-01 EN

 MAN Diesel & Turbo 100.01

Control device operating mechanism

Work Cards, classified into sub-assemblies
L48/60B;L51/60DF
2008-10-22

1 Camshaft gearwheel 5 Hexagon bolt

2 Camshaft 6 Double spur wheel
3 Hexagon bolt 7 Crankshaft gearwheel
4 Axle 8 Crankshaft
Figure 1: Control device operating mechanism

6704 100.01-01 EN 3 (4)

 Work Cards, classified into sub-assemblies Control device operating mechanism

4 (4)
L48/60B;L51/60DF
100.01

6704 100.01-01 EN
MAN Diesel & Turbo

2008-10-22
MAN Diesel & Turbo 102

Camshaft bearing/Camshaft thrust bearing

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.13-1 EN 1 (2)

 MAN Diesel & Turbo
Camshaft bearing/Camshaft thrust bearing

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.13-1 EN

 MAN Diesel & Turbo 102.01

Camshaft bearing bolts

Camshaft bearing/Camshaft thrust bearing

inspection, loosening and tightening

Summary
Tension and release important bolted connections with the correct values,
ensure correct execution of work.
Camshaft bearing bolts should be inspected at regular intervals by means
of hydraulic tensioners.
The work/work steps include:
determining and evaluating the loosening pressure and
tightening the connection as per specified pressure.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Thrust piece 101.018 Standard
2 Tension nut 030.205 Standard
2 Hydraulic tensioner 009.346 Standard
1 High-pressure pump 009.342 Standard
2 High-pressure hose 009.306 Standard
1 Combination spanner (set) 009.231 Option
1 Tommy bar, 6 009.068 Standard
1 Torque wrench 008.017 Standard
1 Adapter 12.5x20 001.927 Standard

Work Cards, classified into sub-assemblies

1 Extension piece 12.5x250 001.912 Option
1 Cross handle 001.891 Option
1 Socket spanner insert 30x12.5 001.759 Standard
1 Feeler gauge 0.05-1 000.451 Option
1 Open-jaw wrench 55 - Inventory
1 Depth gauge - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory

Corresponding Work Cards

Work card Work card Work card
2008-10-06

000.30 000.32 000.33

009.03 009.05 009.07
L48/60B

434.05

6704 102.01-01 EN 1 (8)

 102.01 MAN Diesel & Turbo

Technical data
Camshaft bearing/Camshaft thrust bearing

Designation Information
Bolt projection (A) 86 mm

Work sequence 1 - Checking the camshaft bearing bolts

Starting position Camshaft covering is removed.

Work steps 1. Check that hexagon bolts (9) are tightened firmly with specified torque
(see Work Card 000.30). See Fig. 1.
2. Remove two fuel admission pipes and two fuel return pipes from fuel
injection pump (see Work Card 434.05).

Fuel pipes must be removed so that the tensioner can be attached to the
front camshaft bearing bolt.

3. Remove protection caps (1).

4. Clean threads of the camshaft bearing bolts (4).
5. Place thrust pieces (101.018) over hexagon nuts (2).
6. Check with open-jaw wrench SW55 whether tension nuts (030.205) are
threaded tightly on the hydraulic tensioners (009.346).
7. Screw hydraulic tensioners (009.346) on camshaft bearing bolts (4),
ensuring that thrust pieces are fitted centrally. See Figs. 2 and 3.
8. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
9. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
10. Set the high-pressure pump in operation (see Work Card 009.03) and
Work Cards, classified into sub-assemblies

close the gap that resulted from the turning back.

Ensure that no is present in the extension of the axis of the camshaft

bearing bolts!

11. Pump hydraulic tensioners, until hexagon nuts (2) can be released.

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!
2008-10-06

12. Make a note of the release pressure and compare it to the clamping
pressure.
L48/60B

13. Regulate the high-pressure pump to the specified clamping pressure

(see Work Card 000.30).

2 (8) 6704 102.01-01 EN

 MAN Diesel & Turbo 102.01

14. Hand-tighten hexagon nuts (2) by using tommy bar (009.068) through

Camshaft bearing/Camshaft thrust bearing

cut-out in the thrust pieces.
15. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

The hydraulic tensioner returns to the zero position automatically by a

set of cup springs (resetting duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

16. Detach the tensioners.

17. Screw protection caps (1) onto camshaft bearing bolts (4).
18. Fit fuel admission pipes and fuel return pipes to fuel injection pump (see
Work Card 434.05).

Work sequence 2 - Releasing the camshaft bearing bolts

Starting position Camshaft covering is removed.

Never release camshaft bearing bolts of two immediately adjacent

camshaft bearings at the same time! Every other camshaft bearing must
remain tight (camshaft must remain supported)!

Work steps 1. Remove two fuel admission pipes and two fuel return pipes from fuel
injection pump (see Work Card 434.05).

Fuel pipes must be removed so that the tensioner can be attached to the
front camshaft bearing bolt.

2. Remove protection caps (1).

Work Cards, classified into sub-assemblies

3. Clean threads of the camshaft bearing bolts (4).
4. Place thrust pieces (101.018) over hexagon nuts (2).
5. Check with open-jaw wrench SW55 whether tension nuts (030.205) are
threaded tightly on the hydraulic tensioners (009.346).
6. Screw hydraulic tensioners (009.346) on camshaft bearing bolts (4),
ensuring that thrust pieces are fitted centrally. See Figs. 2 and 3.
7. Turn the hydraulic tensioner back by the turn back angle (see Work Card
000.30).
8. Connect high-pressure hoses (009.306) to the hydraulic tensioners and
connect the high-pressure pump (009.342).
9. Set the high-pressure pump in operation (see Work Card 009.03) and
2008-10-06

close the gap that resulted from the turning back.

L48/60B

When releasing, ensure that no one is in the extended axis of the

camshaft bearing bolts to be released!

6704 102.01-01 EN 3 (8)

 102.01 MAN Diesel & Turbo

10. Pump hydraulic tensioners, until hexagon nuts (2) can be released.
Camshaft bearing/Camshaft thrust bearing

In the process, the pressure must not be more than max. 7 % below or
max. 5 % above the tensioning pressure (see Work Card 000.30)!

11. Make a note of the release pressure and compare it to the clamping
pressure.
12. Turn back hexagon nuts (2) by using tommy bar (009.068) through cut-
out in the thrust pieces (for turn-back angle see Work Card 000.30).
13. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

The hydraulic tensioner returns to the zero position automatically by a

set of cup springs (resetting duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

14. Detach the tensioners.

15. Release and unscrew hexagon bolt (9). See Fig. 1.

Work sequence 3 - Tightening the camshaft bearing bolts

Starting position Hexagon nuts are bolted and tightened by hand, threads of the camshaft
bearing bolts are cleaned. Fuel pipes are removed.

Prerequisite for correct tightening of a bolted connection is a pressure

gauge with an accurate read-out! If in doubt, test the pressure gauge
with a comparative pressure gauge!

Work steps 1. Check that parting line between bearing cover (6) and bearing body (5)
as well as between bearing body and cylinder crankcase (3) is of equal
Work Cards, classified into sub-assemblies

size.
2. Brush the threads and the contact surface of the hexagon bolts (9) using
MoS2 lubricant, screw them in and tighten them using the specified tor-
que (see Work Card 000.30). See Fig. 1.
3. Check length of projection of thread end (A) of the camshaft bearing
bolts (4). See Fig. 3.
4. Place thrust pieces (101.018) over hexagon nuts (2).
5. Check with open-jaw wrench SW55 whether tension nuts (030.205) are
threaded tightly on the hydraulic tensioners (009.346).
6. Screw hydraulic tensioners (009.346) on camshaft bearing bolts (4),
ensuring that thrust pieces are fitted centrally. See Figs. 2 and 3.
2008-10-06

7. Connect high-pressure hoses (009.306) to the hydraulic tensioners and

connect the high-pressure pump (009.342).
L48/60B

8. Set high-pressure pump in operation (see Work Card 009.03) and

tighten camshaft bearing bolts (4) with specified clamping pressure (see
Work Card 000.30).

4 (8) 6704 102.01-01 EN

 MAN Diesel & Turbo 102.01

When tightening, ensure that no one is in the extended axis of the

Camshaft bearing/Camshaft thrust bearing

camshaft bearing bolts to be tightened!

9. Hand-tighten hexagon nuts (2) by using tommy bar (009.068) through

cut-out in the thrust pieces.
10. Release pressure, uncouple high pressure hoses from hydraulic ten-
sioners and high pressure pump.

The hydraulic tensioner returns to the zero position automatically by a

set of cup springs (resetting duration about 2 to 3 minutes). However, the
high-pressure pump must be connected, and its relief valve must be
open (see Work Card 009.03).

11. Detach the tensioners.

12. Screw protection caps (1) onto camshaft bearing bolts (4).
13. Fit fuel admission pipes and fuel return pipes to fuel injection pump (see
Work Card 434.05).

Work Cards, classified into sub-assemblies

2008-10-06

L48/60B

6704 102.01-01 EN 5 (8)

 102.01 MAN Diesel & Turbo
Camshaft bearing/Camshaft thrust bearing
Work Cards, classified into sub-assemblies

1 Protection cap 6 Bearing cover

2 Hexagon nut 7 Hexagon nut
3 Cylinder crankcase 8 Camshaft covering
4 Camshaft bearing bolt 9 Hexagon bolt
5 Bearing body 10 Bearing block
Figure 1: Camshaft bearing and cam-follower bearing
2008-10-06
L48/60B

6 (8) 6704 102.01-01 EN

 MAN Diesel & Turbo 102.01

Camshaft bearing/Camshaft thrust bearing

Work Cards, classified into sub-assemblies
4 Camshaft bearing bolt 9 Hexagon bolt
7 Hexagon nut
Figure 2: Camshaft bearing - camshaft bearing bolts with attached tensioners
2008-10-06

L48/60B

6704 102.01-01 EN 7 (8)

 102.01 MAN Diesel & Turbo
Camshaft bearing/Camshaft thrust bearing

2 Hexagon nut
3 Cylinder crankcase
4 Camshaft bearing bolt
14 Hexagonal insert
A Bolt projection

Figure 3: Camshaft bearing bolt with attached tensioner

Work Cards, classified into sub-assemblies

2008-10-06
L48/60B

8 (8) 6704 102.01-01 EN

 MAN Diesel & Turbo 102.02

Camshaft bearing shells

Camshaft bearing/Camshaft thrust bearing

inspecting

Summary
Carry out the work in good time according to the maintenance schedule,
ensure the operational safety of the bearings.
Bearing shells must be checked at regular intervals. The wear condition and
running profile will give a clue to the load ratios, lubricating oil care etc.
The work/work steps include:
Dismantling components,
Checking bearing shell and
Assembling components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Wood (to support underneath) - Inventory
1 Depth gauge - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work Cards, classified into sub-assemblies

Work card Work card Work card
000.11 000.30 102.01

Technical data
Designation Information
Camshaft bearing bolt 6 kg
Bearing cover 15 kg
Bolt projection (A) 86 mm
L48/60B;L51/60DF

Work sequence 1 - Dismantle and inspection of the camshaft bearing shell

2007-08-28

Starting position Camshaft covering is removed.

6704 102.02-01 EN 1 (6)

 102.02 MAN Diesel & Turbo

Never check two immediately adjacent camshaft bearing shells at the

Camshaft bearing/Camshaft thrust bearing

same time! Every other camshaft bearing must remain attached

(camshaft must remain supported)!

Work steps 1. Remove lube oil pipe (12). See Fig. 1.

2. Release camshaft bearing bolts (1) (see Work Card 102.01).

3. Release and unscrew hexagon bolt (13). See Figs. 1 and 2.
4. Support bearing cover (8) with wooden support (16). See Fig. 2.
5. Unscrew hexagon nuts (9), remove camshaft bearing bolts (1) upwards.
See Fig. 2.
6. Remove wooden support (16), take off bearing cover (8) and remove.
See Fig. 3.
7. Take out bearing shell (10) and place it on a clean support surface.
8. Thread off bearing shell (4), without damaging it and place it on a clean
support surface.

When threading out the bearing shell (4) observe the direction of rotation
(position of the nose for bearing shell fixation)! See Fig. 3.

9. Clean running surfaces of the bearing shells (4 and 10) carefully, without
damaging them.
10. Check the condition of the running surfaces (see Work Card 000.11).

Do not carry out any rework on the bearing shells!

Work Cards, classified into sub-assemblies

Change damaged or very heavily dirt-scored bearing shells!

If the bearing shells have dirt scores, the camshaft must be inspected
and repolished if necessary (polishing linen with grain size < 15 μm)!

Work sequence 2 - Installing the camshaft bearing shells

New bearing shells are delivered ready for installation and must not be
rescraped or adapted in any way!
L48/60B;L51/60DF

2007-08-28

Starting position Bearing shells and camshaft bearing bolt are cleaned.

Work steps 1. Clean contact faces between bearing cover (8) and bearing body (5).

2. Oil the running surface of the bearing shell (4) liberally (reverse side of
the bearing shell remains dry).

2 (6) 6704 102.02-01 EN

 MAN Diesel & Turbo 102.02

3. Drive in bearing shell (4).

Camshaft bearing/Camshaft thrust bearing

Observe position of the nose for bearing shell fixation! See Fig. 3.

4. Oil the running surface of the bearing shell (10) liberally (reverse side of
the bearing shell remains dry).
5. Insert bearing shell (10) in bearing cover (8)

Observe position of the nose for bearing shell fixation! See Fig. 3.

6. Place bearing cover (8) in cylinder crankcase (3) and raise until it rests
on the bearing body (5). Support bearing cover with wooden support
(16). See Figs. 2 and 3.

Ensure correct fitting of the bearing cover! Connection for lube oil pipe
(12) must point to the control side (ST)!
When joining the bearing covers with the bearing body, pay attention to
the parallel pins (7)! See Figs. 1 and 2.

7. Screw hexagon nuts (2) onto camshaft bearing bolts (1).

8. Install camshaft bearing bolts (1), screw on hexagon nuts (9). See Fig.
2.
9. Adjust thread projection (A). See Fig. 1.
10. Hand-tighten hexagon nuts (9).
11. Remove wooden support (16).
12. Apply MoS2-lubricant to threads and resting surface of the hexagon

Work Cards, classified into sub-assemblies

head bolt (13), including washer (14) screw-in and tighten with the
specified torque (see Work Card 000.30). See Fig. 1.
13. Tension camshaft bearing bolts (1) (see Work Card 102.01).
14. Connect lube oil pipe (12). See Fig. 1.
L48/60B;L51/60DF
2007-08-28

6704 102.02-01 EN 3 (6)

 102.02 MAN Diesel & Turbo
Camshaft bearing/Camshaft thrust bearing
Work Cards, classified into sub-assemblies

1 Camshaft bearing bolt 10 Bearing shell, lower

2 Hexagon nut 11 Camshaft covering
3 Cylinder crankcase 12 Lube oil pipe
4 Bearing shell, upper 13 Hexagon bolt
5 Bearing body 14 Washer
6 Camshaft 15 Bearing block
7 Parallel pin
8 Bearing cover A Bolt projection
9 Hexagon nut ST Control side
Figure 1: Camshaft bearing and cam-follower bearing
L48/60B;L51/60DF

2007-08-28

4 (6) 6704 102.02-01 EN

 MAN Diesel & Turbo 102.02

Camshaft bearing/Camshaft thrust bearing

Work Cards, classified into sub-assemblies
1 Camshaft bearing bolt 13 Hexagon bolt
2 Hexagon nut 14 Washer
3 Cylinder crankcase 15 Bearing block
5 Bearing body 16 Wooden support
8 Bearing cover
9 Hexagon nut ST Control side
Figure 2: Camshaft bearing - Removal / installation of the camshaft bearing bolt
L48/60B;L51/60DF
2007-08-28

6704 102.02-01 EN 5 (6)

 102.02 MAN Diesel & Turbo
Camshaft bearing/Camshaft thrust bearing
Work Cards, classified into sub-assemblies

3 Cylinder crankcase 7 Parallel pin

4 Bearing shell, upper 8 Bearing cover
5 Bearing body 10 Bearing shell, lower
6 Camshaft ST Control side
Figure 3: Camshaft bearing - Removal / installation of the bearing cover
L48/60B;L51/60DF

2007-08-28

6 (6) 6704 102.02-01 EN

 MAN Diesel & Turbo 102.03

Camshaft (thrust bearing)

Camshaft bearing/Camshaft thrust bearing

inspecting

Summary
Check components for state/wear condition, ensure/ restore operational
safety.
Examine the thrust bearing of the camshaft at regular intervals for damage,
determine the axial clearance. This helps detect changes / problem sources
in a timely manner and rectify them if necessary.
The work/work steps include:
Removing components,
Checking parts/ components,
Fitting components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Assembly bolts 102.001 Standard
1 Guide tube 021.032 Standard
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.017 Standard
1 Torque wrench 008.011 Standard
2 Shackle A0.6 002.452 Standard

Work Cards, classified into sub-assemblies

1 Adapter 12.5x20 001.927 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Screw driver insert 19x12.5 001.860 Standard
1 Screwdriver insert 10x12.5 001.856 Standard
1 Socket spanner insert 24x12.5 001.757 Standard
1 Thickness gauges 0.05-1 000.454 Standard
2 Lifting eye bolt M12 000.142 Standard
1 Screwdriver (Set) - Inventory
1 Lifting tackle - Inventory
1 Marker pen - Inventory
2008-10-22

1 Combination spanner (set) - Inventory

1 Hexagon screwdriver (set) - Inventory
L48/60B

1 Rope - Inventory
1 Depth gauge - Inventory

6704 102.03-01 EN 1 (8)

 102.03 MAN Diesel & Turbo

Quantity Designation Number Status

Camshaft bearing/Camshaft thrust bearing

1 Sealing compound (Silicone) - Inventory

1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory
1 Securing compound, Loctite 243 - Inventory

Corresponding Work Cards

Work card Work card Work card
000.11 000.19 000.30

Technical data
Designation Information
Bearing body 110 kg

Work sequence 1 - Dismantle and inspection of the camshaft thrust bearing

Starting position Camshaft covering is removed in the area of the camshaft drive.

Work steps 1. Mark the position of the cover (15) to the bearing body (17).

2. Thread off hexagon socket bolts (16) and remove cover (15).
3. Clean contact faces on cover (15) and butting ring (14).
4. Measure and note the projection (C) cover butting ring (15/14) at several
points. See Fig. 3.
5. Remove O-ring seal (6).
6. Clean contact faces on bearing body (17) and butting disc (11).
7. Measure and note the projection () bearing body/butting disc (17/11) at
several points. See Fig. 3.
8. Unscrew hexagon bolts (10) and remove butting disc (11).
Work Cards, classified into sub-assemblies

9. Clean contact faces on camshaft (12) and butting ring (7).

10. Measure and note the projection (E) camshaft butting ring (12/7) at sev-
eral points. See Fig. 3.
11. Calculate axial clearance based on the measurements from points 4, 7
and 10 and compare with permissible clearance (see Volume 010.005
Engine - Operating Instructions).
12. Unscrew and remove the hexagon socket bolts (5).
13. Unscrew two assembly bolts (102.001) through bearing body (17) in
cylinder crankcase (3). See Fig. 4/I.
14. Screw two lifting eye bolts (000.142) into bearing body (17).
2008-10-22

15. Extract bearing body (17) from cylinder crankcase (3). See Fig. 4/II.
16. Fasten cable with shackle (002.452) on lifting eye bolts and suspend
L48/60B

from lifting tackle.

17. Remove bearing body (17) and place on wooden support.
18. Detach tool from the bearing body (17).

2 (8) 6704 102.03-01 EN

 MAN Diesel & Turbo 102.03

19. Remove O-ring seal (4).

Camshaft bearing/Camshaft thrust bearing

20. Clean running surfaces of the bearing bush (18) carefully, without dam-
aging them.
21. Check the condition of the running surface, (see Work Card 000.11).

Do not undertake any rework on the bearing bush!

Change damaged or very heavily dirt-scoured bearing bushes!

The changing of the bearing bush should be carried out only by a service
support location or by MAN-Diesel staff, as the bearing bush is pressed
into the bearing body!
If the bearing bushes have dirt scores, the camshaft must be inspected
and repolished if necessary (polishing linen with grain size < 15 μm)!

22. Clean all individual parts and check for damage and change if neces-
sary.

Type and source of danger

If new butting rings (7 or 14) must be fitted, they are to be fixed with
hexagon socket bolts (8 or 13). Apply securing compound Loctite 243 to
screw thread and contact surface of the hexagon socket bolts, screw in
and tighten.

23. Blow out oil bores with compressed air.

Work sequence 2 - Installation of the camshaft thrust bearing

Starting position All individual parts are cleaned and checked. Two assembly bolts are
screwed into cylinder crankcase.
Work steps 1. Insert a new O-ring seal (4) oiled with clean lubricating oil in the ring

Work Cards, classified into sub-assemblies

groove, making sure that it is evenly tensioned all around the circum-
ference and is not twisted.
2. Screw two lifting eye bolts (000.142) into bearing body (17).
3. Fasten cable with shackle (002.452) on lifting eye bolts and suspend
from lifting tackle. Raise bearing body (17).
4. Oil the running surface of the bearing bush (18) well.
5. Fit bearing bodies (17) on assembly bolts (102.001). See Fig. 4/II.

Before fitting the bearing body, ensure the correct installation position!
See Fig. 1.
2008-10-22

6. Install bearing body (17) in cylinder crankcase (3). See Fig. 4/I.
L48/60B

7. Detach tools.

6704 102.03-01 EN 3 (8)

 102.03 MAN Diesel & Turbo

8. Coat the thread and contact face of the hexagon socket bolts (5) with
Camshaft bearing/Camshaft thrust bearing

MoS2 lubricant, screw in and tighten them to the specified tightening

torque (see Work Card 000.30).
9. Check bearing bush clearance.
10. Oil running surface of the butting ring (7) liberally.
11. Oil butting disc (11) liberally and set it on the camshaft (12).
12. Apply securing compound Loctite 243 to the threads of the hexagon
head bolt (10), screw them including new locking plate pairs (9) into
camshaft (12) and tighten with specified torque (see Work Card 000.30).

Ensure correct installation of the lockwasher pair! Toothed surfaces must

lie one on the other, otherwise there is no locking effect! See Fig. 2.

13. Apply sealing compound Silicone Rhodorsil on contact face of the cover
(15) to the bearing body (17).

Area around the butting ring (14) and O-ring seal (6) must remain free!

14. Place new O-ring seal (6) oiled with clean lubricating oil in ring groove,
ensuring that it is not twisted.
15. Set cover (15) on bearing body (17), paying attention to the marking
made for cover bearing body (see work sequence 1/point 1).
16. Coat the thread and contact face of the hexagon socket bolts (16) with
MoS2 lubricant, screw in and tighten them to the specified tightening
torque (see Work Card 000.30).
Work Cards, classified into sub-assemblies

2008-10-22
L48/60B

4 (8) 6704 102.03-01 EN

 MAN Diesel & Turbo 102.03

Camshaft bearing/Camshaft thrust bearing

1 Camshaft thrust bearing 3 Cylinder crankcase
2 Camshaft covering
Figure 1: Camshaft thrust bearing - Illustration shows view on coupling side

Work Cards, classified into sub-assemblies

2008-10-22

L48/60B

6704 102.03-01 EN 5 (8)

 102.03 MAN Diesel & Turbo
Camshaft bearing/Camshaft thrust bearing

2 Camshaft covering 11 Butting disc

3 Cylinder crankcase 12 Camshaft
4 O-ring seal 13 Hexagon socket bolt
5 Hexagon socket bolt 14 Butting ring
6 O-ring seal 15 Cover
7 Butting ring 16 Hexagon socket bolt
Work Cards, classified into sub-assemblies

8 Hexagon socket bolt 17 Bearing body

9 Lockwasher pair 18 Bearing bush
10 Hexagon bolt
Figure 2: Camshaft thrust bearing - Illustration shows side view 2008-10-22
L48/60B

6 (8) 6704 102.03-01 EN

 MAN Diesel & Turbo 102.03

Camshaft bearing/Camshaft thrust bearing

7 Butting ring 17 Bearing body
11 Butting disc C Projection
12 Camshaft D Projection
14 Butting ring E Projection
15 Cover I-III Work steps
Figure 3: Camshaft thrust bearing - Measuring the projections to determine the axial clearance

Work Cards, classified into sub-assemblies

2008-10-22

2 Camshaft covering 17 Bearing body

L48/60B

3 Cylinder crankcase I-III Work steps

4 O-ring seal
Figure 4: Camshaft thrust bearing - Removal/ installation of the bearing body

6704 102.03-01 EN 7 (8)

 Work Cards, classified into sub-assemblies Camshaft bearing/Camshaft thrust bearing

8 (8)
L48/60B
102.03

6704 102.03-01 EN
MAN Diesel & Turbo

2008-10-22
MAN Diesel & Turbo 111

Rocker arm casing/control arm

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.14-1 EN 1 (2)

 MAN Diesel & Turbo
Rocker arm casing/control arm

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.14-1 EN

 MAN Diesel & Turbo 111.01

Valve clearance

Rocker arm casing/control arm

inspection and adjustment

Summary
Execute the work corresponding to the maintenance schedule in time,
allow/ support economic operation, prevent operational problems/damage.
The valve clearance is to be determined and, if necessary, corrected at reg-
ular intervals.
The work includes:
Checking /adjusting valve clearance.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Setting gauge (exhaust valve) 0.9 113.139 Standard
1 Setting device 111.133 Standard
1 Box spanner 111.133-1 Standard
1 Box spanner 111.133-2 Standard
1 Fixing screw M16 111.132 Standard
1 Fixing screw M12 111.131 Standard
1 Torque wrench 10-60 Nm 008.029 Standard
1 Adapter 12.5x10 001.922 Standard
1 Socket spanner insert 24x12.5 001.757 Standard

Work Cards, classified into sub-assemblies

1 Socket spanner insert 19x12.5 001.755 Standard
1 Feeler gauge (set) 0.2 000.455 Standard
1 Thickness gauges 0.05-1 000.451 Option

Preliminary remark
Execute an inspection and adjustment, if necessary, for the valve clearance,
if new parts are installed or the rocker arm casing is re-fitted after mainte-
nance work.
Work sequence 1 - Checking the valve clearance
48/60B;V48/60CR

Starting position Engine is cold (same temperature of all engine parts).

2008-10-22

With engine at operating temperature 6 hours after switching off at the

earliest!

6704 111.01-01 EN 1 (8)

111.01 MAN Diesel & Turbo

Running gear of relevant cylinder has been turned to the ignition TDC posi-
Rocker arm casing/control arm

tion (inlet and exhaust valves are closed).

Work steps 1. Open cylinder head cover (5).

2. Insert fixing screw (111.131) through bearing block (2) and screw into
inlet rocker arm (3). See Figs. 2 and 3.

It may be necessary to lift the inlet rocker arm a little by hand.

3. Insert fixing screw (111.132) through bearing block (2) and screw into
outlet rocker arm (1). See Figs. 2 and 3.

It may be necessary to lift the exhaust rocker arm a little by hand.

4. Tighten both fixing screws by applying a torque of 40 Nm.

Tightening the fixing screws with torque is required so that intake and
exhaust rocker arms can contact the push rods without any clearance.

5. Measure and note valve clearance (A) for intake and exhaust valves (8
and 9) between valve stem (11 and 12) and ball pan (10) using thickness
gauges (000.451).
For prescribed target values, see Volume 010.005 Engine - Work Instructions!
1. If necessary, reset the valve clearance (see work sequence 2).
2. Unscrew and remove both fixing screws.
3. Close cylinder head cover (5).
Work Cards, classified into sub-assemblies

Work sequence 2 - Setting the valve clearance

Starting position Engine is cold (same temperature of all engine parts).

With engine at operating temperature 6 hours after switching off at the

earliest!

Running gear of relevant cylinder has been turned to the ignition TDC posi-
tion (inlet and exhaust valves are closed).
48/60B;V48/60CR

Work steps 1. Open cylinder head cover (5).

2008-10-22

2. Insert fixing screw (111.131) through bearing block (2) and screw into
inlet rocker arm (3). See Figs. 2 and 3.

2 (8) 6704 111.01-01 EN

 MAN Diesel & Turbo 111.01

It may be necessary to lift the inlet rocker arm a little by hand.

Rocker arm casing/control arm

3. Insert fixing screw (111.132) through bearing block (2) and screw into
outlet rocker arm (1). See Figs. 2 and 3.

It may be necessary to lift the exhaust rocker arm a little by hand.

4. Tighten both fixing screws by applying a torque of 40 Nm.

Tightening the fixing screws with torque is required so that intake and
exhaust rocker arms can contact the push rods without any clearance.

5. Adjust the valve clearance at the inlet valves (8) (see fig. 5/I):
˗ Fit the socket spanner (111.133-2) on the hexagon nut (6).
˗ Insert socket spanner (111.133-1) through socket spanner
(111.133-2) and push onto valve adjusting screw (7).
˗ Loosen hexagon nut (6) with socket spanner (111.133-2); in doing
so, counter the valve adjusting screw (7) with the socket spanner
(111.133-1).
˗ Turn back the valve adjusting screw (7).
˗ Slide a thickness gauge from the feeler gauge set (000.455) between
the valve stem (11) and the ball socket (10).
˗ Screw in the valve adjusting screw (7) until the ball cup (10) is resting
without clearance on the thickness gauge.
˗ With the thickness gauge inserted, tighten the hexagon nut (6); in
doing so, counter the valve adjusting screw (7) with the socket
spanner (111.133-1).

Work Cards, classified into sub-assemblies

˗ Remove the setting device (111.133) and thickness gauge.
˗ Adjust the valve clearance at the second inlet valve in the same
manner.
6. Adjust the valve clearance at the outlet valves (9) (see fig. 5/II):
˗ Fit the socket spanner (111.133-2) on the hexagon nut (6).
˗ Insert socket spanner (111.133-1) through socket spanner
(111.133-2) and push onto valve adjusting screw (7).
˗ Loosen hexagon nut (6) with socket spanner (111.133-2); in doing
so, counter the valve adjusting screw (7) with the socket spanner
(111.133-1).
˗ Turn back the valve adjusting screw (7).
˗ Push the adjusting gauge (113.139) between the valve stem (12) and
48/60B;V48/60CR

ball cup (10).

2008-10-22

˗ Screw in the valve adjusting screw (7) until the ball cup (10) is resting
without clearance on the adjusting gauge.
˗ With the adjusting gauge inserted, tighten the hexagon nut (6); in
doing so, counter the valve adjusting screw (7) with the socket
spanner (111.133-1).
˗ Remove the setting device (111.133) and adjusting gauge.

6704 111.01-01 EN 3 (8)

111.01 MAN Diesel & Turbo

˗ Adjust the valve clearance at the second exhaust valve in the same
Rocker arm casing/control arm

manner.
7. Unscrew and remove both fixing screws (111.131 and 111.132).
8. Close cylinder head cover (5).

1 Outlet rocker arm 5 Cylinder head cover

2 Bearing block 6 Hexagon nut
3 Inlet rocker arm 7 Valve adjusting screw
4 Rocker arm casing
Figure 1: Rocker arm casing with rocker arms
Work Cards, classified into sub-assemblies
48/60B;V48/60CR

2008-10-22

4 (8) 6704 111.01-01 EN

 MAN Diesel & Turbo 111.01

Rocker arm casing/control arm

1 Outlet rocker arm 8 Inlet valve
2 Bearing block 9 Exhaust valve
3 Inlet rocker arm
Figure 2: Rocker arm casing with rocker arms - Setting tools

Work Cards, classified into sub-assemblies

48/60B;V48/60CR
2008-10-22

6704 111.01-01 EN 5 (8)

111.01 MAN Diesel & Turbo
Rocker arm casing/control arm

1 Outlet rocker arm 3 Inlet rocker arm

Figure 3: Rocker arm casing with rocker arms - Raising the intake and exhaust
rocker arms
Work Cards, classified into sub-assemblies
48/60B;V48/60CR

2008-10-22

6 (8) 6704 111.01-01 EN

 MAN Diesel & Turbo 111.01

Rocker arm casing/control arm

1 Outlet rocker arm
9 Exhaust valve A Valve clearance
Figure 4: Rocker arm casing with rocker arms - Adjusting the valve clearance
(Illustration shows fitted setting device on exhaust rocker)

Work Cards, classified into sub-assemblies

48/60B;V48/60CR
2008-10-22

6704 111.01-01 EN 7 (8)

111.01 MAN Diesel & Turbo
Rocker arm casing/control arm
Work Cards, classified into sub-assemblies

1 Outlet rocker arm 11 Valve stem (inlet valve)

3 Inlet rocker arm 12 Valve stem (exhaust valve)
6 Hexagon nut
7 Valve adjusting screw I Illustration shows adjustment at inlet valve
10 Ball socket II Illustration shows adjustment at exhaust valve
Figure 5: Adjusting the valve clearance
48/60B;V48/60CR

2008-10-22

8 (8) 6704 111.01-01 EN

 MAN Diesel & Turbo 111.02

Rocker arm casing with rocker arms

Rocker arm casing/control arm

removing and refitting

Summary
Impart necessary knowledge, Ensure correct execution of work.
Rocker arm casings are to be checked in the course of the service and
maintenance work and replaced if necessary.
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Fixing screw M16 111.132 Standard
1 Fixing screw M12 111.131 Standard
1 Carrier 111.130 Standard
1 Closing cover 055.143 Standard
1 Pilot rod 034.006 Standard
1 Combination spanner (set) 009.231 Option
1 Torque wrench 10-60 Nm 008.029 Standard
1 Torque wrench 008.017 Standard
1 Suspension link 002.481 Standard

Work Cards, classified into sub-assemblies

1 Shackle A2.0 002.455 Standard
1 Adapter 12.5x20 001.927 Option
1 Adapter 25x20 001.924 Standard
1 Adapter 20x12.5 001.923 Option
1 Adapter 12.5x10 001.922 Standard
1 Extension piece 12.5x250 001.912 Option
1 Cross handle 001.891 Option
1 Screwdriver bit 22x25 001.861 Standard
1 Screwdriver insert 8x12.5 001.854 Standard
48/60B;V48/60CR

1 Socket spanner insert 24x12.5 001.757 Option

2009-09-14

1 Socket spanner insert 19x12.5 001.755 Option

1 Receptacle - Inventory
1 Lifting tackle - Inventory
1 Screwdriver insert 19x12.5 - Inventory

6704 111.02-01 EN 1 (10)

111.02 MAN Diesel & Turbo

Quantity Designation Number Status

Rocker arm casing/control arm

1 Screwdriver insert 10x12.5 - Inventory

1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30 111.01

Technical data
Designation Information
Rocker arm casing with rocker arms 715 kg

Work sequence 1 - Inspection

Starting position Running gear of relevant cylinder has been turned to the ignition TDC posi-
tion (inlet and exhaust valves are closed).
Work steps ▪ Check valve clearance, threaded connections and rocker arm lubrica-
tion at the intervals specified in the service schedule.
▪ Check the individual parts for wear every time they are removed and
during overhauling activities.
▪ Blow compressed air through oil bores in the rocker arms.
▪ Turn the engine with turning gear, checking whether inlet and exhaust
valves always follow the movements of the rocker arm or whether they
remain fixed.

Work sequence 2 - Removing the rocker arm casing

Starting position Running gear of relevant cylinder has been turned to the ignition TDC posi-
tion (inlet and exhaust valves are closed).
Work Cards, classified into sub-assemblies

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work steps 1. Place collector under charge air pipe section (3), unscrew locking bolt
(5) and drain condensation from charge air pipe section. See Fig. 1.
2. Screw in locking screw (5) including gasket (4), remove collector.
3. Release the hexagon socket bolts (1 or 20) and push the pipe couplings
48/60B;V48/60CR

(2 or 21) to the side. See Fig. 1.

2009-09-14

Pipe coupling
Move pipe coupling, depending on the space conditions, on the charge
air pipe section of the adjacent cylinder or on the charge air pipe section
of the rocker arm housing to be detached.

2 (10) 6704 111.02-01 EN

 MAN Diesel & Turbo 111.02

4. Detach lubricating oil supply line from rocker arm housing (13) and pro-

Rocker arm casing/control arm

tect it from penetration of dirt.
5. Remove the fastening for indicator valve of the rocker arm housing (13)
(only with in-line engine).
6. Open cylinder head cover (14).
7. Insert fixing bolt (111.131) through bearing block (9), screw into the
intake rocker (12) and tighten by hand. See Figs. 4 and 5.

Intake rocker arm

It may be necessary to lift the intake rocker arm a little by hand.

8. Insert fixing screw (111.132) through bearing block (9), screw into the
exhaust rocker arm (7) and tighten by hand. See Figs. 4 and 5.

Outlet rocker arm

It may be necessary to lift the exhaust rocker arm a little by hand.

9. Fit carrier (111.130) onto rocker arm housing (13) and fasten with hex-
agon head bolts (15 and 16). See Figs. 4 and 5.
10. Fasten suspension element (002.481) with shackle (002.455) to carrier
and suspend lifting tackle from suspension element.

Ensure correct suspension point for in-line engine (see figure 6/B or 6/C)
or for V-engine (see figure 6/A)!

11. Screw the pilot rod (034.006) into the carrier.

12. Loosen and remove hexagon socket bolts (6 and 8). See Fig. 5.

Work Cards, classified into sub-assemblies

13. Raise rocker arm housing (13) carefully, guiding with pilot rod.
14. Remove pipe couplings (2 or 21).
15. Detach rocker arm housing (13) and place it on a clean surface.
16. Block air entry into cylinder head (10) with cover lid (055.143), so that
no foreign matter can fall into the intake channel.
17. Remove carrier (111.130).

Fixing bolts
Fixing bolts (111.131 and 111.132) must not be removed!
48/60B;V48/60CR
2009-09-14

18. Clean rocker arm housing (13), rocker arm (7 and 12) and charge air pipe
section (3).
19. Clean the sealing lips on pipe couplings (2 or 21) and check for damage,
renew pipe couplings if necessary.

6704 111.02-01 EN 3 (10)

111.02 MAN Diesel & Turbo

Work sequence 3 - Attaching the rocker arm casing

Rocker arm casing/control arm

Starting position Rocker arm casing, rocker arms and the charge air pipe section are cleaned,
rocker arms are fixed with fixing bolts. Sealing lips of pipe couplings are
cleaned.

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work steps 1. Clean the contact face on cylinder head (10).

2. Insert new O-rings (17, 18 and 19), lubricated with clean lubricating oil,
into ring grooves, ensuring that they are tensioned equally on the entire
circumference and are not twisted. See Fig. 6.
3. Fit carrier (111.130) on rocker arm housing (13) and fasten with hexagon
head bolts (15 and 16). See Figs. 4 and 5.
4. Fasten suspension element (002.481) with shackle (002.455) to carrier
and suspend lifting tackle from suspension element.

Ensure correct suspension point for in-line engine (see figure 6/B or 6/C)
or for V-engine (see figure 6/A)!

5. Screw the pilot rod (034.006) into the carrier.

6. Raise rocker arm housing (13) and move above cylinder head (10).
7. Attach pipe couplings (2 or 21). See Fig. 1.

Pipe coupling
Move pipe coupling, depending on the space conditions, on charge air
Work Cards, classified into sub-assemblies

pipe section of the adjacent cylinder or on charge air pipe section of the
rocker arm housing to be attached.

8. Remove cover lid (055.143).

9. Lower rocker arm housing (13) carefully onto cylinder head (10), guiding
with the pilot rod.

Fitting the rocker arm casing

Ensure proper fixing with two cylinder pins (11) in the cylinder head when
assembling the rocker arm housing! See Fig. 6.
Moreover, ensure that the pressure pieces engage with the rocker arms
in the thrust cups of the push rods!
48/60B;V48/60CR

2009-09-14

10. Coat the thread and contact face of the hexagon socket bolts (8) with
MoS2 lubricant, screw in and tighten them to the specified tightening
torque (see Work Card 000.30).

4 (10) 6704 111.02-01 EN

 MAN Diesel & Turbo 111.02

11. Apply MoS2lubricant to threads and contact face of the hexagon socket

Rocker arm casing/control arm

bolt (6), screw in and tighten with the specified torque (see Work Card
000.30).
12. Remove carrier (111.130).
13. Readjust valve clearance on intake and exhaust valves (see Work Card
111.01).

Fixing bolts
Make sure that the fixing bolts (111.131 and 111.132) for the setting of
the valve clearance are tightened with torque 40 Nm!

14. Unscrew and remove fixing bolts (111.131 and 111.132) after setting the
valve clearance.
15. Close cylinder head cover (14).
16. Attach lubricating oil supply line to rocker arm housing (13).
17. Fasten indicator valve on rocker arm housing (13) (only for in-line
engine).
18. Slide the pipe couplings (2 or 21) over the joints and centrally align them.
See Fig. 2.
19. Coat the thread and contact face of the hexagon socket bolts (1 or 20)
with MoS2 lubricant and tighten them to the specified tightening torque
(see Work Card 000.30).

Hexagon socket bolts

Use the appropriate torque when tightening the hexagon socket bolts (1
or 20) - Observe work card 000.30!

Work Cards, classified into sub-assemblies

48/60B;V48/60CR
2009-09-14

6704 111.02-01 EN 5 (10)

111.02 MAN Diesel & Turbo
Rocker arm casing/control arm

1 Hexagon socket bolt 5 Screw plug

2 Pipe coupling 20 Hexagon socket bolt
3 Charge air pipe section 21 Pipe coupling
4 Seal 22 Housing on the charge air cooler
Figure 1: Charge air pipe - charge air pipe section with pipe couplings
(illustration shows V-engine - top view: pipe couplings attached / bottom view:
pipe couplings moved)
Work Cards, classified into sub-assemblies

2 Pipe coupling
3 Charge air pipe section

Figure 2: Pipe coupling between the charge air pipe sections (sectional
drawing)
48/60B;V48/60CR

2009-09-14

6 (10) 6704 111.02-01 EN

 MAN Diesel & Turbo 111.02

Rocker arm casing/control arm

6 Hexagon socket bolt 11 Cylinder pin
7 Exhaust rocker arm 12 Intake rocker arm
8 Hexagon socket bolt 13 Rocker arm housing
9 Bearing block 14 Cylinder head cover
10 Cylinder head
Figure 3: Rocker arm housing with rocker arms and charge air pipe section

Work Cards, classified into sub-assemblies

48/60B;V48/60CR
2009-09-14

6704 111.02-01 EN 7 (10)

111.02 MAN Diesel & Turbo
Rocker arm casing/control arm

7 Exhaust rocker arm 15 Hexagon head bolt M20x300

12 Intake rocker arm 16 Hexagon head bolt M20x180
13 Rocker arm housing
Figure 4: Rocker arm housing with rocker arms and charge air pipe section -
Tools for assembly/disassembly
Work Cards, classified into sub-assemblies
48/60B;V48/60CR

2009-09-14

8 (10) 6704 111.02-01 EN

 MAN Diesel & Turbo 111.02

Rocker arm casing/control arm

6 Hexagon socket bolt 10 Cylinder head
8 Hexagon socket bolt 13 Rocker arm housing
Figure 5: Rocker arm housing with rocker arms and charge air pipe section -
Removing/installing the hexagon socket bolts

Work Cards, classified into sub-assemblies

48/60B;V48/60CR
2009-09-14

6704 111.02-01 EN 9 (10)

111.02 MAN Diesel & Turbo
Rocker arm casing/control arm

10 Cylinder head 19 O-ring

11 Cylinder pin
13 Rocker arm housing A Illustration of suspension point for V-engine
17 O-ring B Illustration of suspension point for in-line
engine (with cylinder head cover)
18 O-ring C Illustration of suspension point for in-line
Work Cards, classified into sub-assemblies

engine (without cylinder head cover)

Figure 6: Attaching/detaching the rocker arm housing - Illustration "A" shows
suspension point for V-engine /Illustration "B" shows suspension point for in-
line engine (rocker arm housing with cylinder head cover)/Illustration "C" shows
suspension point for in-line engine (rocker arm housing without cylinder head
cover)
48/60B;V48/60CR

2009-09-14

10 (10) 6704 111.02-01 EN

MAN Diesel & Turbo 112

Push rods
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.15-1 EN 1 (2)

 MAN Diesel & Turbo
Push rods

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.15-1 EN

 MAN Diesel & Turbo 112.01

Push rod

Push rods
removal and installation

Summary
Check components for quality/wear status, ensure /restore operating
safety.
push rods are to be disassembled and assessed within the scope of main-
tenance and repair work.
The work/work steps include:
Disassembling components,
Checking parts/ components,
Assembling components.
Safety requirements
- Driving shaft secured against turning
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Suspension device 112.006 Standard
1 Combination spanner (set) - Inventory
1 Lifting tackle - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
111.01 111.02

Work Cards, classified into sub-assemblies

Technical data
Designation Information
Push rod 20,5 kg
48/60;48/60B;48/60CR;51/60DF

Work sequence 1 - Disassembly of the push rod

Starting position Rocker arm casing is detached.

Work steps 1. Fasten suspension device (112.006) on push rod (2) and suspend from
lifting tackle. See Fig. 2.
2. Pull out push rod (2) carefully upwards, guiding the push rod by hand.
2007-06-15

3. Place push rod (2) aside, detach suspension fixture.

4. Dismantle second push rod (2) in the same manner.
5. Clean push rods (2) and check pressure cups.

6644 112.01-01 EN 1 (4)

112.01 MAN Diesel & Turbo

Work sequence 2 - Installing the push rod

Push rods

Starting position Push rods are cleaned.

Work steps 1. Fasten suspension device (112.006) on push rod (2) and suspend from
lifting tackle. See Fig. 2.
2. Oil the pressure cups of the push rod (2).
3. Introduce push rod (2) carefully in push rod covering (3) and fit it to thrust
piece of the cam-follower (4).
4. Remove the suspension device.
5. Install second push rod (2) in the same manner.
6. Attach rocker arm casing (see Work Card 111.01 or 111.02), fitting thrust
piece of the control lever (1) on pressure cups of the push rods (2).
Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

2007-06-15

2 (4) 6644 112.01-01 EN

 MAN Diesel & Turbo 112.01

Push rods
Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

1 Control lever 3 Push rods casing

2 Push rod 4 Cam follower
Figure 1: Push rod - illustration shows in-line engine L 48/60
2007-06-15

6644 112.01-01 EN 3 (4)

112.01 MAN Diesel & Turbo
Push rods

2 Push rod
5 Hexagon bolt M8x25

Figure 2: Push rod with attached suspension fixture

Work Cards, classified into sub-assemblies
48/60;48/60B;48/60CR;51/60DF

2007-06-15

4 (4) 6644 112.01-01 EN

MAN Diesel & Turbo 113/114

Inlet and exhaust valves

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.16-1 EN 1 (2)

 MAN Diesel & Turbo
Inlet and exhaust valves

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.16-1 EN

 MAN Diesel & Turbo 113.01

Inlet valve

Inlet and exhaust valves

removal and installation

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for quality/wear condition.
Inlet valves should be dismantled at regular intervals and overhauled if nec-
essary.
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Valve spring tensioner 113.204 Standard
1 Spindle 113.204-1 Standard
1 Bridge 113.204-2 Standard
1 Deep groove thrust ball bearing 113.204-3 Standard
1 Spherical disc 113.204-4 Standard
1 Ball socket 113.204-5 Standard
1 Extension pipe 113.204-6 Standard
1 Blanking washer 113.204-7 Standard
1 Tommy bar, 12 000.264 Standard

Work Cards, classified into sub-assemblies

1 Combination spanner (set) - Inventory
1 Marker pen - Inventory
1 Special anti-seize agent (Molykote G Rapid, Moly- - Inventory
kote G-n)

Corresponding Work Cards

Work card Work card Work card
055.02 055.05 113.02
113.03 113.04 113.05
113.06
48/60B;48/60CR

Technical data
2009-07-15

Designation Information
Valve cone 9 kg

6707 113.01-02 EN 1 (5)

113.01 MAN Diesel & Turbo

Work sequence 1 - Monitoring the valve rotator

Inlet and exhaust valves

The function of the valve rotator is checked with the cylinder head cover
closed and the engine running (see Work Card 113.02).
Work sequence 2 - Removing the inlet valve
Starting position Cylinder head is removed and clamped in turnover stand (see Work Card
055.05).

If only the valve rotators or the compression springs are to be removed,

the cylinder head remains attached and the piston is in Ignition-TDC.

Work steps 1. Screw spindle (113.204-1) onto valve taper (9) up to the stop.

2. Fit bridge (113.204-2) on spindle and place on valve rotator (2).

3. Insert blank plate (113.204-7) in spindle. See Fig. 2.

Always insert blank plate in spindle! This works as safety against

automatic release of the spindle from valve taper during the removal
sequence for the two-part tapered piece (point 7 to 9)!

4. Fit conical socket (113.204-5), spherical disc (113.204-4) and deep

groove thrust ball bearing (113.204-3). See Fig. 2.

Ensure correct fitting of conical socket, spherical disc and deep groove
thrust ball bearing!

5. Apply Molykote G-n to threads of the spindle.

6. Screw the extension pipe (113.204-6) onto spindle.
Work Cards, classified into sub-assemblies

7. Pretension / press down compression springs (3 and 4) by means of

tensioner (113.204) until two-part tapered piece (1) can be removed.
Hold the bridge with tommy bar (000.264). See Fig. 2/II.
8. Remove both parts of the tapered piece (1).
9. Unscrew extension pipe, releasing compression springs (3 and 4). See
Fig. 2/III.
10. Remove tensioner (113.204), holding valve taper (9) by hand.

If valve taper is not held, it falls out when removing the extension pipe
from valve guide!
48/60B;48/60CR

2009-07-15

11. Push out valve taper (9) from valve guide (8) and place it on clean sur-
face.

2 (5) 6707 113.01-02 EN

 MAN Diesel & Turbo 113.01

Note the assignment of valve taper/valve guide. If the valve taper is not

Inlet and exhaust valves

renewed, it must be installed again in the same valve guide.

12. Remove valve rotator (2) and compression spring (3 and 4).
13. Remove washer (6) and O-ring seal (5).
14. Clean all individual parts and check for wear (for max. clearance see
Volume 010.005 Engine - Operating Instructions), replace if necessary.
If necessary, regrind/ turn valve taper (9) or valve seat on valve seat ring
(10) again (see Work Card 113.04 and 113.05).
15. Check state of the valve guide (8) and disassemble if necessary (see
Work Card 113.06).

Work sequence 3 - Fitting the inlet valve

Starting position All individual parts are cleaned, checked and renewed where necessary.
Channel for valve guide is cleaned.
Work steps 1. Carry out the touching test (see Work Card 113.03).

2. Insert new O-ring seal (5) in ring groove, see that it is not twisted.
3. Treat shank of the valve taper (9) with Molykote spray G-Rapid.
4. Introduce valve taper (9) in valve guide (8) and hold by hand.
5. Screw spindle (113.204-1) onto valve taper (9) up to the stop.
6. Place washer (6) in cylinder head (7).
7. Install compression springs (3 and 4) and fit valve rotator (2) on com-
pression spring. See Fig. 1.
8. Fit bridge (113.204-2) on spindle and place on valve rotator (2).
9. Insert blank plate (113.204-7) in spindle. See Fig. 2.

Work Cards, classified into sub-assemblies

Always insert blank plate in spindle! This works as safety against
automatic release of the spindle from valve taper during the fitting
sequence for the two-part tapered piece (point 13 to 16)!

10. Fit conical socket (113.204-5), spherical disc (113.204-4) and deep
groove thrust ball bearing (113.204-3). See Fig. 2.

Ensure correct fitting of conical socket, spherical disc and deep groove
thrust ball bearing!
48/60B;48/60CR

11. Apply Molykote G-n to threads of the spindle.

2009-07-15

12. Screw the extension pipe (113.204-6) onto spindle.

13. Pretension / press down compression springs (3 and 4) by means of
tensioner (113.204) until two-part tapered piece (1) can be fitted. Hold
the bridge with tommy bar (000.264). See Fig. 2.
14. Assemble both parts of the tapered piece (1).

6707 113.01-02 EN 3 (5)

113.01 MAN Diesel & Turbo

15. Check that both parts of the tapered piece (1) are correctly inserted and
Inlet and exhaust valves

the gap between the two parts is uniform.

16. Unscrew extension pipe, releasing compression springs (3 and 4). See
Fig. 2.
17. Remove tensioner (113.204).

1 Tapered piece, two parts

2 Valve rotator
3 Compression spring
4 Compression spring
5 O-ring seal
6 Washer
7 Cylinder head
8 Valve guide
9 Valve cone
10 Valve seat ring

Figure 1: Inlet valve

Work Cards, classified into sub-assemblies
48/60B;48/60CR

2009-07-15

4 (5) 6707 113.01-02 EN

 MAN Diesel & Turbo 113.01

Inlet and exhaust valves

Work Cards, classified into sub-assemblies

1 Tapered piece, two parts 4 Compression spring 9 Valve cone

2 Valve rotator 5 O-ring seal I-III Work steps
48/60B;48/60CR

3 Compression spring 8 Valve guide

2009-07-15

Figure 2: Removal of the two-part tapered piece

6707 113.01-02 EN 5 (5)

 MAN Diesel & Turbo 113.02

Valve rotator

Inlet and exhaust valves

Checking rotating motion

Summary
Execute work on time according to the maintenance schedule, check com-
ponents for state/wear condition.
Valve rotators are to be assessed at regular intervals.
The work/work steps include:
Checking parts/components,
removing components,
disassembling and re-assembling,
installing components.
Tools/aids required
Quantity Designation Number Status
1 Screwdriver (Set) - Inventory
1 Felt-tip pen/marker pen - Inventory
1 Lubricating oil, clean - Inventory

Corresponding work cards

Work card Work card Work card
113.01 113.03

Structure of the valve rotator

The basic body (1) has several pockets arranged peripherally, in which the
balls (2) are pressed by tangential compression springs (6) to the upper end
of an inclined track. See Image 3. The cup spring (3) is located between the
basic body and the cap (4) to which the valve spring forces apply. See Image

Work Cards, classified into sub-assemblies

1. The snap ring (5) holds the rotator together when it is removed.
Principle of operation 48/60B;48/60CR;L58/64CD;51/60DF
When opening the valve, the cup spring (3) in the valve rotator is pressed
flat by the increasing force of the valve spring. The cup spring pressurises
the balls (2) in the pockets in the basic body (1) and compels them to roll
down their inclined track and itself rolls off on the balls. Support on the balls
reduces the pressure of the cup spring on the inside edge of the basic body
(1), which causes sliding here. The cup spring, cap (4) and valve springs are,
on the other hand, held together by friction to prevent rotation. The relative
rotation between cup spring/cap and basic body is transferred to the valve
via the basic body.
When the valve closes, the cup spring is relieved and also the balls, which
2009-07-15

are then pushed back to their initial position without rolling by the com-
pression spring (6).

6682 113.02-03 EN 1 (6)

113.02 MAN Diesel & Turbo
Inlet and exhaust valves

1 Basic body 4 Cover

2 Ball 5 Snap ring
3 Cup spring
Figure 1: Inlet valve rotator

Work sequence 1 - Checking the valve rotators

Starting position Engine at a standstill.

Work steps 1. Open cylinder head cover.

2. Make line markings on the valve rotators (15) and axial bearings (17) with
a felt-tip pen. See Fig. 2.
3. Close the cylinder head cover.
4. Start up the engine and run it for 1 minute at nominal speed and 25%
to 30% power output.
5. Shut down the engine.

Danger of burning due to hot components!

Work Cards, classified into sub-assemblies

Wear protective gloves during assembly work! Do not walk on hot

surfaces!
48/60B;48/60CR;L58/64CD;51/60DF

6. Open cylinder head cover.

7. Check the markings. If the valve rotators are working correctly, the
markings will now be in a different position. If the position of the mark-
ings has not changed, repeat work steps 3 and 4 again once.

Soiling in ball pockets!

Due to dirt, especially of the ball pockets from residues in the oil (due to
attrition, combustion products) there can be malfunctions. The
depositions stick to the individual parts and hinder the movement of the
2009-07-15

balls. The valve rotator must be removed, dismantled, washed carefully

and lubricated before reassembling. See work sequence 3.

2 (6) 6682 113.02-03 EN

 MAN Diesel & Turbo 113.02

If the balls have been pressed in through concentrated load with a non-

Inlet and exhaust valves

rotating inlet and exhaust valve in the running surface, the complete
valve rotator or the thrust bearing must be replaced. Moreover, for non-
rotating inlet or exhaust valves, check the condition of the valve cone
and valve seat ring (see Work Card 113.03).

8. Close the cylinder head cover and fasten.

Work Cards, classified into sub-assemblies

48/60B;48/60CR;L58/64CD;51/60DF

8 Inlet valve seat ring 13 O-ring 18 Outlet valve cone with valve propeller
9 Cylinder head 14 Pressure spring 19 Exhaust valve seat ring
2009-07-15

10 Inlet valve cone 15 Valve rotator 20 Cylinder head cover

11 Valve guide 16 Valve cone piece (two-part)
12 Pressure spring 17 Axial bearing M Mark
Figure 2: Inlet and outlet valve

6682 113.02-03 EN 3 (6)

113.02 MAN Diesel & Turbo

Work sequence 2 - Possible malfunctions and troubleshooting

Inlet and exhaust valves

1. Contamination, especially of the ball pockets, due to residues in the oil

(abrasion products, combustion products). The residues stick the indi-
vidual parts together and hamper the balls in their movement.
The rotator must be dismantled, carefully washed and oiled before re-
assembling. See work sequence 3.
2. Major base torque as a result of the friction between control lever and
valve stem end or due to stem seals. If there is a major positional skew-
ing of the valve springs, the cover (4) itself may cause appreciable
moment of friction on the basic body (1), which brings the rotator to a
halt.
The friction-generating parts or the valve springs must be replaced.

If the balls have been pressed into the tracks of the basic body due to
point load when the valve is not rotating, the complete valve rotator
needs to be replaced.

If an inlet valve has not rotated over a long period, check the state of the
valve taper and valve seat (refer to Work Card 113.03)!

Work sequence 3 - Dismantling and assembling the valve rotator

Starting position Valve rotator disassembled (refer to Work Card 113.01) and place on sup-
port surface (snap ring is at top).
Work steps 1. Remove snap ring (5).

2. Remove cover (4) and cup spring (3).

3. Remove all balls (2) and compression springs (6) from the basic body
Work Cards, classified into sub-assemblies

(1). See Fig. 3.

4. Wash all individual parts in suitable cleaning medium and then dry them.
5. Check individual parts for wear and ball impressions, renew if necessary
48/60B;48/60CR;L58/64CD;51/60DF

(for wear, refer to engine spare parts catalogue). 2009-07-15

4 (6) 6682 113.02-03 EN

 MAN Diesel & Turbo 113.02

Inlet and exhaust valves

1 Basic body
2 Ball
3 Cup spring
6 Compression spring
A Max. allowable wear = 0.1 mm
Figure 3: Limit of wear on the ball pocket tracks

When changing parts of the valve rotator, the basic body of the valve
rotator must be identified with the item No. of the used wear sets.

1. Place balls (2) and compression springs (6) in ball pocket tracks.

Ensure that balls are at the highest point of the inclined ball pocket tracks
and thus all are in the same direction! See Fig. 3.

2. Insert cup spring (3), place cover (4) on top and install snap ring (5).

The cup spring must rest with its inside edge on the basic body. See Fig.
1.

Work Cards, classified into sub-assemblies

3. Place valve rotator in clean lubricating oil and remove shortly before
installation. 48/60B;48/60CR;L58/64CD;51/60DF

Never put grease in valve rotator!

Work sequence 4 - Fitting the valve rotator

Starting position Valve rotator cleaned and oiled.
2009-07-15

Fitting the valve rotator - refer to Work Card 113.01.

Use only genuine valve springs, because only genuine valve springs will
guarantee smooth functioning of the rotator.

6682 113.02-03 EN 5 (6)

113.02 MAN Diesel & Turbo

Bearings Parts which are contaminated as a result of storage over a long period or
Inlet and exhaust valves

transport must be washed in suitable cleaning medium, dried and then

placed in clean lubricating oil for a few minutes.

Parts held in store must be well packaged, protected against dust, water,
humidity and aggressive media. Dust causes individual parts to stick and
prevents or hampers the rotation at the time of commissioning.

1 Basic body 3 Cup spring

2 Ball 6 Compression spring
Work Cards, classified into sub-assemblies

Figure 4: Ball tracks in the basic body of the valve rotator

48/60B;48/60CR;L58/64CD;51/60DF

2009-07-15

6 (6) 6682 113.02-03 EN

 MAN Diesel & Turbo 113.03

Inlet and exhaust valves

Inlet and exhaust valves

Check and assess valve cone and valve seating surfaces

Summary
Execute work on time according to the maintenance schedule, check com-
ponents for state/wear condition, assess the contact pattern /wear status.
Inlet and exhaust valve cones and seat surfaces are to be checked at regular
intervals and overhauled or replaced if necessary.
The work/work steps include:
executing touching tests ,
assessing contact pattern /wear status.
Tools/aids required
Quantity Designation Number Status
1 Touching bracket for engine L,V48/60B+CR: 114.033 Standard
51/60DF
1 Touching bow for engine 40/54 114.032 Standard
1 Touching bow for engine 58/64 114.054 Standard
1 Touching up device for engine 32/40, 32/44CR 113.224 Standard
1 Combination spanner (set) 009.231 Option
1 Hexagon screwdriver (set) - Inventory
1 Grinding paste, silicon-free - Inventory
1 Touching-test ink - Inventory

Preliminary remark
Exhaust and inlet valves with a faulty wear surface appearance will not have
a long service life. And must be overhauled or replaced.
The overhaul intervals specified in the maintenance schedule (see operating

Work Cards, classified into sub-assemblies

instructions) represent guide values that depend on the mode of operation,
the condition of the engine and the quality of the fuel used. The most expe-
dient overhaul intervals should be defined based on the prescribed inspec-
tion.
The valve cone material is subject to fatigue as a result of frequent temper-
ature fluctuations. The valve cones must be replaced once the operating
periods specified in the maintenance schedule (see operating instructions)
have elapsed, even if the maximum permissible refinishing limits have not
yet been reached.

Continued use poses an inestimable risk to the engine!

2009-12-03

General

6682 113.03-05 EN 1 (8)

113.03 MAN Diesel & Turbo
Inlet and exhaust valves

1 Cylinder head 4 Exhaust valve cone

2 Inlet valve cone 5 Valve seat ring
3 Valve seat ring
Figure 1: Inlet and exhaust valve
The valve seat angle (α) of the valve cone is 120° with a positive tolerance.
The valve seat angle (β) in the valve seat ring has been engineered with a
negative tolerance which produces a small differential angle (γ). This ensures
that a seal against the hot gases at the outer edge of the valve seat area is
maintained during operation. See Fig. 2.
The wear surface appearance is tested by performing a touching test.
Work Cards, classified into sub-assemblies

2 Inlet valve cone α Angle at valve cone γ Differential angle

3 Valve seat ring β Angle at valve seat ring
Figure 2: Relationship of geometric angle between valve seat ring and valve cone - illustration shows inlet
valve

Check machining tools!

Clearance may develop in older valve seat grinders or valve seat lathes
as a result of wear that changes the valve seat angle and therefore
produces an incorrect wear surface appearance! We recommend that a
touching test is carried out using a new original MAN Diesel & Turbo valve
2009-12-03

cone! If deviations are identified, check the valve seat grinder or valve
seat lathe!
General

2 (8) 6682 113.03-05 EN

 MAN Diesel & Turbo 113.03

Work sequence 1 - Touching test

Inlet and exhaust valves

Starting position Cylinder head is clamped in the cylinder head turnover stand, inlet and
exhaust valves are dismantled.

2 Inlet valve cone

Figure 3: Touching bow or touching up device - figure shows inlet valve
Work steps 1. Clean valve seating surfaces carefully.

Do not damage valve cones by using the wrong cleaning device (e.g.
chipping hammer)!

2. Attach touching bow or touching up device to the valve cone (2 or 4).

See Fig. 3.
3. Apply the thinnest possible layer of touching-test ink to the valve seating

Work Cards, classified into sub-assemblies

surfaces of the valve cone (2 or 4) and spread very thinly.
4. Introduce valve cone (2 or 4) in the relevant valve guide in the cylinder
head (1) and move by half a revolution with the touching bow or touching
up device under pressure in a vertical position.
5. Remove valve cone (2 or 4).
6. Check valve seating surfaces in the valve seat ring (3 or 5). With the
correct differential angle and proper rework, a closed, load bearing face
must form a closed load bearing surface on the outer edge of the valve
seat.
7. Remove touching bow or touching up device.

Work sequence 2 - Assessing the valve seating surfaces

2009-12-03

Starting position Cylinder head is clamped in the cylinder head turnover stand, inlet and
exhaust valves are dismantled.
General

Result 1 Valve seating surfaces of the valve seat rings are clean, lightly lacquered or
only have slight scar formation. Uniform contact pattern all around - see
figure 4.

6682 113.03-05 EN 3 (8)

113.03 MAN Diesel & Turbo
Inlet and exhaust valves

Figure 4: Figure for Result 1

Action
Apply silicon-free grinding paste on the valve seating surfaces of the valve
seat rings (follow the manufacturer's instructions!) and clean by hand using
a touching bow or touching up device, until the lacquer is removed. Conduct
touching test after the cleaning (see work sequence 1).

Clean as little as possible with grinding paste and then wash valve cone
and valve seat ring carefully. Residues of grinding paste promote further
wear.

Existing small cracks after cleaning are still permitted, they do not affect the
durability too much.
Result 2 Valve seating surface of the valve seat ring shows heavy deposit, deeper
corrosion cracks and/or distinct impact marks. Wear on valve seat ring - see
Work Cards, classified into sub-assemblies

figure 5.

2009-12-03
General

4 (8) 6682 113.03-05 EN

 MAN Diesel & Turbo 113.03

Inlet and exhaust valves

Figure 5: Figure for Result 2
Action
Machine valve seat ring by using valve seat grinder or valve seat lathe until
valve seating surfaces are clean and a new contact pattern appears (see
Work Card 113.04 and 113.05). Conduct touching test after the cleaning
(see work sequence 1).

Grind or turn as little as possible and then wash valve cone and valve
seat ring carefully. Residues of grinding paste promote further wear.

Existing small cracks after grinding/ turning are still permitted, they do not
affect the durability too much.
Result 3 Valve seating surfaces of valve cones are clean, lightly lacquered or only
have light crack formation. Uniform contact pattern all around.

Work Cards, classified into sub-assemblies

Action
Apply silicon-free grinding paste on valve seating surfaces of valve cones
and valve seat rings (follow the manufacturer's instructions!) and clean by
hand using a touching bow or touching up device, until lacquer is removed.
Conduct touching test after the cleaning (see work sequence 1).

Clean as little as possible with grinding paste and then wash valve cone
and valve seat ring carefully. Residues of grinding paste promote further
wear.

Existing small cracks after cleaning are still permitted, they do not affect the
durability too much.
2009-12-03

Result 4 Valve seating surface of the valve cone shows heavy deposit, deeper cor-
rosion cracks and/or distinct impact marks. Wear on the valve cone - see
General

figure 6.

6682 113.03-05 EN 5 (8)

113.03 MAN Diesel & Turbo
Inlet and exhaust valves

Figure 6: Figure for Result 4

Action
Machine valve cone with valve cone grinder until valve seating surfaces are
clean or a new contact pattern appears (see Work Card 113.xx). Conduct
touching test after the cleaning (see work sequence 1).

Grind as little as possible and then wash valve cone carefully. Residues
of grinding paste promote further wear.

Existing small cracks after grinding/ turning are still permitted, they do not
affect the durability too much.
Result 5 Valve cone with the start of burning through or cracks in the valve seat
armouring. Wear on the valve cone - see figure 7.
Work Cards, classified into sub-assemblies

2009-12-03
General

Figure 7: Figure for Result 5

6 (8) 6682 113.03-05 EN

 MAN Diesel & Turbo 113.03

Action

Inlet and exhaust valves

Replace the valve cone.
Work sequence 3 - Assessing the valve cone
Starting position Cylinder head is clamped in the cylinder head turnover stand, inlet and
exhaust valves are dismantled.
Result 6 Valve cone with the start of stem corrosion. Wear on the valve cone - see
figure 8.

A Stem corrosion

Work Cards, classified into sub-assemblies

Figure 8: Figure for Result 6
Action
Replace the valve cone.
Result 7 Valve cone with burn-up on the valve plate. Wear on the valve cone - see
figure 9.
2009-12-03

General

6682 113.03-05 EN 7 (8)

113.03 MAN Diesel & Turbo
Inlet and exhaust valves

B Burn-up on the valve plate

Figure 9: Figure for Result 7
Action
Replace the valve cone if the limits indicated on the Work Card 113.09 are
exceeded.
Result 8 Valve cone with tension cracks on the valve stem. Wear on the valve cone
- see figure 10.
Work Cards, classified into sub-assemblies

C Tension cracks on the valve stem

2009-12-03

Figure 10: Figure for Result 8

Action
General

Replace the valve cone, if tension cracks are detected on the valve stem.
Conduct a crack test as given in Work Card 000.34.

8 (8) 6682 113.03-05 EN

 MAN Diesel & Turbo 113.04

Valve seating surface

Inlet and exhaust valves

working/machining

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, restore contact pattern.
Valve seating surfaces are to be checked at regular intervals and rema-
chined if necessary. This is carried out using the valve seat turning machine
HUNGER Type VD4E.
The work includes:
Creating a correct contact pattern.
Tools/aids required
Quantity Designation Number Status
1 Valve seat lathe of type VD4E (277V) 113.253 Option
1 Valve seat lathe of type VD4E (120V) 113.252 Option
1 Valve seat lathe of type VD4E (230V) 113.251 Option
1 Lathe with boring head 113.251-1 Option
1 Control unit 277V 113.253-2 Option
1 Control unit 120V 113.252-2 Option
1 Control unit 230V 113.251-2 Option
1 Tool holder 113.251-3 Option
2 Clamping screw 113.251-4 Option
10 Indexable insert 113.251-5 Option
1 Pilot 113.251-6 Option
1 Support frame 113.251-7 Option
1 Milling cutter 113.251-8 Option

Work Cards, classified into sub-assemblies

1 Hexagon screw driver 4 113.251-9 Option
1 Hexagon screw driver 5 113.251-10 Option
1 TORX screwdriver 113.251-11 Option
1 Carry case 113.251-12 Option
1 Pilot nut 113.251-13 Option
1 Marker pen - Inventory
1 Lubricating oil, clean - Inventory
1 Cutting oil - Inventory

Corresponding Work Cards

48/60B;51/60DF
2007-05-07

Work card Work card Work card

055.04 113.01 113.03
114.01

6704 113.04-02 EN 1 (10)

113.04 MAN Diesel & Turbo

Work sequence - Machining the valve seating surface

Inlet and exhaust valves

Starting position Cylinder head is clamped disassembled in turnover stand, inlet and/or
exhaust valves are dismantled.

Read the manufacturer's instructions carefully before commissioning the

valve seat lathe!

Work steps 1. Clean valve guide (3) and valve seating surface (A) on valve seat ring (1
or 4).
2. Chamfer valve guide (3) on both sides. See Fig. 3.
˗ Introduce milling cutter (113.251-8) in valve guide (3),
˗ Rotate milling cutter and simultaneously press lightly against valve
guide (3),
˗ mill until a tapering surface free from any adhering carbon residues
and thus clean contact image is created for pilot or pilot nut
(113.251-13),
˗ Remove milling cutter,
˗ Clean the valve guide (3).
3. Introduce pilot (113.251-6) in valve guide (3) on combustion chamber
side.
4. Mount supporting spider (113.251-7). See Fig. 4.
˗ Fit supporting spider on pilot,
˗ Slide supporting spider downwards until bolts (5) are below the valve
seat ring (1 or 4),
˗ Mark the position,
˗ Dismantle pilot and supporting spider,
˗ Clamp tightly the supporting spider in the marked position on pilot.
5. Install pilot with supporting spider. See Fig. 4.
˗ Insert pilot with mounted supporting spider in valve guide (3),
˗ Screw pilot nut on pilot and tighten with moderate force, until pilot
Work Cards, classified into sub-assemblies

sits firmly in valve guide (3).

6. Oil shank and front surface of the pilots lightly with clean lubricating oil.
7. Prepare lathe (113.251-1).
˗ Unlock stop pin (6), to the extent possible in feed (7) and lock again,
˗ Rotate feed (7) clockwise until only 1 to 2 mm of the feed scale (8)
is visible,
˗ Install indexable insert (113.251-5) and clamping screw (113.251-4)
in tool holder (113.251-3),
˗ Install tool holder in tool rail of the boring head (9).
8. Fit lathe on pilot. See Fig. 5.
48/60B;51/60DF

Do not let insert impact on the valve seat ring!

2007-05-07

9. Adjust indexable insert.

˗ Swivel out lever (12),

2 (10) 6704 113.04-02 EN

 MAN Diesel & Turbo 113.04

˗ Press lever (12) inwards and swivel until the indexable insert is above

Inlet and exhaust valves

the centre of the valve seating surface (A).

Check that indexable insert can travel over the entire width of the valve
seating surface!

10. Lower the lathe to working height.

˗ Support lathe from below,
˗ Unlock stop pin (6),
˗ Lower lathe carefully until the indexable insert is about 2 to 3 mm
above the valve seating surface (A),
˗ Press stop pin (6) downward against pilot and lock it.
11. Connect control unit (113.251-2, 113.252-2 or 113.253-2). See Fig. 5.
˗ Connect control unit to lathe,
˗ Connect mains cable (11) to suitable power supply.

Check that supply voltage matches the input voltage indicated on the
nameplate of the control unit!

12. Advance indexable insert.

˗ Check that lever (12) is latched in rest position,
˗ Stop lathe and put it into operation by pressing the pushbutton
switch (13),
˗ Rotate feed (7) counter clockwise, until indexable insert touches
valve seating surface (A),
˗ Rotate feed (7) clockwise by 2 scale divisions, to lift the tip of the
indexable insert off the valve seating surface (A),
˗ Switch off lathe by releasing the pushbutton switch (13).
13. Adjust the indexable insert.
˗ Move boring head (9) inwards by means of lever (12), until insert is

Work Cards, classified into sub-assemblies

before inside edge of the valve seating surface (A),
˗ Latch lever (12),
˗ Rotate feed (7) counter clockwise by 2 scale divisions, to bring
indexable insert to valve seating surface height.
14. Adjust depth of cut.
˗ Rotate feed (7) counter clockwise by 6 to 8 scale divisions.
15. Machine the valve seating surface (A).
˗ Check that advance actuation (14) is pressed down,
˗ Adjust rotary knob (10) on the control unit to about 180 RPM ,
˗ Wet valve seating surface (A) with cutting oil,
˗ Stop lathe and put it into operation by pressing the pushbutton
switch (13),
48/60B;51/60DF

˗ Keep pushbutton switch (13) pressed until the valve seating surface
2007-05-07

(A) is completely machined,

˗ Release pushbutton switch (13) as soon as indexable insert has
moved away over valve seating surface (A),
˗ Rotate feed (7) clockwise by 2 scale divisions, to lift the tip of the
indexable insert from valve seat.

6704 113.04-02 EN 3 (10)

113.04 MAN Diesel & Turbo

16. Adjust indexable insert again, adjust depth of cut (approx. 2 to 4 scale
Inlet and exhaust valves

divisions) and machine the valve seating surface (A). See point 13 to 15.

Repeat the sequence until the valve seating surface to be machined is

bright overall.

17. Make markings using a marking pen at several places on the valve seat-
ing surface (A).

Markings are for checking a uniform chip removal.

18. Execute the last boring operation as follows:

˗ Feed 1 Scale division,
˗ Adjust rotary knob (10) on the control unit to about 200 RPM.
19. Disassemble valve seat lathe (113.251, 113.252 or 113.253) completely,
clean and store in carrying case (113.251-12).
20. Carry out the touching test (see Work Card 113.03).

If the required contact pattern cannot be realised with the valve seat
lathe, it must be handed over for repair to a MAN Diesel & Turbo
Customer Service workshop!

Maximum allowable rework The maximum allowable rework is reached if the valve seating surface (A) is
reworked till the face (B). See Fig. 6.
On reaching the rework limit, change the valve seat ring (1 or 4) (see Work
Card 055.04).
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2007-05-07

4 (10) 6704 113.04-02 EN

 MAN Diesel & Turbo 113.04

Inlet and exhaust valves

Work Cards, classified into sub-assemblies
48/60B;51/60DF
2007-05-07

Figure 1: Valve seat lathe HUNGER Type VD4E

6704 113.04-02 EN 5 (10)

113.04 MAN Diesel & Turbo
Inlet and exhaust valves

1 Valve seat ring (inlet valve) 4 Valve seat ring (exhaust valve)
2 Cylinder head
3 Valve guide A Valve seating surface
Figure 2: Intake and exhaust valve seat ring in the cylinder head
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2007-05-07

6 (10) 6704 113.04-02 EN

 MAN Diesel & Turbo 113.04

Inlet and exhaust valves

1 Valve seat ring (inlet valve) 3 Valve guide
2 Cylinder head 4 Valve seat ring (exhaust valve)
Figure 3: Cleaning the valve guide

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2007-05-07

6704 113.04-02 EN 7 (10)

113.04 MAN Diesel & Turbo
Inlet and exhaust valves
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2007-05-07

1 Valve seat ring (inlet valve) 4 Valve seat ring (exhaust valve)
2 Cylinder head 5 Pin
3 Valve guide
Figure 4: Fitting the pilot

8 (10) 6704 113.04-02 EN

 MAN Diesel & Turbo 113.04

Inlet and exhaust valves

Work Cards, classified into sub-assemblies

1 Valve seat ring (inlet valve) 9 Boring head

2 Cylinder head 10 Rotary knob
48/60B;51/60DF

4 Valve seat ring (exhaust valve) 11 Mains cable

2007-05-07

6 Stop pin 12 Lever

7 Feed 13 Push-button
8 Feed scale 14 Advance actuation
Figure 5: Attaching the lathe

6704 113.04-02 EN 9 (10)

113.04 MAN Diesel & Turbo
Inlet and exhaust valves

1 Valve seat ring (inlet valve)

2 Cylinder head A Valve seating surface
4 Valve seat ring (exhaust valve) B Face (Rework limit)
Figure 6: Rework limit on the valve seating surfaces
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2007-05-07

10 (10) 6704 113.04-02 EN

 MAN Diesel & Turbo 113.05

Valve cone

Inlet and exhaust valves

grinding

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, restore contact pattern.
Valve seating surfaces are to be checked at regular intervals and rema-
chined if necessary. This is carried out using the valve seat turning machine
Hunger VKM 3.1.
The work includes:
Creating a correct contact pattern.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Valve cone grinder VKM 3.1 113.242 Option
1 Clamp for engine 20/27 113.244 Option
1 Clamp for engine 40/45, 40/54 113.248 Option
1 Clamp for engine 48/60 113.249 Option
1 Clamp for engine 52/55B 113.250 Option
1 Grinding wheel 113.258-1 Option
1 Dressing diamond 113.258-3 Option
1 Coolant concentrate 113.258-5 Option
1 Dial gauge - Inventory

Work Cards, classified into sub-assemblies

1 Magnetic post - Inventory
1 Sliding calliper - Inventory
1 Hammer (wood/plastic-) - Inventory

Corresponding Work Cards

Work card Work card Work card
113.03 113.09
2008-10-24

General

6682 113.05-02 EN 1 (8)

113.05 MAN Diesel & Turbo

Work sequence 1 - Concentricity check on run valve taper

Inlet and exhaust valves

1 Valve cone 2 Collet 3 Collar plate

Figure 1: Concentricity check on the valve cone (figure shows inlet valve)
Work steps 1. Clean the valve taper.

2. Clamp valve taper in valve taper grinder on the rear shank diameter. See
Fig. 1.
3. Measure concentricity on front shank diameter and seat of the valve
taper.
4. Decide whether valve taper can be reworked or must be replaced.

The maximum permissible concentricity of the shank and seat area of

the worn valve is 0.05 mm. Replace the valve cone if this value is
exceeded!
Work Cards, classified into sub-assemblies

For additional instructions about evaluation of the valve seating surface,

refer to Work Card 113.03.
Work sequence 2 - Grinding the valve taper seat

Before commissioning the device, read the manufacturer's user manual

the manufacturer carefully, use existing guards.

Starting position Valve cone is cleaned.

To set and grind the valve cone see the User Manual and observe the fol-
lowing points:
2008-10-24

Work steps 1. Before beginning work, check the grinding wheel fastening for firm seat-
ing.
General

2. Dress grinding wheel with dressing diamond. In doing so, guide dressing
diamond to grinding wheel, pulling at an angle of 15-20°.

2 (8) 6682 113.05-02 EN

 MAN Diesel & Turbo 113.05

Due to the cutting speed the grinding wheel diameter must not be smaller

Inlet and exhaust valves

than 150 mm.

Figure 2: Clamped exhaust valve cone

1. Insert suitable clamp in spindle head suitable for the engine type.
2. Insert valve cone in the workpiece spindle head. Keep valve taper
clamping on the special collar as short as possible (valve plate near to
clamp). See Fig. 2.
3. Tighten collet (manually with hook wrench). Knock valve plate bottom
with plastic hammer to centre the clamp (two to three light hits), tighten
the clamp again.
4. Check concentricity

Work Cards, classified into sub-assemblies

If the concentricity is over the allowable value, check back with the
Service Department of MAN Diesel & Turbo SE.

5. Grinding slide is fixed at a set angle by the manufacturer with a pin.

6. Before starting the cut, set grinding wheel and valve taper such that
centre of the valve taper seat = Centre of grinding wheel. See Fig. 3.
7. Advance until the valve cone seat surface starts to be ground.
8. Grinding with thin cooling water and oscillating (to and fro) movement
of the grinding wheel by hand. See that the grinding wheel is always on
2008-10-24

the valve seat. Grinding motion as low as possible (0.025 mm = 1/2

greater than the pitch mark on the scale), to avoid chatter marks.
General

6682 113.05-02 EN 3 (8)

113.05 MAN Diesel & Turbo

Always supply sufficient cooling water to the taper between the grinding
Inlet and exhaust valves

wheel and valve cone seating surface. During the grinding process
ensure that the grinding wheel does not cut into the valve cone radius
(R). See Figs. 4 to 8.
The increasing grinding noise points out that the grinding wheel is not
removing the material any longer. The grinding wheel should then be
dressed.
When grinding valve taper from NIMONIC 80 A grinding wheel, dress
more often, because it clogs up faster and presses (higher grinding tone).

9. Dress the grinding wheel again before the last grind.

10. For grinding out (last grinding) set for lower quantity (< 0.02 mm) and
grind out completely.

After grinding out do not lift grinding wheel from valve cone seating
surface, but lift valve cone seating surface away from the grinding wheel.
On reaching the maximum value (H) the valve taper may no longer be
used (see table 2 to 7).

11. Remove burr on the outer diameter of the valve plate with suitable tool
(file, grindstone) or break edge on seat inner diameter using grindstone.

1 Valve cone
4 Grinding wheel
Work Cards, classified into sub-assemblies

Figure 3: Position grinding wheel/valve taper seat before the start of cut

Work sequence 3 - Maximum rework on exhaust valve

Preliminary remark Exhaust valve are subject to constant development. This affects the shape
design or material composition of the valve taper.

For the rework on valve taper seat, it is important to classify the exhaust
valve cone correctly by its shape and finish and to read off corresponding
maximum reworking measure from the concerned table (see Table 2 to
2008-10-24

4).

Differentiation features on exhaust valve cone:

General

▪ Exhaust valve cones are executed generally as single piece propeller

valves (old /existing with wing bush).

4 (8) 6682 113.05-02 EN

 MAN Diesel & Turbo 113.05

▪ The shape on the valve seat can be executed with lug angle (see Figure

Inlet and exhaust valves

4 or 5) or with undercut (see Figure 6).
▪ Exhaust valve cones can be made either from a steel alloy with armour
or from NIMONIC 80 A. The same rework limits (H) are applicable to
exhaust valve.
In general Maximum allowable rework is done on the valve taper seat if the valve taper
seat width (G, new condition) has increased to dimension (H).

For allowable rework on outer diameter of valve and allowable burn-up

and corrosion depth on valve plate see Work Card 113.09.

Exhaust valve cone with

wing bush

5 Exhaust valve cone H Max. rework

6 Wing bush R Valve cone radius
G Valve taper seat width (new condition) X Tangential point
Figure 4: Rework on exhaust valve cone with wing bush (old version with
connection angle)
Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B

Work Cards, classified into sub-assemblies

G new 4.0 7.3 9.8 11.5 9.3
H maximum 15.5 23.5 25.5 32.0 27.5
Table 1: Rework limits [mm] to figure 4
Exhaust valve cone version
with connection angle
2008-10-24

General

6682 113.05-02 EN 5 (8)

113.05 MAN Diesel & Turbo
Inlet and exhaust valves

5 Exhaust valve cone H Max. rework

7 Rotating wing R Valve cone radius
G Valve taper seat width (new condition) X Tangential point
Figure 5: Rework on exhaust valve cone (version with connection angle)
Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B
G new 16.5
H maximum 25.8
Table 2: Rework limits [mm] to figure 5
Exhaust valve cone version
with undercut
Work Cards, classified into sub-assemblies

5 Exhaust valve cone H Max. rework

7 Rotating wing R Valve cone radius
G Valve taper seat width (new condition) X Tangential point
Figure 6: Rework on exhaust valve cone with undercut
48/60B
Engine type 20/27 40/45 40/54 48/60 52/55 A+B
51/60DF
G new 4.6 11.5 11.5
H maximum 7.8 18.4 18.4
Table 3: Rework limits [mm] to figure 6
2008-10-24

Work sequence 4 - Maximum rework on inlet valve

Preliminary remark Inlet valves are subject to constant development. This affects the shape
General

design or material composition of the valve taper.

6 (8) 6682 113.05-02 EN

 MAN Diesel & Turbo 113.05

For the rework on valve taper seat, it is important to classify the valve

Inlet and exhaust valves

taper correctly according to its shape and finish and to read off the
corresponding maximum rework dimension from the relevant table.

Differentiation features on inlet valve taper:

▪ The shape on the valve seat can be executed with lug angle (see Figure
7) or with undercut (see Figure 8).
▪ Inlet valve taper can be produced either from a steel alloy with hard
facing (valve plate magnetic) or from NIMONIC 80 A (valve plate not
magnetic).

For inlet valve cones with undercut and hard faced execution, there are
other rework limits than for inlet valve cones with undercut from
NIMONIC 80 A!

Conducting a magnetism test on valve plate underside.

In general Maximum allowable rework is done on the valve taper seat if the valve taper
seat width (G, new condition) has increased to dimension (H).
Inlet valve taper version
with connection angle

Work Cards, classified into sub-assemblies

8 Inlet valve cone G Valve taper seat width (new condition) R Valve cone radius
H Max. rework X Tangential point
Figure 7: Rework on inlet valve taper (version with connection angle)
2008-10-24

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B

G new 4.0 7.3 9.8 9.3
General

H maximum 15.5 23.5 25.5 27.5

Table 4: Rework limits [mm] to figure 7

6682 113.05-02 EN 7 (8)

113.05 MAN Diesel & Turbo

Inlet valve taper version

Inlet and exhaust valves

with undercut

8 Inlet valve cone G Valve taper seat width (new condition) R Valve cone radius
H Max. rework X Tangential point
Figure 8: Rework on inlet valve taper with undercut
Inlet valve taper with hard facing and undercut
48/60B
Engine type 20/27 40/45 40/54 48/60 52/55 A+B
51/60DF
G new 4.6 6.7 8.0 11.5 11.5
H maximum 7.8 11 14.0 16.0 16.0
Table 5: Rework limits [mm] to figure 8
Inlet valve taper from NIMONIC 80 A with undercut
Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B
G new 4.6 6.7 8.0 11.5 8.7
Work Cards, classified into sub-assemblies

H maximum 8.0 11 12.1 18.4 15.5

Table 6: Rework limits [mm] to figure 8

2008-10-24
General

8 (8) 6682 113.05-02 EN

 MAN Diesel & Turbo 113.06

Valve guide (inlet valve)

Inlet and exhaust valves

inspection, removal and installation

Summary
Ensure correct execution of work.
Valve guides are to be checked in the course of the service and maintenance
work and replaced if necessary.
The work/work steps include:
Checking parts/components,
Removing components,
Fitting components.
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 113.206 Standard
1 Guide piece 113.206-1 Standard
1 Plate 113.206-2 Standard
1 Clamping piece 113.206-3 Standard
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Combination spanner (set) 009.231 Option
1 Hydraulic tensioner (hollow piston) 009.022 Standard

Corresponding Work Cards

Work card Work card Work card
009.03 009.05 055.05
113.01

Work Cards, classified into sub-assemblies

Work sequence 1 - Check valve guide

Replace the valve guide, if the wear limit is reached! The wear limit is
reached,
- if the valve taper (20) on the elongation (C) of the valve guide (21) on the
combustion chamber has started! See Fig. 1.
48/60B;V48/60CR;51/60DF

- if the wearing edge (A) all-around on the valve guide (21) can no longer
be seen or felt! This can also occur only on part of the periphery!
2008-10-07

6707 113.06-01 EN 1 (6)

113.06 MAN Diesel & Turbo
Inlet and exhaust valves

20 Valve cone A Wearing edge in new condition

21 Valve guide B Wearing edge worn
C cylindrical hollowing out
Figure 1: Wear edge on the valve guide - Illustration shows Exhaust valve cone)

Work sequence 2 - Removing the valve guide

Starting position Cylinder head is clamped in turnover stand, inlet valve is dismantled.

Work steps 1. Fit guide piece (113.206-1) in valve guide (1) and tighten hexagon nut
Work Cards, classified into sub-assemblies

(5) manually.
2. Fit clamping piece (113.206-3) and plate (113.206-2) over guide piece,
ensuring centring of clamping piece plate. See Fig. 3/I.
3. Fit hydraulic hollow piston tensioner (009.022) over guide piece and
tighten hexagon nut (4) by hand. See Fig. 3/I.
4. Connect high-pressure hose (009.306) to hydraulic hollow piston ten-
sioner and high-pressure pump (009.342). Connect oil pressure gauge
48/60B;V48/60CR;51/60DF

(0-400 bar) to high-pressure pump.

5. Put high-pressure pump in operation (see Work Card 009.03) and pump
hydraulic hollow piston tensioner slowly.

Type and source of danger

2008-10-07

Observe pressure gauge during the pumping up.

2 (6) 6707 113.06-01 EN

 MAN Diesel & Turbo 113.06

6. Pull in valve guide (1) in several steps, letting off pressure every time,

Inlet and exhaust valves

press in piston of the hydraulic hollow piston tensioner and retighten
hexagon nut (4). See Figure 3/II and 3/III.
7. Release the pressure.
8. Separate the high-pressure hose from hydraulic hollow piston tensioner
and high-pressure pump and detach tool.
9. Clean the valve guide (1) and check for wear/damage, renew if neces-
sary.

Work sequence 3 - Installing the valve guide

Starting position Valve guide is cleaned, checked and replaced if necessary. Hole in cylinder
head cleaned.
Work steps 1. Fit valve guide (1) on guide piece (113.206-1) and screw on hexagon nut
(5) and tighten by hand. Fit guide piece through cylinder head (7).
2. Fit plate (113.206-2) over guide piece and place on valve seat ring (3),
ensuring centring of plate valve seat ring. See Fig. 4/I.
3. Fit hydraulic hollow piston tensioner (009.022) over guide piece and
tighten hexagon nut (4) by hand.
4. Connect high-pressure hose (009.306) to hydraulic hollow piston ten-
sioner and high-pressure pump (009.342). Connect oil pressure gauge
(0-400 bar) to high-pressure pump.
5. Put high-pressure pump in operation (see Work Card 009.03) and pump
hydraulic hollow piston tensioner slowly.

Type and source of danger

Ensure that valve guide (1) is pulled into the hole properly! Observe
pressure gauge during the pumping up! Sudden pressure rise during
fitting points to tilting of the valve guide!

6. Pull in valve guide (1) in several steps, releasing pressure every time,

Work Cards, classified into sub-assemblies

press in piston of the hydraulic hollow piston tensioner and retighten
hexagon nut (4). See Figure 4/II and 4/III.
7. Release the pressure.
8. Separate the high-pressure hose from hydraulic hollow piston tensioner
and high-pressure pump and detach tool.
48/60B;V48/60CR;51/60DF
2008-10-07

6707 113.06-01 EN 3 (6)

113.06 MAN Diesel & Turbo
Inlet and exhaust valves

1 Valve guide
2 Cylinder head
3 Valve seat ring

Figure 2: Valve guide

Work Cards, classified into sub-assemblies
48/60B;V48/60CR;51/60DF

2008-10-07

4 (6) 6707 113.06-01 EN

 MAN Diesel & Turbo 113.06

Inlet and exhaust valves

Work Cards, classified into sub-assemblies
48/60B;V48/60CR;51/60DF

1 Valve guide 4 Hexagon nut M30 I-III Work steps

2 Cylinder head 5 Hexagon nut M30
Figure 3: Removing the valve guide
2008-10-07

6707 113.06-01 EN 5 (6)

113.06 MAN Diesel & Turbo
Inlet and exhaust valves
Work Cards, classified into sub-assemblies
48/60B;V48/60CR;51/60DF

2008-10-07

1 Valve guide 3 Valve seat ring 5 Hexagon nut M30

2 Cylinder head 4 Hexagon nut M30 I-III Work steps
Figure 4: Installation of valve guide

6 (6) 6707 113.06-01 EN

 MAN Diesel & Turbo 113.09

Valve seating surface

Inlet and exhaust valves

inspecting

Summary
Combat corrosion attack, keep quality in the permitted range.
When regrinding the valve seating surface, the permissible valve plate thick-
ness is to be determined.
The work/work steps include:
Measuring components and
Assessing contact pattern /wear condition.
Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Option
1 Sliding calliper - Inventory
1 Felt-tip pen/marker pen - Inventory
1 Steel ruler - Inventory

Corresponding Work Cards

Work card Work card Work card
113.03 113.05 113.06

Work sequence 1 - Checking the valve thickness

Work steps 1. Clean valve cone and remove any adhering carbon residue.

2. Determine plate thickness in new condition (HN) at measuring point (C)

on a new, same valve and note.
3. Mark one or more measuring points (C), depending on the state of the

Work Cards, classified into sub-assemblies

valve cone to be tested, distributed on the periphery, using a felt-tip pen.
4. Measure and note the plate thickness using sliding calliper at point (C).
Dimension A = Difference between HN and the measured value must
not be greater than 10 % of HN (new condition) at any point

If regrinding is necessary on a used valve cone on the seating surface,

then the expected material reduction due to grinding should be taken
into account when assessing the determined grinding dimension A. (The
material reduction on the seating surface S further reduces the plate
thickness).

5. Measure and take note of the wear dimension (B) by placing a ruler on
the plate bottom with depth gauge or feeler gauge somewhere in the
2008-09-11

centre of the plate. Dimension B may be maximum 3.0 mm at the deep-

est point.
General

6682 113.09-01 EN 1 (3)

113.09 MAN Diesel & Turbo

Regrinding the valve seating surface (S) and possibly occurring hot
Inlet and exhaust valves

corrosion on the plate bottom could reduce the valve plate thickness to
inadmissible values.

1 Valve plate in new condition 2 Valve plate with

maximum permitted
wear
A Wear dimension on the plate edge at meas- B Wear dimension in
uring point C the plate centre
C Measuring point at 1/6 D from the plate diam- D Valve plate outer
Work Cards, classified into sub-assemblies

eter diameter
E Tracer arms of the sliding calliper HN Plate thickness in
the new condition at
measuring point C
S Seating surface
Figure 1: Determine wear dimension A on the valve plate

Work sequence 2 - Checking for corrosion grooves on the valve plate outer diameter (D)

Circumferential corrosion grooves of low depth can be produced at the

transition from the base to the armouring material on the valve plate
2008-09-11

outside diameter (D). The transition point must be checked for cracks. If
there are cracks the outside diameter it must be ground down until there
are no more cracks, whilst maintaining machining limits.
General

Work steps 1. Clean valve cone, do not damage surface by using the wrong cleaning
device (e.g. chipping hammer).

2 (3) 6682 113.09-01 EN

 MAN Diesel & Turbo 113.09

2. Check armouring transition by using the dye-penetrant method (Met-L-

Inlet and exhaust valves

Check) for cracks (see Work Card 000.34)
3. If there are cracks, regrind on valve plate outer diameter without coolant
supply until free from cracks, maintaining machining limits (see table 1).
Permitted rework related to diameter against
Valve plate outer diameter
new condition
up to 100 mm 0.2 mm
over 100 mm 0.5 mm
Table 1: Limit values for rework on valve plate outer diameter

Work Cards, classified into sub-assemblies

2008-09-11

General

6682 113.09-01 EN 3 (3)

 MAN Diesel & Turbo 114.01

Exhaust valve

Inlet and exhaust valves

removal and installation

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for quality/wear condition.
Exhaust valves are to be disassembled at regular intervals and overhauled
if necessary.
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Valve spring tensioner 113.204 Standard
1 Spindle 113.204-1 Standard
1 Bridge 113.204-2 Standard
1 Deep groove thrust ball bearing 113.204-3 Standard
1 Spherical disc 113.204-4 Standard
1 Ball socket 113.204-5 Standard
1 Extension pipe 113.204-6 Standard
1 Blanking washer 113.204-7 Standard
1 Tommy bar, 12 000.264 Standard

Work Cards, classified into sub-assemblies

1 Combination spanner (set) - Inventory
1 Marker pen - Inventory
1 Special anti-seize agent (Molykote G Rapid, Moly- - Inventory
kote G-n)

Corresponding Work Cards

Work card Work card Work card
055.02 055.05 113.03
113.04 113.05 114.03

Technical data
48/60B;48/60CR
2009-07-15

Designation Information
Valve cone 10 kg

6707 114.01-02 EN 1 (5)

114.01 MAN Diesel & Turbo

Work sequence 1 - Monitoring the valve rotator

Inlet and exhaust valves

The function of the valve rotator (rotation wing on valve stem and axial
bearing) is checked with the cylinder head cover closed and the engine
running (see Work Card 113.02).
Work sequence 2 - Disassembling of the exhaust valve cone
Starting position Cylinder head is removed and clamped in turnover stand (see Work Card
055.05).

Should only the axial bearings or the pressure springs be disassembled,

the cylinder head remains attached and the piston is in Ignition-TDC.

Work steps 1. Screw spindle (113.204-1) onto valve cone (9) up to the stop.

2. Fit bridge (113.204-2) on spindle and place on axial bearing (2).

3. Insert blank plate (113.204-7) in spindle. See Fig. 2.

Always insert blank plate in spindle! This works as safety against

automatic release of the spindle from valve cone during the removal
sequence for the two-part tapered piece (points 7 to 9)!

4. Fit ball socket (113.204-5), spherical washer (113.204-4) and axial

grooved ball bearing (113.204-3). See Fig. 2.

Ensure correct fitting of conical socket, spherical disc and deep groove
thrust ball bearing!

5. Apply Molykote G-n to thread of the spindle.

Work Cards, classified into sub-assemblies

6. Screw the extension pipe (113.204-6) onto spindle.

7. Pre-tension / press down pressure springs (3 and 4) by means of ten-
sioner (113.204) until two-part tapered piece (1) can be removed. Hold
the bridge with tommy bar (000.264). See Fig. 2/II.
8. Remove both parts of the tapered piece (1).
9. Unscrew extension pipe, releasing pressure springs (3 and 4). See Fig.
2/III.
10. Remove tensioner (113.204), holding valve cone (9) by hand.

If valve cone is not held, it falls out when removing the extension pipe
from valve guide.
48/60B;48/60CR

2009-07-15

11. Push out valve cone (9) from valve guide (6) and place it on clean surface.

2 (5) 6707 114.01-02 EN

 MAN Diesel & Turbo 114.01

Note the assignment of valve cone/valve guide. If the valve cone is not

Inlet and exhaust valves

renewed, it must be installed again in the same valve guide.

12. Remove axial bearing (2) and pressure springs (3 and 4).
13. Remove washer (7) and O-ring (5).
14. Check all individual components and check for wear (for max. clearan-
ces see Engine - Operating Instructions Volume 010.005), possibly
renew. If necessary, grind/turn down valve cone (9) or valve seat on valve
seat ring (10) (see Work Card 113.04 and 113.05).
15. Check state of the valve guide (6) and disassemble if necessary (see
Work Card 114.03).

Work sequence 3 - Fitting of the exhaust valve

Starting position All individual parts are cleaned, checked and renewed where necessary.
Channel for valve guide is cleaned.
Work steps 1. Carry out the touching test (see Work Card 113.03).

2. Insert new O-ring seal (5) in ring groove, see that it is not twisted.
3. Treat shank of the valve taper (9) with Molykote spray G-Rapid.
4. Introduce valve taper (9) in valve guide (6) and hold by hand.
5. Screw spindle (113.204-1) onto valve taper (9) up to the stop.
6. Place washer (7) in cylinder head (8).
7. Install compression springs (3 and 4) and fit thrust bearing (2) on com-
pression springs. See Fig. 1.
8. Fit bridge (113.204-2) on spindle and place on thrust bearing (2).
9. Insert blank plate (113.204-7) in spindle. See Fig. 2.

Work Cards, classified into sub-assemblies

Always insert blank plate in spindle! This works as safety against
automatic release of the spindle from valve taper during the fitting
sequence for the two-part tapered piece (point 13 to 16)!

10. Fit conical socket (113.204-5), spherical disc (113.204-4) and deep
groove thrust ball bearing (113.204-3). See Fig. 2.

Ensure correct fitting of conical socket, spherical disc and deep groove
thrust ball bearing!
48/60B;48/60CR

11. Apply Molykote G-n to threads of the spindle.

2009-07-15

12. Screw the extension pipe (113.204-6) onto spindle.

13. Pretension / press down compression springs (3 and 4) by means of
tensioner (113.204) until two-part tapered piece (1) can be fitted. Hold
the bridge with tommy bar (000.264). See Fig. 2.
14. Assemble both parts of the tapered piece (1).

6707 114.01-02 EN 3 (5)

114.01 MAN Diesel & Turbo

15. Check that both parts of the tapered piece (1) are correctly inserted and
Inlet and exhaust valves

the gap between the two parts is uniform.

16. Unscrew extension pipe, releasing compression springs (3 and 4). See
Fig. 2.
17. Remove tensioner (113.204).

1 Tapered piece, two parts

2 Thrust bearing
3 Compression spring
4 Compression spring
5 O-ring seal
6 Valve guide
7 Washer
8 Cylinder head
9 Valve cone
10 Valve seat ring

Figure 1: Exhaust valve

Work Cards, classified into sub-assemblies
48/60B;48/60CR

2009-07-15

4 (5) 6707 114.01-02 EN

 MAN Diesel & Turbo 114.01

Inlet and exhaust valves

Work Cards, classified into sub-assemblies

1 Tapered piece, two parts 4 Compression spring 9 Valve cone

2 Valve rotator 5 O-ring seal I-III Work steps
48/60B;48/60CR

3 Compression spring 6 Valve guide

2009-07-15

Figure 2: Removal of the two-part tapered piece

6707 114.01-02 EN 5 (5)

 MAN Diesel & Turbo 114.03

Valve guide (exhaust valve)

Inlet and exhaust valves

inspection, removal and installation

Summary
Ensure correct execution of work.
Valve guides are to be checked in the course of the service and maintenance
work and replaced if necessary.
The work/work steps include:
Checking parts/components,
Removing components,
Fitting components.
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 113.206 Standard
1 Guide piece 113.206-1 Standard
1 Plate 113.206-2 Standard
1 Clamping piece 113.206-3 Standard
1 High-pressure pump 009.342 Standard
1 High-pressure hose 009.306 Standard
1 Combination spanner (set) 009.231 Option
1 Hydraulic tensioner (hollow piston) 009.022 Standard

Corresponding Work Cards

Work card Work card Work card
009.03 009.05 055.05
114.01

Work Cards, classified into sub-assemblies

Work sequence 1 - Check valve guide

Replace the valve guide, if the wear limit is reached! The wear limit is
reached,
- if the valve taper (20) on the elongation (C) of the valve guide (21) on the
combustion chamber has started! See Fig. 1.
48/60B;V48/60CR;51/60DF

- if the wearing edge (A) all-around on the valve guide (21) can no longer
be seen or felt! This can also occur only on part of the periphery!
2008-10-07

6707 114.03-01 EN 1 (6)

114.03 MAN Diesel & Turbo
Inlet and exhaust valves

20 Valve cone A Wearing edge in new condition

21 Valve guide B Wearing edge worn
C cylindrical hollowing out
Figure 1: Wear edge on the valve guide - Illustration shows Exhaust valve cone)

Work sequence 2 - Removing the valve guide

Starting position Cylinder head is clamped in turnover stand, exhaust valve is dismantled.

Work steps 1. Fit guide piece (113.206-1) in valve guide (1) and tighten hexagon nut
Work Cards, classified into sub-assemblies

(5) manually.
2. Fit clamping piece (113.206-3) and plate (113.206-2) over guide piece,
ensuring centring of clamping piece plate. See Fig. 3/I.
3. Fit hydraulic hollow piston tensioner (009.022) over guide piece and
tighten hexagon nut (4) by hand. See Fig. 3/I.
4. Connect high-pressure hose (009.306) to hydraulic hollow piston ten-
sioner and high-pressure pump (009.342). Connect oil pressure gauge
48/60B;V48/60CR;51/60DF

(0-400 bar) to high-pressure pump.

5. Put high-pressure pump in operation (see Work Card 009.03) and pump
hydraulic hollow piston tensioner slowly.

Type and source of danger

2008-10-07

Observe pressure gauge during the pumping up.

2 (6) 6707 114.03-01 EN

 MAN Diesel & Turbo 114.03

6. Pull in valve guide (1) in several steps, letting off pressure every time,

Inlet and exhaust valves

press in piston of the hydraulic hollow piston tensioner and retighten
hexagon nut (4). See Figure 3/II and 3/III.
7. Release the pressure.
8. Separate the high-pressure hose from hydraulic hollow piston tensioner
and high-pressure pump and detach tool.
9. Clean the valve guide (1) and check for wear/damage, renew if neces-
sary.

Work sequence 3 - Installing the valve guide

Starting position Valve guide is cleaned, checked and replaced if necessary. Hole in cylinder
head cleaned.
Work steps 1. Fit valve guide (1) on guide piece (113.206-1) and screw on hexagon nut
(5) and tighten by hand. Fit guide piece through cylinder head (7).
2. Fit plate (113.206-2) over guide piece and place on valve seat ring (3),
ensuring centring of plate valve seat ring. See Fig. 4/I.
3. Fit hydraulic hollow piston tensioner (009.022) over guide piece and
tighten hexagon nut (4) by hand.
4. Connect high-pressure hose (009.306) to hydraulic hollow piston ten-
sioner and high-pressure pump (009.342). Connect oil pressure gauge
(0-400 bar) to high-pressure pump.
5. Put high-pressure pump in operation (see Work Card 009.03) and pump
hydraulic hollow piston tensioner slowly.

Type and source of danger

Ensure that valve guide (1) is pulled into the hole properly! Observe
pressure gauge during the pumping up! Sudden pressure rise during
fitting points to tilting of the valve guide!

Work Cards, classified into sub-assemblies

6. Pull in valve guide (1) in several steps, releasing pressure every time,
press in piston of the hydraulic hollow piston tensioner and retighten
hexagon nut (4). See Figure 4/II and 4/III.
7. Release the pressure.
8. Separate the high-pressure hose from hydraulic hollow piston tensioner
and high-pressure pump and detach tool.
48/60B;V48/60CR;51/60DF
2008-10-07

6707 114.03-01 EN 3 (6)

114.03 MAN Diesel & Turbo
Inlet and exhaust valves

1 Valve guide
2 Cylinder head
3 Valve seat ring

Figure 2: Valve guide

Work Cards, classified into sub-assemblies
48/60B;V48/60CR;51/60DF

2008-10-07

4 (6) 6707 114.03-01 EN

 MAN Diesel & Turbo 114.03

Inlet and exhaust valves

Work Cards, classified into sub-assemblies
48/60B;V48/60CR;51/60DF

1 Valve guide 4 Hexagon nut M30 I-III Work steps

2 Cylinder head 5 Hexagon nut M30
Figure 3: Removing the valve guide
2008-10-07

6707 114.03-01 EN 5 (6)

114.03 MAN Diesel & Turbo
Inlet and exhaust valves
Work Cards, classified into sub-assemblies
48/60B;V48/60CR;51/60DF

2008-10-07

1 Valve guide 3 Valve seat ring 5 Hexagon nut M30

2 Cylinder head 4 Hexagon nut M30 I-III Work steps
Figure 4: Installation of valve guide

6 (6) 6707 114.03-01 EN

MAN Diesel & Turbo 125

Operating device
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.17-1 EN 1 (2)

 MAN Diesel & Turbo
Operating device

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.17-1 EN

 MAN Diesel & Turbo 125.02

Three-way valve M306

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory

Spare parts
Quantity Designation Number
1 Three-way valve 125.98.306
1 Set of wear parts 125.99.306

Work Cards, classified into sub-assemblies

Work sequence 1 - Disassembling the three-way valve
Starting position Compressed air or control air system depressurised. Valve exterior cleaned.

Work steps 1. Undo pipe connections (mark if necessary), remove fastening screws
and take out valve.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equip-
ment.
3. Unscrew roller lever (11), valve guide (12) with valve slide (13) and spring.
4. Disassemble the valve and clean all individual parts carefully.
5. Check wear parts (V) for wear or hardening (in case of sealing rings),
replace parts if necessary.
2007-08-01

To overhaul the three-way valve M306, a set of wear parts can be ordered
General

from MAN Diesel & Turbo SE.

6682 125.02-01 EN 1 (2)

125.02 MAN Diesel & Turbo

6. Check all moving parts for ease of movement prior to assembly.

Operating device

Work sequence 2 - Assembling the three-way valve

The assembly is done in reverse order of the dismantling. In doing so,
observe the following points:

When assembling, take utmost care in maintaining cleanliness at the

workplace, even the smallest dirt particles can cause faults in the valve
or in the compressed air / control air system.

1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.

11 Roller lever 14 Valve seat

Work Cards, classified into sub-assemblies

12 Valve guide
13 Valve slide V Wear parts
Figure 1: Sectional view of the three-way valve M306

Principle of operation
Connection 1 2 4
Position I closed connected
Position II connected closed
2007-08-01
General

2 (2) 6682 125.02-01 EN

 MAN Diesel & Turbo 125.04

Three-way valve M317

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Hook wrench - Inventory
1 Grease (acid-free) - Inventory

Spare parts
Quantity Designation Number
1 Three-way valve 125.98.317

Work Cards, classified into sub-assemblies

1 Set of wear parts 125.99.317

Work sequence 1 - Disassembling the three-way valve

Starting position Compressed air or control air system depressurised. Valve exterior cleaned.

Work steps 1. Undo pipe connections (mark if necessary), remove fastening screws
and take out valve.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equip-
ment.
3. Thread out hexagon socket bolt (11) and remove casing upper part (12).
4. Using a hook wrench, thread off valve guide (15) together with piston
(13) and valve tappet (14).
2007-08-01

5. Take out valve seat (16) and remove valve (17).

6. Dismantle valve further and thoroughly clean all individual parts and
General

blow with compressed air.

6682 125.04-01 EN 1 (3)

125.04 MAN Diesel & Turbo

7. Check wear parts (V) for wear or hardening (in case of sealing rings),
Operating device

replace parts if necessary.

To overhaul the three-way valve M317, a set of wear parts can be ordered
from MAN Diesel & Turbo SE.

8. Check all moving parts for ease of movement prior to assembly.

Work sequence 2 - Assembling the three-way valve

The assembly is done in reverse order of the dismantling. In doing so,
observe the following points:

When assembling, take utmost care in maintaining cleanliness at the

workplace, even the smallest dirt particles can cause faults in the valve
or in the compressed air / control air system.

1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.
Work Cards, classified into sub-assemblies

11 Hexagon socket bolt 16 Valve seat

12 Casing top section 17 Valve
13 Piston 18 Casing bottom section
14 Valve slide
15 Valve guide V Wear parts
Figure 1: Sectional view of the three-way valve M317
2007-08-01

Principle of operation
General

Connection 1 2 4
5 pressurised connected closed

2 (3) 6682 125.04-01 EN

 MAN Diesel & Turbo 125.04

5 without pressure closed connected

Operating device
Work Cards, classified into sub-assemblies
2007-08-01

General

6682 125.04-01 EN 3 (3)

MAN Diesel & Turbo 125.05

3/2-way solenoid valve M329

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory

Work card Work card Work card

125.30

Spare parts

Work Cards, classified into sub-assemblies

Quantity Designation Number
1 3/2-way solenoid valve 125.98.329
1 Set of wear parts 125.99.329

Work sequence 1 - Disassembling the 3/2-way solenoid valve

Starting position Compressed air or control air system depressurised. Valve exterior cleaned.

Work steps 1. Undo pipe connections (mark if necessary), remove fastening screws
and take out valve.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equip-
ment.
3. Unscrew hexagon bolts (11) and hexagon socket bolt (12).
4. Remove connecting piece (13) with emergency actuation (14) and
unscrew hexagon socket bolt (12).
General

5. Disassemble the valve and clean all individual parts carefully.

6682 125.05-01 EN 1 (4)

125.05 MAN Diesel & Turbo

6. Check wear parts (V) for wear or hardening (in case of sealing rings),
Operating device

replace parts if necessary.

A set of wear parts is available from MAN Diesel & Turbo SE for the
purposes of overhauling the 3/2-way solenoid valve M329.

7. Check all moving parts for ease of movement prior to assembly.

Work sequence 2 - Assembling the 3/2-way solenoid valve

The assembly is done in reverse order of the dismantling. In doing so,
observe the following points:

When assembling, take utmost care in maintaining cleanliness at the

workplace, even the smallest dirt particles can cause faults in the valve
or in the compressed air / control air system.

1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.

Depending on what the 3/2-way solenoid valve M329 is used for, make
sure the pins are arranged correctly in the valve casing. If the pins are
arranged incorrectly, this could inflict severe injuries and also seriously
damage the machine.
Work Cards, classified into sub-assemblies
General

2 (4) 6682 125.05-01 EN

MAN Diesel & Turbo 125.05

Operating device
11 Hexagon bolt 14 Emergency actuation
12 Hexagon socket bolt 15 Valve casing
13 Connecting piece V Wear parts
Figure 1: Sectional view of 3/2-way solenoid valve M329

Principle of operation
Depending on the arrangement of the pins in the valve casing, the functions
as represented in figures 1 and 2 are performed.

Work Cards, classified into sub-assemblies

General

6682 125.05-01 EN 3 (4)

125.05 MAN Diesel & Turbo
Operating device
Work Cards, classified into sub-assemblies

Figure 2: Valve functions depending on the arrangement of the pins

General

4 (4) 6682 125.05-01 EN

 MAN Diesel & Turbo 125.08

4/2-Way solenoid valve M392

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory

Spare parts
Quantity Designation Number
1 4/2-way solenoid valve 125.98.392

Work Cards, classified into sub-assemblies

1 Set of wear parts 125.99.392

Work sequence 1 - Disassembling the 4/2-way solenoid valve

Starting position Compressed air or control air system depressurised. Valve exterior cleaned.

Work steps 1. Release pipe connections or cable connections (mark if necessary),

remove fastening screws and disassemble valve.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equip-
ment.
3. Unscrew socket (11).
4. Disassemble the valve and clean all individual parts carefully.
2007-03-28

5. Check wear parts (V) for wear or hardening (in case of sealing rings),
replace parts if necessary.
General

6682 125.08-01 EN 1 (2)

125.08 MAN Diesel & Turbo

To overhaul the 4/2 way solenoid valve M392, a set of wear parts can be
Operating device

ordered from MAN Diesel & Turbo SE.

6. Check all moving parts for ease of movement prior to assembly.

Work sequence 2 - Assembling the 4/2-way solenoid valve

The assembly is done in reverse order of the dismantling. In doing so,
observe the following points:

When assembling, take utmost care in maintaining cleanliness at the

workplace, even the smallest dirt particles can cause faults in the valve
or in the compressed air / control air system.

1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.

10 Magnet part
11 Socket
12 Manual actuation
V Wear parts
Work Cards, classified into sub-assemblies

Figure 1: Sectional view of the 4/2-way solenoid valve M392

Principle of operation
2007-03-28

Connection 4 3 1 2 4
Magnet energised connected connected
General

Magnet deenergised connected connected

2 (2) 6682 125.08-01 EN

 MAN Diesel & Turbo 125.08

5/2-way solenoid valve M367

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory

Spare parts
Quantity Designation Number
1 5/2-way solenoid valve 125.98.367

Work Cards, classified into sub-assemblies

Work sequence 1 - Disassembling the 5/2-way valve
Starting position Compressed air or control air system depressurised. Valve exterior cleaned.

Work steps 1. Undo pipe connections (mark if necessary), remove fastening screws
and take out valve.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equip-
ment.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check wear parts for wear or hardening (in sealing rings), replace with
new ones if necessary.
5. Check all moving parts for ease of movement prior to assembly.
2007-08-01

Work sequence 2 - Assembling the 5/2-way solenoid valve

General

The assembly is done in reverse order of the dismantling. In doing so,

observe the following points:

6682 125.08-02 EN 1 (2)

125.08 MAN Diesel & Turbo

When assembling, take utmost care in maintaining cleanliness at the

Operating device

workplace, even the smallest dirt particles can cause faults in the valve
or in the compressed air / control air system.

1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.

Figure 1: 5/2-way solenoid valve M367

Principle of operation
Work Cards, classified into sub-assemblies

Connection 5 4 1 2 3
Magnet deenergised connected connected closed
Magnet energised closed connected connected 2007-08-01
General

2 (2) 6682 125.08-02 EN

 MAN Diesel & Turbo 125.09

Pressure-reducing valve M409

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory

Spare parts
Quantity Designation Number
1 Pressure-reducing valve with pressure gauge 125.98.409

Work Cards, classified into sub-assemblies

1 Set of wear parts 125.99.409

Work sequence 1 - Disassembling the pressure-reducing valve

Starting position Compressed air or control air system depressurised. Valve exterior cleaned.

Work steps 1. Undo pipe connections (mark if necessary), remove fastening screws
and take out valve.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equip-
ment.
3. Unscrew cylinder screws (11) and knurled screw (14).
4. Separate casing upper part (12) from casing lower part (13) and disas-
semble wear parts (V).
2007-03-28

5. Disassemble the valve and clean all individual parts carefully.

6. Check wear parts (V) for wear or hardening (in case of sealing rings),
General

replace parts if necessary.

6682 125.09-01 EN 1 (2)

125.09 MAN Diesel & Turbo

To overhaul the pressure-reducing valve M409, a set of wear parts can

Operating device

be ordered from MAN Diesel & Turbo SE.

7. Check all moving parts for ease of movement prior to assembly.

Work sequence 2 - Assembling the pressure-reducing valve

The assembly is done in reverse order of the dismantling. In doing so,
observe the following points:

When assembling, take utmost care in maintaining cleanliness at the

workplace, even the smallest dirt particles can cause faults in the valve
or in the compressed air / control air system.

1. When assembling new sealing rings ensure that they are not twisted.
2. Lightly oil all parts prior to assembly.
Work Cards, classified into sub-assemblies

2007-03-28

11 Cylinder screw 14 Knurled screw

12 Casing top section
General

13 Casing bottom section V Wear parts

Figure 1: Sectional view of the pressure-reducing valve M409

2 (2) 6682 125.09-01 EN

 MAN Diesel & Turbo 125.10

Compressed air filter M462

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory

Spare parts
Quantity Designation Number
1 Compressed air filter 125.98.462
1 Filter insert 125.99.462

Work Cards, classified into sub-assemblies

Work sequence 1 - Disassembling the compressed air filter
Starting position Compressed air or control air system depressurised. Filter cleaned on the
outside.
Work steps 1. Loosen pipe connections (mark if necessary), remove fastening screws
and disassemble filter.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equip-
ment.
3. Drain compressed air filter first through the hexagon bolt (13).
4. Unscrew hexagon nut (11) and remove pipe clamp.
5. Disassemble the filter and thoroughly clean all individual parts.
2007-03-28

6. Clean the filter insert (12) according to manufacturer's specifications or

replace with a new one if necessary.
General

6682 125.10-01 EN 1 (2)

125.10 MAN Diesel & Turbo

The filter insert for the compressed air filter M462 can be ordered from
Operating device

MAN Diesel & Turbo SE.

Work sequence 2 - Assembling the compressed air filter

The assembly is done in reverse order of the dismantling. In doing so,
observe the following points:

When assembling, take utmost care in maintaining cleanliness at the

workplace, even the smallest dirt particles can cause faults in the valve
or in the compressed air / control air system.

11 Hexagon nut
12 Filter insert
13 Hexagon bolt
Work Cards, classified into sub-assemblies

Figure 1: Sectional view of the compressed air filter M462

2007-03-28
General

2 (2) 6682 125.10-01 EN

 MAN Diesel & Turbo 125.12

Limit switch M745

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Electric/ electronic control and/or switch elements are to be checked and,
if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling components,
Checking parts/ components,
Assembling components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory

Spare parts
Quantity Designation Number
1 Limit switch 125.98.745
1 Set of wear parts 125.99.745

Work Cards, classified into sub-assemblies

Work sequence 1 - Disassembling the limit switch
Starting position No voltage is present at the limit switch.

Work steps 1. Release cable connections (mark if necessary), remove fastening

screws and disassemble switch.
2. Remove roller lever (1), unscrew cylinder screws (2) and remove push-
button.
3. Unscrew cylinder screw (3) and cover (4).
4. Disassemble the limit switch further and thoroughly clean all individual
parts.
5. Check all moving parts for ease of movement prior to assembly.
2007-03-28

Work sequence 2 - Assembling the limit switch

General

The assembly is done in reverse order of the dismantling. In doing so,

observe the following points:

6682 125.12-01 EN 1 (2)

125.12 MAN Diesel & Turbo

Keep the workplace absolutely clean when assembling.

Operating device

1 Roller lever
2 Cylinder screw
3 Cylinder screw
4 Cover

Figure 1: Illustration of the limit switch M745

Work Cards, classified into sub-assemblies

2007-03-28
General

2 (2) 6682 125.12-01 EN

 MAN Diesel & Turbo 125.14

2/2-way solenoid valve M314/M315/M316

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory

Work sequence 1 - Disassembling the 2/2-way solenoid valve

Starting position Compressed air or control air system depressurised. Valve exterior cleaned.

Work steps 1. Undo pipe connections (mark if necessary), remove fastening screws

Work Cards, classified into sub-assemblies

and take out valve.
2. Seal open pipe ends to prevent the ingress of dirt using suitable equip-
ment.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check wear parts for wear or hardening (in sealing rings), replace with
new ones if necessary.
5. Check all moving parts for ease of movement prior to assembly.

Work sequence 2 - Assembling the 2/2-way solenoid valve

The assembly is done in reverse order of the dismantling. In doing so,
observe the following points:
2007-07-31

When assembling, take utmost care in maintaining cleanliness at the

workplace, even the smallest dirt particles can cause faults in the valve
General

or in the compressed air / control air system.

6682 125.14-01 EN 1 (2)

125.14 MAN Diesel & Turbo

1. When assembling new sealing rings ensure that they are not twisted.
Operating device

2. Lightly oil all parts prior to assembly.

Figure 1: 2/2-way solenoid valve M314/M315/M316

Principle of operation
Connection A B
Magnet deenergised closed closed
Magnet energised connected
Work Cards, classified into sub-assemblies

2007-07-31
General

2 (2) 6682 125.14-01 EN

 MAN Diesel & Turbo 125.21

Pressure reducing station M615

Operating device
checking, overhauling

Summary
Check components for quality/wear condition, ensure / restore operational
safety.
Control elements in the compressed air or control air system resp. are to be
checked and, if necessary, overhauled at regular intervals.
The work/work steps include:
Disassembling/separating components,
Replacing sealing rings /sealing elements,
Assembling/refitting components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Grease (acid-free) - Inventory

Preliminary remarks
In the case of marine systems, the pressure of the starter air tank is reduced
by the pressure-reducing station M615 from 30 to 8 bar. It is arranged in the
operating stand behind the cover. The pressure reducing station (see sche-

Work Cards, classified into sub-assemblies

matic drawing) consists of 2 filters and 2 reducing valves. It is possible to
switch over from one branch to another by means of the lever. After that
becomes necessary, the pressure reducing station is to be checked/over-
hauled at the next opportunity.
Work on the pressure reducing station should be carried out with the great
care that its significance of the instrument air supply requires, wear parts
should be stocked and replaced at the right time.
2007-03-28

General

6629 125.21-01 EN 1 (3)

125.21 MAN Diesel & Turbo
Operating device

1 Hexagon bolt 6 sealing screw on distribution block

2 Casing 7 Adjusting screw
3 Hexagon bolt 8 Hexagon bolt
4 Casing 9 Switching lever
5 Cylinder screw 10 Drain valve
Figure 1: Pressure reducing station M615 - Cutaway drawing /Schema

Work sequence 1 - Changing the filter inserts

Work steps 1. Remove obtrusive casing sheets.
Work Cards, classified into sub-assemblies

2. Make system pressureless and open drain cocks in the system and at
the pressure reducing station 615 (item 10).
3. Remove hexagon bolt (3) on both sides, Renew wear parts (V), i.e. filter
insert and sealing ring.

Work sequence 2 - Inspection /Overhauling

Starting position Execution only after critically examining the need!

Work steps 1. Remove obtrusive casing sheets.

2. Make system pressureless, open release and drain cocks.

3. Release pipe connections (mark if necessary), remove fastening screws
2007-03-28

and disassemble pressure reducing station.

4. Block open pipe ends against penetration of dirt.
General

5. Remove hexagon bolt (3) on both sides, Renew wear parts (V), i.e. filter
insert and sealing ring.

2 (3) 6629 125.21-01 EN

 MAN Diesel & Turbo 125.21

6. Release hexagon bolt (1), separate casing (2) from casing (4) and dis-

Operating device
assemble wear parts (V).
7. Release 5 cylinder screws (5) and disassemble wear parts (V).
8. Release locking screws (6) and disassemble wear parts (V).
9. Release 2 setting screws (7) and disassemble wear parts (V).
10. Release 4 hexagon bolts (8) and pull out switching lever unit (9).
11. Unscrew drain valve (10).
12. Clean individual parts, blow out with compressed air.
13. Check wear parts for attrition. Renew if necessary. Sealing rings must
always be replaced.
14. Check all moving parts for easy movement before and after assembly.
Carry out assembly in the reverse sequence. After fitting the pressure-
reducing station to the operating device, and after connection of the pipes,
check for leakages and correct function of the pressure-reducing station.
The pressure gauge shows the pressure in both control air channels.

When carrying out work on components / fittings under compressed air,

painstakingly ensure cleanliness, because even the smallest dirt
particles can cause really serious malfunctions.

Work Cards, classified into sub-assemblies

2007-03-28

General

6629 125.21-01 EN 3 (3)

MAN Diesel & Turbo 140

Speed regulation
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.18-1 EN 1 (2)

 MAN Diesel & Turbo
Speed regulation

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.18-1 EN

 MAN Diesel & Turbo 140.01

Woodward controller PGG 200/PGG-EG 200

Speed regulation
servicing and checking

Summary
Execute work on time according to the maintenance schedule.
Check the hydraulic oil in the speed governor at regular intervals.
The work/work steps include:
Venting,
Changing operating materials,
Removal of components,
Assembly of components.
Tools/aids required
Quantity Designation Number Status
1 Tools set (Woodward controller) 140.110 Standard
1 Hexagon screw driver 10 000.298 Standard
1 Combination spanner (set) - Inventory
1 Sealing compound (Silicone) - Inventory

Corresponding Work Cards

Work card Work card Work card
140.02

Preliminary remarks
Before commissioning, fill up new controllers with oil and ensure the fol-
lowing: When the engine is running, the oil level should move between the
marks on the oil dipstick (13). When the engine is at rest, fill up to about the
upper mark and top up when the engine is running, as mentioned above.

Work Cards, classified into sub-assemblies

Do not top up too quickly, because oil only runs slowly through the controller
sump. After the initial commissioning, extended service life and after recon-
structing the controller, vent the oil chambers.
PGG-EG 200 = Mechanical hydraulic controller/electrical actuator
PGG 200 = Only mechanical hydraulic controller
2008-10-22

General

6641 140.01-02 EN 1 (5)

140.01 MAN Diesel & Turbo
Speed regulation

1 Speed setting by hand 9 Connection for electrical con- 17 Oil outlet to the booster
trol part (PGG-EG governor)
2 Load limiting by hand 10 P-degree setting by hand 18 Oil outlet to oil cooler (if
present)
3 Oil entry from booster to speed 11 Connection for cut-off sole- 19 Oil inlet from booster to
adjusting system of the gover- noid and speed setting motor working part of the governor
nor (booster output 2) (booster output 1)
4 Switch over device pneumatic 12 Needle valve 20 Oil entry from booster to
(PGG-EG governor) control part of the governor
Work Cards, classified into sub-assemblies

(booster output 3)
5 Governor output shaft 13 Oil dipstick 21 Pipe filter for EG part (PGG-
EG governor)
6 Drive shaft 14 Oil filler neck 22 Connection for air pressure
(if present)
8 Oil outlet to oil cooler (if present) 15 Filling indicator
Figure 1: Woodward speed governor

Work sequence 1 - Venting

Starting position Engine running.

Work steps 1. Close needle valve (12) by rotating to the right and note the revolutions
2008-10-22

required. Then open up by around three to five turns. The controller then
starts to oscillate. If not, it must be made to do so by rhythmic changes
General

in the filling settings.

2. Open pipe union (20) until air can escape. Governor must oscillate until
only bubble-free oil comes out.

2 (5) 6641 140.01-02 EN

 MAN Diesel & Turbo 140.01

3. Tighten pipe union. If necessary, top up oil.

Speed regulation
4. Close needle valve (12) slowly, until governor oscillations stop, but not
further than noted in Point 1. Never close needle valve fully for an exten-
ded period!
For setting instructions see the manufacturer pressure text concerning the
governor (see Volume 010.120 Speed governor).

Type and source of danger

If electrical control does not work smoothly, check pipe filter (21) for
contamination, flush if necessary (only PGG-EG governor).

Type and source of danger

Opening the governor and thus violating the lead seal without permission
or instructions from MAN Diesel & Turbo SE will void guarantee claims.

Work sequence 2 - Oil change

Starting position Engine stopped.

Work steps 1. Separate pipe line for oil escape (17) to booster from governor housing,
to drain oil from the governor.
2. Drain oil, mount pipe line for oil escape on the governor casing again.
3. Pour diesel fuel through the oil filler neck (14) up to the dipstick mark.
4. Close needle valve (12) by rotating to the right and note the revolutions
required. Then open by about three to five turns and let the engine run
for 1/2 - 1 minute (governor must oscillate).
5. Switch engine off and drain diesel fuel completely (see Point 1 and 2).
6. Pour fresh oil into the governor and let engine run for a short time (gov-
ernor must oscillate).

Work Cards, classified into sub-assemblies

7. Drain oil again (see Point 1 and 2).
8. Fill in fresh oil up to the upper mark on the dipstick (13).
9. Start engine and vent governor if necessary (see Work sequence 1).
10. Check oil level and top up with oil if necessary (oil should be between
upper and lower mark).
11. Close needle valve (12) and open it by the revolutions noted under Point
4.

Operational oil for governor: The use of a suitable oil type is a

requirement for a smooth working of the governor. The oil must not have
any tendency to foam, to take up small air bubbles and for the separation
2008-10-22

of sludge or deposits. The oil also serves as a corrosion protection for

the internal components. Use of multigrade oil is advisable. List of
suitable oils is available from MAN Diesel & Turbo SE Augsburg.
General

6641 140.01-02 EN 3 (5)

140.01 MAN Diesel & Turbo

Work sequence 3 - Removing and installing the governor

Speed regulation

Starting position Engine stopped.

Work steps 1. Separate the pipe line for oil escape (17) to booster from governor hous-
ing, drain oil from the governor.
2. Mark the position of the lever on the governor outlet side (5) and remove
the lever (do not release the screw connection between lever and con-
necting rod).
3. Remove other pipe connections and electrical connections (if present).
4. Unscrew four screws from the casing foot, loosen governor casing from
the resting surface by rotating to and fro.

Do not tilt governor when removing, otherwise it may damage the drive
shaft (6).

5. Lift the governor vertically upwards and put it aside carefully on a

wooden support.
6. Clean flange face on the governor and drive casing.
7. Re-fit the governor in reverse sequence. Seal the contact surface with
the drive casing using a sealing compound. Note the marking when
installing the lever on the governor output shaft (5).
8. Fill in oil and vent (see work sequence 1).

Check the setting of the governor linkage after every re-fitting of the
speed governor to the engine. The speed governor must also be at zero
when the position of the control rods on the injection pumps is at zero.
Release the locknuts of the connecting rods to achieve the zero position,
if necessary, (see Work Card 203.01) and readjust by rotating the rod.
Never release the screw connection between connecting rod and lever
Work Cards, classified into sub-assemblies

(on the governor) and never readjust on the slotted hole, as the governor
stroke wear would be affected.

2008-10-22
General

4 (5) 6641 140.01-02 EN

 MAN Diesel & Turbo 140.01

Speed regulation
5 Governor output shaft 23 Oil cooler
Figure 2: Woodward speed governor PGG-EG 200 (Governor control linkage
detached)

Work Cards, classified into sub-assemblies

2008-10-22

General

6641 140.01-02 EN 5 (5)

 MAN Diesel & Turbo 140.02

Booster Servomotor (two-stage)

Speed regulation
servicing and checking

Summary
Execute work on time according to the maintenance schedule, prevent
operating problems/damages.
The booster servomotor should be serviced at the specified intervals.
The work/work steps include:
Dismantling components,
Renewing packing ring /sealing elements,
Assembling components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory

Corresponding Work Cards

Work card Work card Work card
140.01

Preliminary remarks
Drain oil from booster servomotor, when operating oil of the Woodward
controller is changed.
Work sequence 1 - Detaching and dismantling

Refer to the Woodward Booster Servomotor Manual for dismantling and

assembly (see Operating Instructions).

Work steps 1. Unscrew feed and return pipes as well compressed air pipes (draw lines
and connections together where necessary) and remove servomotor.
Work Cards, classified into sub-assemblies
2. Unscrew four nuts, remove cover and pour out oil.
3. Take out compression springs and piston.
4. Clean all individual parts in fuel, check sealing ring, renew if necessary
and check suction and pressure valves in the cover for leakage and free
movement.
2007-06-15

General

6619 140.02-01 EN 1 (3)

140.02 MAN Diesel & Turbo
Speed regulation
Work Cards, classified into sub-assemblies

1 Oil inlet from governor 6 Stroke limiting screw for auxili-

ary piston
2 Oil outlet to speed setting system of 7 Stroke limiting screw for main
the governor piston
3 Oil outlet to working part of the gov- 8 Air inlet
ernor
4 Oil outlet to control part of the gov- 9 Cover
ernor
5 Throttle valve to 4
2007-06-15

Figure 1: Booster servomotor

General

2 (3) 6619 140.02-01 EN

 MAN Diesel & Turbo 140.02

Work sequence 2 - Assembly and installation

Speed regulation
Work steps 1. Assemble servomotor in the sequence reverse to the one followed in
dismantling, ensuring free movability of the piston and of the valve balls.
Check position of the stroke limiting screw.
2. Attach servomotor to engine and connect to the governor with both oil
pipes.
3. Connect compressed air pipe.

See that all pipes have been reconnected where they were earlier.

4. Top up oil in governor (if not already done).

5. Start the engine a few times, thus forcing air from the oil chamber and
fill servomotor with oil.
6. Fill up oil up to the lower marking on sight glass and check tightness of
all connections.

Work Cards, classified into sub-assemblies

2007-06-15

General

6619 140.02-01 EN 3 (3)

 MAN Diesel & Turbo 140.04

Speed controller

Speed regulation
removing and refitting

Summary
Prevent operating problems/damages, ensure / restore operating reliability
again.
It may be necessary to detach the speed governor for servicing work on the
engine, for the sake of better accessibility.
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Suspension gear 140.006 Standard
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Lifting tackle - Inventory
1 Rope - Inventory

Corresponding Work Cards

Work card Work card Work card
140.01

Work Cards, classified into sub-assemblies

Technical data
Designation Information
Speed controller 160 kg

Work sequence 1 - Removing the speed governor

Work steps 1. Drain oil from speed governor (1) (see Work Card 140.01).
L48/60;L48/60B;V48/60

2. Mark position of the control rod and separate from the speed governor
(1).
3. Remove pipes and electrical connections (if any) from the speed gov-
2008-10-22

ernor (1).
4. Screw four hexagon socket bolts or hexagon bolts (including washers)
onto the speed governor legs.

6647 140.04-01 EN 1 (3)

140.04 MAN Diesel & Turbo

5. Place suspension gear (140.006) around speed governor (1) (see Volume
Speed regulation

010.120 speed governor), fasten with shackle and cable onto the lifting
tackle.
6. Lift speed governor (1) carefully using the lifting tackle.

Type and source of danger

It may be necessary to release two supports from the governor control
linkage.

7. Remove speed governor (1) and place on wooden support

Type and source of danger

Do not rest speed governor on drive shaft!

Work sequence 2 - Attaching the speed governor

The attachment of the speed governor is done in a sequence reverse to that
of detachment. After attaching the speed governor, connect the control rod,
fill oil into speed governor and vent it (see Work Card 140.01).

Check the setting of the control linkage after every reassembly of the
speed governor to the engine! The speed governor must also be at zero
when the position of the control rods on the injection pumps is at zero!
Work Cards, classified into sub-assemblies
L48/60;L48/60B;V48/60

2008-10-22

2 (3) 6647 140.04-01 EN

 MAN Diesel & Turbo 140.04

Speed regulation
1 Speed controller 2 Governor drive casing

Work Cards, classified into sub-assemblies

Figure 1: Speed governor with suspension gear - Illustration shows engine V
48/60 L48/60;L48/60B;V48/60
2008-10-22

6647 140.04-01 EN 3 (3)

MAN Diesel & Turbo 160-162

Starting air pilot valve/Starting valve/Main starting valve

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.19-1 EN 1 (2)

 MAN Diesel & Turbo
Starting air pilot valve/Starting valve/Main starting valve

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.19-1 EN

 MAN Diesel & Turbo 160.01

Starting air pilot valve

Starting air pilot valve/Starting valve/Main starting valve

inspection, removal and installation

Summary
Carry out the work in due time according to the maintenance schedule,
ensure/restore operational safety.
Starting air pilot valves are to be dismounted and overhauled at regular
intervals.
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Option
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Sliding calliper - Inventory

Corresponding Work Cards

Work card Work card Work card
160.02

Work Cards, classified into sub-assemblies

Technical data
Designation Information
Starting air pilot valve 8 kg

Work sequence 1 - Checking the starting air pilot valve

Carry out checks for smooth functioning at the intervals specified in the
service schedule.
Work sequence 2 - Disassembling of the starting air pilot valve
L48/60B;L51/60DF
2007-10-22

Make all air piping pressureless before starting work on starting air pilot
valve! Close shut-off valve on compressed air tank!
On opening the starter air systems, ensure especially that no dirt of any
kind can enter the valves and pipelines! Block open pipe ends with
plastic caps or adhesive tape!

6704 160.01-01 EN 1 (3)

 160.01 MAN Diesel & Turbo

Work steps 1. Detach air supply line (8) and starting air pipe (1) from starting air pilot
Starting air pilot valve/Starting valve/Main starting valve

valve (6).
2. Unscrew and remove the hexagon bolts (3).
3. Remove starting air pilot valve (6).
4. Remove spacing washer (2).
5. Measure thickness of the spacing washer (2).

If the thickness of the spacing washer is less than 1.4 mm, install a new
spacer plate.

6. Clean Starting air pilot valve (6) externally.

7. Dismantle Starting air pilot valve (6) (see Work Card 160.02).

Work sequence 3 - Fitting of the starting air pilot valve

Starting position Starting air pilot valve is cleaned and assembled. Thickness of the spacing
washer is measured and renewed if necessary.
Work steps 1. Clean the resting surface on cylinder crankcase (4).

2. Fit spacing washer (2) on starting air pilot valve (6).

3. Install starting air pilot valve (6), ensuring correct installation position and
position of the dowel pins (5). See Fig. 1.
4. Screw in the hexagon bolts (3) and tighten them.
5. Check clearance (B), readjust if necessary. See Fig. 1.

The clearance can be set by pulling off foil sheets from the spacing
washer.
Check the thickness of the spacing washer after setting the clearance.
If the thickness (A) of the spacer is less than 1.4 mm, install a new spacing
Work Cards, classified into sub-assemblies

washer.

6. Attach air supply pipe (8) and starting air pipe (1) from starting air pilot
valve (6).
L48/60B;L51/60DF

2007-10-22

2 (3) 6704 160.01-01 EN

 MAN Diesel & Turbo 160.01

Starting air pilot valve/Starting valve/Main starting valve

1 Starting air pipe 7 Starting cams
2 Spacing washer 8 Supply air line
3 Hexagon bolt
4 Cylinder crankcase A Thickness of the spacing washer

Work Cards, classified into sub-assemblies

5 Dowel pin B Clearance
6 Starting air pilot valve ST Control side
Figure 1: Starting air pilot valve
L48/60B;L51/60DF
2007-10-22

6704 160.01-01 EN 3 (3)

 MAN Diesel & Turbo 160.02

Starting air pilot valve

Starting air pilot valve/Starting valve/Main starting valve

dismantling and assembling

Summary
Carry out the work in due time according to the maintenance schedule,
ensure/restore operational safety.
Starting air pilot valves are to be dismounted and overhauled at regular
intervals.
The work/work steps include:
Dismantling components,
assembling components.
Tools/aids required
Quantity Designation Number Status
1 Eye bolt 001.405 Standard
1 Combination spanner (set) - Inventory
1 Side cutter - Inventory
1 Lubricating oil, clean - Inventory
1 Securing compound, Loctite 243 - Inventory

Corresponding Work Cards

Work card Work card Work card
000.19

Work sequence 1 - Dismantling the starting air pilot valve

Dismantle starting air pilot valve only in a clean workplace, use grease
solvent and compressed air for cleaning!

Starting position Starting air pilot valve is removed and cleaned externally. Work Cards, classified into sub-assemblies
Work steps 1. Unscrew and remove the hexagon bolts (6).

2. Remove pitot tube (7).

3. Thread eye bolt (001.405) into control piston (2) and remove it from the
48/60B;48/60CR;51/60DF

casing (1).
4. Remove the tool.
5. Remove sealing ring (3) from control piston (2).
6. Clean all individual parts, check for attrition and damage.
2007-06-15

6707 160.02-01 EN 1 (3)

 160.02 MAN Diesel & Turbo

Work sequence 2 - Assembly of the starting air pilot valve

Starting air pilot valve/Starting valve/Main starting valve

Keep the workplace absolutely clean during assembly! Dirt particles of

any kind can cause malfunctioning in the starter system!

Starting position All individual parts have been cleaned, inspected and replaced where nec-
essary.
Work steps 1. Install new sealing ring (3) in control piston (2) (see Work sequence 3).

2. Thread eye bolt (001.405) into control piston (2).

3. Oil control piston (2) lightly with clean lubricating oil and install in casing
(1).
4. Remove the tool.
5. Fit pitot tube (7) on casing (1), ensuring correct position of the dowel pin
(8).
6. Coat screw thread and contact surface of the hexagon bolts (6) with
securing compound Loctite 243, screw in and tighten.

Work sequence 3 - Assembly of the sealing ring

Work steps 1. Place O-ring seal (5) in the groove, making sure that it is clamped uni-
formly on the entire periphery and is not twisted.
2. Heat PTFE-Ring (4) in oil to 80 °C - 100 °C.

Do not use bare hands to insert PTFE ring in oil bath or to take it out!

3. Pull PTFE-Ring (4) over control piston (2) into the groove.
Work Cards, classified into sub-assemblies

4. Reshape the expanded PTFE-Ring (4) by placing the control piston (2)
into the oiled casing (1).
48/60B;48/60CR;51/60DF

2007-06-15

2 (3) 6707 160.02-01 EN

 MAN Diesel & Turbo 160.02

Starting air pilot valve/Starting valve/Main starting valve

1 Casing
2 Control piston
3 Sealing ring
6 Hexagon bolt
7 Pitot tube
8 Dowel pin

Figure 1: Starting air pilot valve

2 Control piston
3 Sealing ring
4 PTFE ring
5 O-ring seal

Work Cards, classified into sub-assemblies

Figure 2: Control piston with sealing ring
48/60B;48/60CR;51/60DF
2007-06-15

6707 160.02-01 EN 3 (3)

 MAN Diesel & Turbo 161.01

Starting valve

Starting air pilot valve/Starting valve/Main starting valve

inspection, removal and installation

Summary
Carry out all work on time in accordance with the maintenance schedule,
and make sure that operational safety is established (or re-established if
necessary).
The starting valves must be inspected at regular intervals and removed for
overhauling.
The work/work steps include:
checking for leaks,
removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Suspension device 221.189 Standard
1 Threaded pipe 221.189-1 Standard
1 Pilot rod 221.189-2 Standard
1 Removal and fitting fixture 161.020 Standard
1 Extractor sleeve 221.179-1 Standard
1 Threaded spindle 221.179-2 Standard

Work Cards, classified into sub-assemblies

1 Deep groove thrust ball bearing 221.179-5 Standard
1 Cap 221.179-6 Standard
1 Extension 161.020-4 Standard
1 Intermediate piece 161.020-5 Standard
1 Cleaning tool 055.133 Standard
1 Combination spanner (set) 009.231 Option
1 Torque wrench 008.017 Standard
48/60B;48/60CR;51/60DF

1 Shackle A1.6 002.454 Standard

1 Shackle A0.6 002.452 Standard
1 Adapter 12.5x20 001.927 Option
1 Adapter 20x12.5 001.923 Option
2009-01-29

1 Extension piece 12.5x250 001.912 Option

1 Cross handle 001.891 Option
1 Socket spanner insert 36x20 001.779 Option
1 Lifting eye bolt M12 000.142 Standard

6707 161.01-02 EN 1 (11)

 161.01 MAN Diesel & Turbo

Quantity Designation Number Status

Starting air pilot valve/Starting valve/Main starting valve

1 Lifting tackle - Inventory

1 Rope - Inventory
1 Depth gauge - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory
1 Securing compound, Loctite 638 - Inventory

Corresponding Work Cards

Work card Work card Work card
000.19 000.30 055.03
161.02

Technical data
Designation Information
Thrust flange 12,5 kg
Starting valve 6,5 kg
Bolt projection (A) 188 mm

Preliminary remark

If the starting air pipe becomes hot during the operation, shut off the
engine immediately whenever possible and replace the defective starting
valve! Make all air pipes pressureless before work on starting valve!
Close shut-off valve on compressed air tank!

Work sequence 1 - Checking for leakage

Work Cards, classified into sub-assemblies

Work steps 1. Block control air pipe with cap nut and sealing plug before distributing
pipe to the starting air pilot valves (after detaching a pipe section).

This ensures that no starting valve can be charged with pontrol air.
48/60B;48/60CR;51/60DF

2. Open the indicator valve on the cylinder head.

3. Turn the running gear, until piston is in ignition TDC (inlet and exhaust
valve closed).
4. Aerate starting air pipe. Leaking starting valves can be detected by the
air outlet on the indicator valve.
2009-01-29

Overhaul leaking starting valves as soon as possible, otherwise the valve

seat will continue to deteriorate.

2 (11) 6707 161.01-02 EN

 MAN Diesel & Turbo 161.01

Work sequence 2 - removing the starting valve

Starting air pilot valve/Starting valve/Main starting valve

Starting position Cylinder head cover and indicator valve are open.

Pressure in the combustion chamber

Do not remove the starting valve unless the engine is at an absolute standstill
and the indicator valve is open! The combustion chamber can be under high
pressure when the indicator valve is closed!

Work steps 1. Unscrew and remove the two hexagon nuts (1).

2. Screw the lifting eye bolt (000.142) into the thrust flange (2).
3. Fasten the rope (8) with the shackle (002.452) to the lifting eye bolt and
attach it to lifting tackle. See Fig. 2/I.
4. Remove the thrust flange (2) and place it to one side. See Fig. 2/II.
5. Detach the tool.
6. Screw on the extension (161.020-4) until it is seated on the starting valve
(5). See Fig. 3/I.
7. Screw on the threaded spindle (221.179-2) until it is seated on the
extension.
8. Place the intermediate piece (161.020-5) on the cylinder head (6).
9. Place the extractor sleeve (221.179-1) on the intermediate piece.

Locating the extractor sleeve

Fit the extractor sleeve in such a way that it is fixed by a stud (7). See
Fig. 3/I.

10. Push the deep groove thrust ball bearing (221.179-5) over the threaded
spindle and insert it in the extractor sleeve. Place the cap (221.179-6)
on the deep groove thrust ball bearing. See Fig. 3/I.

Work Cards, classified into sub-assemblies

Installation of the deep groove thrust ball bearing
Make sure the deep groove thrust ball bearing is correctly installed. See
Fig. 3/I.

11. Screw the hexagon nut (9) onto the threaded spindle.
12. By turning the hexagon nut (9) release the starting valve (5) and carefully
lift it out. See Fig. 3/II.
48/60B;48/60CR;51/60DF

13. Remove the tool, extension (161.020-4) remains screwed onto the start-
ing valve (5).
14. Screw on the threaded pipe (221.189-1) until it is seated on the exten-
sion. See Fig. 4/I.
2009-01-29

15. Fasten the rope (8) with the shackle (002.454) to the lifting eye bolt (10)
and attach it to lifting tackle.
16. Screw the pilot rod (221.189-2) into the threaded pipe.

6707 161.01-02 EN 3 (11)

 161.01 MAN Diesel & Turbo

17. Remove the starting valve (5) and place it down on the workbench. See
Starting air pilot valve/Starting valve/Main starting valve

Fig. 4/II.
18. Clean the locating hole in the cylinder head (6) with the cleaning tool
(055.133). See Fig. 5.

Cleaning the locating hole

During cleaning, make sure that no foreign bodies are allowed to drop
into the combustion chamber!

19. Check valve seating surface in the cylinder head (6), grind if necessary
(see Work Card 055.03).
20. Cover the opening in the cylinder head (6).
21. Remove the suspension device (221.189) and the extension.
22. Remove the O-ring seals (3 and 4).
23. Clean the starting valve (5) from the outside, dismantle it if necessary
(see Work Card 161.02).

Work sequence 3 - installing the starting valve

Starting position All individual parts have been cleaned, inspected and replaced where nec-
essary.
Work steps 1. Insert a new O-ring seal (4) oiled with clean lubricating oil in the ring
groove, making sure that it is evenly tensioned all around the circum-
ference and is not twisted.
2. Screw on the extension (161.020-4) until it is seated on the starting valve
(5). See Fig. 6/I.
3. Screw on the threaded pipe (221.189-1) until it is seated on the exten-
sion.
4. Fasten the rope (8) with the shackle (002.454) to the lifting eye bolt (10)
and attach it to lifting tackle.
Work Cards, classified into sub-assemblies

5. Screw the pilot rod (221.189-2) into the threaded pipe.

6. Lift up the starting valve (5) and move it over the cylinder head (6).
7. Remove the cover for the locating hole.
8. Insert the starting valve (5) in the locating hole. See Fig. 6/I.
9. Install the starting valve (5) until it makes contact. See Fig. 6/II.
10. Detach the tool.
48/60B;48/60CR;51/60DF

11. Insert new O-ring seals (3) which have been oiled with clean lubricating
oil in the ring grooves; in doing so, make sure that they are evenly ten-
sioned all around the circumference and that they are not twisted.
12. Screw the lifting eye bolt (000.142) into the thrust flange (2).
2009-01-29

13. Fasten the rope (8) with the shackle (002.452) to the lifting eye bolt and
attach it to lifting tackle. Lift up the thrust flange (2).
14. Move the thrust flange (2) over the cylinder head (6) and insert it into the
locating hole. See Fig. 2/II.
15. Install the thrust flange (2) until it makes contact. See Fig. 2/I.

4 (11) 6707 161.01-02 EN

 MAN Diesel & Turbo 161.01

16. Detach the tool.

Starting air pilot valve/Starting valve/Main starting valve

17. Apply MoS1-lubricant to threads and resting surface of the hexagon nuts
(2), screw on and tighten alternately with the specified torque (see Work
Card 000.30).

Installation in a cylinder head at operating temperature

If the starting valve is installed in a cylinder head which is at operating
temperature, initially only tighten the two hexagon nuts finger-tight. Once
the temperature of the components has been equalized they should then
be tightened to the specified torque!
If dummy inserts are to be installed in place of the starting valves then
they must also be tightened to the specified torque!

18. After installing the starting valve, check for leakage (see work sequence
1).

Work sequence 4 - Installing the studs (7)

Starting position Starting valve has been removed and cleaned. Studs have been unscrewed
and removed, threaded bores have been cleaned.
Work steps 1. Prepare the starting valve (5) and thrust flange (2) for installation.

2. Coat the screw-in thread of the studs (7) with Loctite 638 securing com-
pound and screw them in until the specified projection (A) is reached.
See Fig. 1.
3. Install the starting valve (5) and thrust flange (2) (see work sequence 3).
4. Apply MoS1-lubricant to threads and resting surface of the hexagon nuts
(2), screw on and tighten alternately with the specified torque (see Work
Card 000.30).

Hardening of the securing compound

Steps 3 and 4 need to be performed quickly! The hexagon nuts should
be tightened to the specified torque before the Loctite 638 securing

Work Cards, classified into sub-assemblies

compound on the screwed-in stud bolts has hardened (approx. 10
minutes)! 48/60B;48/60CR;51/60DF
2009-01-29

6707 161.01-02 EN 5 (11)

 161.01 MAN Diesel & Turbo
Starting air pilot valve/Starting valve/Main starting valve

1 Hexagon nut
2 Thrust flange
3 O-ring seal
4 O-ring seal
5 Starting valve
6 Cylinder head
7 Stud
A Bolt projection

Figure 1: Starting valve in the cylinder head

Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2009-01-29

6 (11) 6707 161.01-02 EN

 MAN Diesel & Turbo 161.01

Starting air pilot valve/Starting valve/Main starting valve

Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2 Thrust flange 7 Stud

3 O-ring seal 8 Rope
5 Starting valve I - II Work steps
2009-01-29

6 Cylinder head
Figure 2: Removal/installation of the thrust flange

6707 161.01-02 EN 7 (11)

 161.01 MAN Diesel & Turbo
Starting air pilot valve/Starting valve/Main starting valve
Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2009-01-29

4 O-ring seal 6 Cylinder head 9 Hexagon nut M24

5 Starting valve 7 Stud I - II Work steps
Figure 3: Removal of the starting valve

8 (11) 6707 161.01-02 EN

 MAN Diesel & Turbo 161.01

Starting air pilot valve/Starting valve/Main starting valve

Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF
2009-01-29

4 O-ring seal 6 Cylinder head 10 Lifting eye bolt

5 Starting valve 8 Rope I - II Work steps
Figure 4: Removal of the starting valve

6707 161.01-02 EN 9 (11)

 Work Cards, classified into sub-assemblies Starting air pilot valve/Starting valve/Main starting valve

10 (11)
48/60B;48/60CR;51/60DF
161.01

6707 161.01-02 EN
Figure 5: Cleaning the locating hole in the cylinder head
6 Cylinder head
MAN Diesel & Turbo

2009-01-29
 MAN Diesel & Turbo 161.01

Starting air pilot valve/Starting valve/Main starting valve

Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF
2009-01-29

4 O-ring seal 6 Cylinder head 10 Lifting eye bolt

5 Starting valve 8 Rope I - II Work steps
Figure 6: Installation of the starting valve

6707 161.01-02 EN 11 (11)

 MAN Diesel & Turbo 161.02

Starting valve

Starting air pilot valve/Starting valve/Main starting valve

dismantling and assembling

Summary
Carry out the work in due time according to the maintenance schedule,
ensure/restore operational safety.
Check starting valves at regular intervals and overhaul if necessary.
The work/work steps include:
Dismantling components,
Replace packing rings /sealing elements,
Assembling components.
Tools/aids required
Quantity Designation Number Status
1 Torque wrench 008.016 Standard
1 Cross handle 001.891 Standard
1 Socket spanner insert 24x12.5L 001.768 Standard
1 Combination spanner (set) - Inventory
1 Side cutter - Inventory
1 Grinding paste, silicon-free - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory
1 Touching-test ink - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30 161.01

Work Cards, classified into sub-assemblies

Work sequence 1 - Dismantling the starting valve
Starting position Starting valve is removed.

Work steps 1. Load starting valve on two surfaces of the valve cone (10) in the vice.
48/60;48/60B;L40/54;V48/60CR

2. Unscrew hexagon nut (1), this releases the compression spring (2).
3. Remove piston (14) from valve taper (10).
4. Remove casing (3) with compression spring (2).
5. Remove sealing rings (4 and 7) from piston (14).
6. Clean all individual parts, check for attrition and damage.
2007-07-31

7. Check valve seat with touching test.

Grinding the valve seat If grinding is necessary, clamp casing (3) carefully in vice, not damaging any
sealing faces. Apply grinding paste on valve seat. Install valve taper (10) with
piston (14) without compression spring and sealing rings (4 and 7) in casing.
Rotate valve taper to and fro. Raise valve cone in the meanwhile, so that

6644 161.02-01 EN 1 (3)

 161.02 MAN Diesel & Turbo

grinding paste can be redistributed. After grinding, clean valve taper, casing
Starting air pilot valve/Starting valve/Main starting valve

and piston carefully.

Remove as little material as possible and grind only until a uniform matt
grey ring face has appeared (check with touching test)!

Work sequence 2 - Assembling the starting valves

Starting position All individual parts have been cleaned, inspected and replaced where nec-
essary.
Work steps The assembly of the starting valve is done in reverse order of the disman-
tling. The following must be observed when doing so:
▪ Install new sealing rings (4 and 7) in piston (14) (see Work sequence 3).
▪ Apply MoS2-lubricant to threads and resting surface of the hexagon nut
(1), screw-on and tighten with the specified torque (see Work Card
000.30).

Work sequence 3 - Mounting of the sealing rings (4 and 7)

Work steps 1. Place O-ring seal (5 and 8) in the groove, making sure that it is clamped
uniformly on the entire periphery and is not twisted.
2. Heat PTFE-Ring (6 or 9) in oil to 80 °C - 100°C.

Do not use bare hands to insert PTFE ring in oil bath or to take it out!

3. Pull PTFE ring over piston (14) into the groove.

4. Reshape the expanded PTFE-Ring (6 or 9) by placing the piston (14) into
the oiled casing (3).
Work Cards, classified into sub-assemblies
48/60;48/60B;L40/54;V48/60CR

2007-07-31

2 (3) 6644 161.02-01 EN

 MAN Diesel & Turbo 161.02

Starting air pilot valve/Starting valve/Main starting valve

1 Hexagon nut (self-locking)
2 Compression spring
3 Casing
4 Sealing ring
7 Sealing ring
10 Valve cone
14 Piston

Figure 1: Starting valve

4 Sealing ring
5 O-ring seal
6 PTFE ring
7 Sealing ring
8 O-ring seal
9 PTFE ring
14 Piston

Work Cards, classified into sub-assemblies

Figure 2: Piston with sealing rings
48/60;48/60B;L40/54;V48/60CR
2007-07-31

6644 161.02-01 EN 3 (3)

 MAN Diesel & Turbo 162.01

Main starting valve

Starting air pilot valve/Starting valve/Main starting valve

dismantling and assembling

Summary
Carry out the work in due time according to the maintenance schedule,
ensure/restore operational safety.
The main starting valve is to be checked, cleaned and overhauled if neces-
sary at regular intervals.
The work/work steps include:
Removing components,
Separating and assembling,
Installing components.
Safety requirements
- Operating media systems closed/depressurised
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory

Preliminary remarks
Check for free movement and good condition of the individual components
at the time intervals stipulated in the maintenance schedule. Check sealing
rings, replace damaged parts if required.
Check valve taper and valve seats for damage and regrind with fine emery
if necessary.
Work sequence 1 - Removal and dismantling

Work Cards, classified into sub-assemblies

Starting position Compressed air tank closed. Compressed air line between compressed air
tank and main starting valve bled.
48/60;48/60CR;L58/64;51/60DF
2008-10-09

6619 162.01-01 EN 1 (3)

 162.01 MAN Diesel & Turbo
Starting air pilot valve/Starting valve/Main starting valve

1 Casing 8 Compression spring 17 Seal consisting of O-ring seal and

PTFE ring
3 Valve seat 9 Seal consisting of O-ring seal and 18 Nut
PTFE ring
4 Valve piston 14 Valve seat (vent valve) 19 Closing cap
5 Safety valve 15 Vent valve 20 Set screw
7 Hexagon bolt 16 Piston
Figure 1: Main starting valve
Work Cards, classified into sub-assemblies

On opening the instrument or starter air systems, ensure especially that

no dirt of any kind can enter the valves and pipelines. Block open pipe
ends with plastic caps or adhesive tape. Dismantle valve only in a clean
workplace, use grease solvent and compressed air for cleaning.
When assembling, take utmost care for maintaining cleanliness at
48/60;48/60CR;L58/64;51/60DF

workplace for the work steps, even smallest dirt particles can cause
faults in the valve or in compressed air / control air system.

Work steps 1. Release pipe connections, remove hexagon bolts and remove valve.

2. Block open pipe ends against penetration of dirt.

3. Release and remove hexagon bolts (7), mark the position of the casing
(1) to the valve seat (3).
2008-10-09

4. Separate casing from valve seat. Remove, clean and blow with com-
pressed air all individual parts and check the condition, change if nec-
essary.

2 (3) 6619 162.01-01 EN

 MAN Diesel & Turbo 162.01

5. Release and remove closing cap (19), take out vent valve, separate into

Starting air pilot valve/Starting valve/Main starting valve

all individual parts.
6. Clean and blow with compressed air all individual parts and check the
condition, change if necessary.
7. If necessary, finish grind valve piston (4) or venting taper (15) in valve
seat (3 or 14) using fine emery.

When grinding, remove only a little material and grind only until a matt
grey annular surface has appeared without scarring. The tightness can
be tested by using fuel or touching-test ink. A hexagon bolt M10 is used
for grinding the valve piston (4) which is screwed into the valve piston.

Work sequence 2 - Assembly

Carry out assembly in the reverse sequence. Pay particular attention to the
ease of movement of the moving parts and the tightness of the parting lines.
Carry out functioning check after the attachment. If the tightness of the
casing is to be tested, the internal moving parts are not installed first and
pressed with a testing pressure of 45 bar.
When installing new seals (9 or 17) proceed as follows:
1. Insert O-ring seal in groove.
2. Heat PTFE-Ring in water or oil to 80 -100 °C.
3. Pull PTFE-Ring over groove edge into the groove.
4. Shape back the expanded PTFE Ring by placing the valve piston (4) or
venting taper (15) in the oiled casing (1) or the valve seat (14).

Work Cards, classified into sub-assemblies

48/60;48/60CR;L58/64;51/60DF
2008-10-09

6619 162.01-01 EN 3 (3)

MAN Diesel & Turbo 200

Fuel injection pump

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.20-1 EN 1 (2)

 MAN Diesel & Turbo
Fuel injection pump

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.20-1 EN

 MAN Diesel & Turbo 200.01

Fuel injection pump

Fuel injection pump

inspecting

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for quality/wear condition.
Check Fuel injection pumps at regular intervals.
The work includes:
Checking parts/ components.
Safety requirements
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Side cutter - Inventory
1 Locking wire - Inventory
1 Pliers for locking wire - Inventory

Corresponding Work Cards

Work card Work card Work card
200.05 201.01 209.01

Preliminary remark
The attrition of the pump elements depends mainly on abrasive or corrosive

Work Cards, classified into sub-assemblies

components of the fuel. Preheating as specified, separation and filtering as
well as timely servicing and change of wear parts (baffle screws) also con-
tribute towards extending the life in the face of adverse initial conditions.
Work sequence - Inspection
Starting position Covers of the camshaft casing are removed.

Work steps 1. Check condition (lubrication) of the injection cam, drive roller and lifter
bore of the fuel injection pump drive (see Work Card 201.01 and 209.01).
2. Remove hexagon bolt (4) between control rod (2) and jointed head (5)
check easy movability of control rod and regulating sleeve (18). See Figs.
1 and 2.
2008-03-12

Heavy to move or stuck regulating sleeve can be made free moving again
by using diesel fuel.
48/60B

3. Insert hexagon bolt (4) again and fasten with lock nut (3).

6704 200.01-01 EN 1 (4)

200.01 MAN Diesel & Turbo

4. Block fuel admission pipe and drain pipe.

Fuel injection pump

5. Remove locking wire (6) for baffle screws (7). See Fig. 1.
6. Unscrew both baffle screws (7) and check for attrition (see Work Card
200.05), renew baffle screws if necessary.
7. Screw baffle screws (7) including new sealing rings (8) into fuel injection
pump (1) by hand.
8. Secure baffle screws (7) by means of locking wire (6). See Fig. 1.
9. Check the remaining fuel injection pumps in the same manner. See point
1 to 3 and point 5 to 8.
10. Open fuel admission pipe and drain pipe.
11. Check leakage fuel drain of all fuel injection pumps at longer intervals.

If there are major leakage losses, remove the relevant pump element (10).
If the sealing rings (9, 13 and 14) and the O-ring seals (15 and 16) are in
order, the pump element must be replaced. See Fig. 2.

A pump element comprises monobloc cylinder (11) and pump plunger

(12). Pump plunger and monobloc cylinder can only be changed together
because both parts are matched to each other! It is also advisable to use
new sealing rings and O-ring seals at the time of installation of a new
pump element!
Work Cards, classified into sub-assemblies

2008-03-12
48/60B

2 (4) 6704 200.01-01 EN

 MAN Diesel & Turbo 200.01

Fuel injection pump

Work Cards, classified into sub-assemblies
2008-03-12

1 Fuel injection pump 5 Jointed head

2 Rack 6 Locking wire
48/60B

3 Lock-nut *7 Baffle screw

4 Hexagon bolt 8 Sealing ring
Figure 1: Fuel injection pump

6704 200.01-01 EN 3 (4)

200.01 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

1 Fuel injection pump 12 Pump plunger 16 O-ring seal

9 Sealing ring 13 Sealing ring 17 Casing
10 Pump element 14 Sealing ring 18 Regulating sleeve
*11 Monobloc cylinder 15 O-ring seal
Figure 2: Fuel injection pump
* Shape of the baffle screws and the inlet ports in the monobloc cylinder can differ from the representation in the
figures.
2008-03-12
48/60B

4 (4) 6704 200.01-01 EN

 MAN Diesel & Turbo 200.02

Fuel injection pump

Fuel injection pump

shut off

Summary
Ensure correct execution of work, enable emergency operation.
Switch off injection pumps are to be switched off every time individual run-
ning gear is to be put out of operation.
The work extends to:
Putting components out of operation.
Tools/aids required
Quantity Designation Number Status
1 Pipe clamp 200.055 Standard
1 Hexagon screwdriver (set) - Inventory

Preliminary remark
In the event of malfunctioning on the injection system, on cylinder head, on
the valve control or on dismounted running gear, the associated fuel injec-
tion pump should be switched off, so that an emergency operation can be
ensured (see Volume 010.005 Engine - Operating Instructions).
When switching off the control rod of the corresponding fuel injection pump
is blocked in the ZERO position.
The filling of the remaining fuel injection pumps is enabled by unbuckling
the buckling lever on the switched-off fuel injection pump.
Work sequence - Shutting off a fuel injection pump
Starting position Required measures for realising the emergency operation (see Volume
010.005 Engine - Operating Instructions).

Work Cards, classified into sub-assemblies

Work steps 1. With the engine at a standstill, check that the control rod (2) is in the
ZERO position. When the engine is running, pull the control rod (2)
against the force of the buckling lever spring to the ZERO position, and
hold.
2. Fit two-part pipe clamp (200.055) on control rod (2), screw in hexagon
socket bolts (3) loosely.
3. Push the pipe clamp until it rests and tighten the hexagon socket bolts
(3) by hand. See Fig. 2.
48/60B;51/60DF
2008-10-22

6704 200.02-01 EN 1 (3)

200.02 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

1 Fuel injection pump 2 Rack

Figure 1: Fuel injection pump
48/60B;51/60DF

2008-10-22

2 (3) 6704 200.02-01 EN

 MAN Diesel & Turbo 200.02

Fuel injection pump

Work Cards, classified into sub-assemblies
1 Fuel injection pump 3 Hexagon socket bolt M8x60
2 Rack
Figure 2: Fuel injection pump with blocked control rod
48/60B;51/60DF
2008-10-22

6704 200.02-01 EN 3 (3)

 MAN Diesel & Turbo 200.03

Fuel-injection pump

Fuel injection pump

Removal and installation

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for quality/wear condition.
Check Fuel injection pumps at regular intervals.
The work/work steps include:
removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Adapter plate 200.134 Option
1 Suspension bolt with wire cable 200.127 Standard
1 Support fixture 200.114 Standard
1 Holder 200.113 Standard
1 Combination spanner (set) 009.231 Option
1 Power amplifier 008.030 Standard
1 Adapter 008.030-1 Standard
1 Ratchet tool 008.023 Standard

Work Cards, classified into sub-assemblies

1 Torque wrench 008.011 Standard
2 Shackle A1.0 002.453 Standard
1 Extension piece 25x200 001.915 Standard
1 Cross handle 001.891 Option
1 Socket spanner insert 41x25 001.801 Standard
1 Socket spanner insert 32x12.5 001.760 Option
1 Lifting tackle - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory
L48/60B;L51/60DF

Corresponding work cards

2009-12-02

Work card Work card Work card

000.30 055.05 111.02
112.01 200.06 434.01
434.05

6704 200.03-03 EN 1 (17)

200.03 MAN Diesel & Turbo

Technical data
Fuel injection pump

Designation Information
Fuel injection pump 110 kg

Work sequence 1 - Removing the fuel-injection pump

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work steps 1. Detach rocker arm casing (see Work Card 111.02).

2. Removing push rods (see Work Card 112.01).

3. Turn the engine over so that roller of the fuel cam follower stands on the
pitch circle of the injection cam.
4. Close all requisite shut-off valves (e.g. fuel pipes, air pipes etc.).
5. Remove fuel admission pipe (7) and fuel return pipe (6) from fuel injection
pump (5) (see Work Card 434.05).
6. Remove all pipelines (e.g. fuel leakage pipe, air pipe etc.) from fuel
injection pump (5).
7. Remove fuel injection pipe (2) (see Work Card 434.01).
8. Separate the connecting rod (9) from the fuel injection pump (5) by
removing a hexagon bolt (11). See Figs. 1 and 2.

Length of connecting rod

Connecting rod (9) is set to the correct length and locked by MAN Diesel
& Turbo SE! It is advisable not to dismantle it or to change the set length!

9. Push the regulating rod (8) in completely to protect it (full load position).
Work Cards, classified into sub-assemblies

10. Place holding fixture (200.113) on fuel-injection pump (5). See Figs. 3
and 4.
11. Fit socket wrench insert (001.801) on hexagon nut (3).
12. Insert extension piece (001.915) in socket wrench insert.
13. Fit support fixture (200.114) on force amplifier (008.030).
14. Insert force amplifier in extension piece, ensuring that support fixture
rests on the holding fixture. See Figs. 5 and 6.
15. Fit adapter (008.030-1), socket wrench insert (001.760) and tee handle
(001.891) onto force amplifier.
L48/60B;L51/60DF

16. Release hexagon nut (3).

2009-12-02

17. Detach tool (holding fixture remains attached).

18. Release the remaining two hexagon nuts (3) in the same manner. See
Points 11 to 16.
19. Completely detach the tool.

2 (17) 6704 200.03-03 EN

 MAN Diesel & Turbo 200.03

20. Unscrew hexagon nuts (3).

Fuel injection pump

21. Screw suspension bolt (200.127) into fuel-injection pump (5). See Fig.
7.
22. Suspend wire cable (17) with shackle (002.453) from lifting gear.
23. Carefully remove the fuel-injection pump (5), taking care not to damage
the stud bolts (4). See Fig. 8.
24. Cover the resulting opening on fuel-injection pump drive.
25. Move fuel-injection pump (5) forwards with lifting gear, observing buck-
ling lever on regulating rod. See Fig. 9.
26. Lift mounting plate (200.134) into turning device (055.130) and secure
with the appropriate equipment (see manufacturer's instructions). See
Fig. 11.
27. Remove O-ring (14).
28. Lower fuel-injection pump (5) and set it down on the mounting plate,
making sure the correct mounting hole is used. Do not damage the
threaded bolt (30). See Figs. 12 and 13.
29. Fasten fuel-injection pump (5) to mounting plate with hexagon nuts (31).
30. Detach suspension bolt from fuel-injection pump (5).

Possibility of turning the fuel injection pump

When the locking lever is moved upwards, the fuel injection pump can
be brought into any desired position by turning the handwheel. It is
possible to fix the fuel injection pump at all 45° intervals by inserting the
locking lever into the groove of the ratchet disc (see Work Card 055.05).

Work on clamped fuel injection pump

When working on the clamped fuel injection pump, always insert the
locking lever into a groove in the ratchet disc!

Work Cards, classified into sub-assemblies

31. Disassemble O-rings (15) and supporting rings (16).
32. Clean fuel-injection pump (5) externally.

Work sequence 2 - Installing the fuel-injection pump

Starting position Fuel-injection pump is placed in turning device, cleaned and checked, reg-
ulating rod is pushed in completely for protection (full load position). Roller
of the fuel cam follower is on the base circle of the injection cam.

Danger of death when lifting and moving loads!

L48/60B;L51/60DF

Unless absolutely necessary, do not enter or remain in the area below

suspended loads!
2009-12-02

Work steps 1. Check new supporting rings (16) and O-rings (15) for integrity.

2. Apply clean lubricating oil to supporting rings (16) and place them in
appropriate grooves.

6704 200.03-03 EN 3 (17)

200.03 MAN Diesel & Turbo

3. Apply lubricating oil to O-rings (15), press them into a kidney shape and
Fuel injection pump

place in appropriate grooves, ensuring that they are not twisted. See
Fig. 10.

Installing the supporting ring and O-ring

Ensure correct position of supporting ring and O-ring! O-ring always on
pressure side, supporting ring on the other side, with recess in the
supporting ring pointing towards O-ring! See Fig. 2.

4. Screw suspension bolt (200.127) into fuel-injection pump (5).

5. Suspend wire cable (17) with shackle (002.453) from lifting gear.
6. Unscrew hexagon nuts (31).
7. Lift the fuel-injection pump (5) out of the mounting plate (200.134), taking
care not to damage the threaded bolts (30). See Fig. 12.
8. Clean the contact surface on the fuel-injection pump (5).
9. Insert a new O-ring (14) oiled with clean lubricating oil in the annular
groove, making sure that it is evenly tensioned all around the circum-
ference and is not twisted.
10. Move fuel-injection pump (5) up to the engine, observing buckling lever
on regulating rod. See Fig. 8.
11. Remove cover for opening on fuel-injection pump drive (12).
12. Clean the contact surface on the fuel-injection pump drive (12).
13. Slowly and carefully lower the fuel-injection pump (5) into the bore, tak-
ing care not to damage the stud bolts (4). See Fig. 7.

Fixing the location of the fuel-injection pump

Make sure that the bore in the fuel-injection pump and the parallel pin
(13) on the fuel-injection pump drive (12) are aligned. See Fig. 1.

14. Remove the tool once the fuel-injection pump (5) has been lowered
Work Cards, classified into sub-assemblies

completely.
15. Apply MoS2lubricant to threads and contact faces of the hexagon nuts
(3) and screw on until they abut.
16. Mount fuel supply line (7) and fuel return line (6) on fuel-injection pump
(5) (see Work Card 434.05), align fuel-injection pump.
17. Place holding fixture (200.113) on fuel-injection pump (5). See Figs. 3
and 4.
18. Fit socket wrench insert (001.801) on hexagon nut (3).
19. Insert extension piece (001.915) in socket wrench insert.
L48/60B;L51/60DF

20. Fit support fixture (200.114) on force amplifier (008.030).

2009-12-02

21. Insert force amplifier in extension piece, ensuring that support fixture
rests on the holding fixture. See Figs. 5 and 6.
22. Fit adapter (008.030-1), socket wrench insert (001.760) and torque
wrench (008.011) with ratchet (008.023) on force amplifier.

4 (17) 6704 200.03-03 EN

 MAN Diesel & Turbo 200.03

23. Tighten hexagon nut (3) to specified torque - 1st stage - (see Work Card

Fuel injection pump

000.30 and conversion table for force amplifier).

Setting the correct torque at the torque wrench

To set the correct torque on the torque wrench, proceed as follows:
- Take the value for specified torque from Work Card 000.30,
- Search for the value in the conversion table and determine the
tightening torque from table,
- Set the tightening torque from the conversion table at the torque
wrench!

24. Detach tool (holding fixture remains attached).

25. Tighten the remaining two hexagon nuts (3) in the same manner to
specified torque - 1st stage. See Points 18 to 24.
26. Place tool on first hexagon nut (3) again (see Points 18 to 22) and tighten
it to the specified torque - 2nd stage - (see Work Card 000.30 and conver-
sion table for force amplifier).
27. Detach tool (holding fixture remains attached).
28. Tighten the remaining two hexagon nuts (3) in the same manner to
specified torque - 2nd. stage. See Points 18 to 22 and Points 26 and 27.
29. Place tool on first hexagon nut (3) again (see Points 18 to 22) and tighten
it to specified torque - 3rd stage - (see Work Card 000.30 and conversion
table for force amplifier).
30. Detach tool (holding fixture remains attached).
31. Tighten the remaining two hexagon nuts (3) in the same manner to
specified torque - 3rd stage. See Points 18 to 22 and Point 29.
32. Completely detach the tool.
33. Attach fuel-injection pipe (2) (see Work Card 434.01).
34. Attach all removed pipes (e.g. fuel leakage line, air pipe etc.) to fuel-
injection pump (5), open all closed stopcocks.

Work Cards, classified into sub-assemblies

35. Connect regulating rod (8) to connecting rod (9). See Figs. 1 and 2.

Length of connecting rod

Connecting rod (9) is set to the correct length and locked by MAN Diesel
& Turbo SE! It is advisable not to change the set length (unless a new
fuel injection pump is fitted, in which case the length should be set by
MAN Diesel & Turbo personnel).

36. Attach push rods (see Work Card 112.01).

37. Attach rocker housing (see Work Card 111.02).
L48/60B;L51/60DF

38. Remove mounting plate (200.134) from turning device (055.130), clean
and store.
2009-12-02

When connecting a new fuel-injection pump to the regulating rod, determine

the ignition pressure by indexing after commissioning and compare it with
the adjacent cylinders.

6704 200.03-03 EN 5 (17)

200.03 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

1 Cylinder head 8 Rack

L48/60B;L51/60DF

2 Fuel injection pipe 9 Connecting rod

3 Hexagon nut 10 Hexagon nut
2009-12-02

4 Stud 11 Hexagon bolt

5 Fuel injection pump 12 Fuel injection pump drive
6 Fuel return pipe 13 Parallel pin
7 Fuel admission pipe 14 O-ring seal
Figure 1: Fuel injection pump

6 (17) 6704 200.03-03 EN

 MAN Diesel & Turbo 200.03

Fuel injection pump

2 Fuel-injection pipe 9 Connecting rod
3 Hexagon nut 10 Hexagon nut

Work Cards, classified into sub-assemblies

4 Stud bolt 11 Hexagon head screw
5 Fuel-injection pump 15 O-ring
6 Fuel return pipe 16 Supporting ring
8 Regulating rod
Figure 2: Fuel injection pump - View (indicated in Fig. 1)
L48/60B;L51/60DF
2009-12-02

6704 200.03-03 EN 7 (17)

200.03 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

5 Fuel injection pump 9 Connecting rod

8 Rack
Figure 3: Fuel injection pump - Loosening /tightening the hexagon nut
L48/60B;L51/60DF

2009-12-02

8 (17) 6704 200.03-03 EN

 MAN Diesel & Turbo 200.03

Fuel injection pump

5 Fuel injection pump 7 Fuel admission pipe
6 Fuel return pipe
Figure 4: Fuel injection pump - Loosening /tightening the hexagon nuts (view
on figure 3)

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2009-12-02

6704 200.03-03 EN 9 (17)

200.03 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

3 Hexagon nut 5 Fuel-injection pump

Figure 5: Fuel-injection pump - Loosening /tightening the hexagon nuts
L48/60B;L51/60DF

2009-12-02

10 (17) 6704 200.03-03 EN

 MAN Diesel & Turbo 200.03

Fuel injection pump

3 Hexagon nut 5 Fuel injection pump
Figure 6: Fuel injection pump - Loosening /tightening the hexagon nuts (view on figure 5)

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2009-12-02

6704 200.03-03 EN 11 (17)

200.03 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

5 Fuel injection pump 17 Wire rope

Figure 7: Removal/installation of fuel injection pump
L48/60B;L51/60DF

2009-12-02

12 (17) 6704 200.03-03 EN

 MAN Diesel & Turbo 200.03

Fuel injection pump

Work Cards, classified into sub-assemblies
4 Stud 13 Parallel pin
5 Fuel injection pump
Figure 8: Removal/installation of fuel injection pump
L48/60B;L51/60DF
2009-12-02

6704 200.03-03 EN 13 (17)

200.03 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

5 Fuel injection pump 14 O-ring seal

Figure 9: Removal/installation of fuel injection pump
L48/60B;L51/60DF

2009-12-02

Figure 10: Kidney-shaped compression of a O-ring seal

14 (17) 6704 200.03-03 EN

 MAN Diesel & Turbo 200.03

Fuel injection pump

Figure 11: Turning device with mounting plate

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2009-12-02

6704 200.03-03 EN 15 (17)

200.03 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

5 Fuel-injection pump 30 Threaded bolt M27x2

L48/60B;L51/60DF

17 Wire rope
Figure 12: Inserting the fuel-injection pump into the mounting plate
2009-12-02

16 (17) 6704 200.03-03 EN

 MAN Diesel & Turbo 200.03

Fuel injection pump

5 Fuel-injection pump 31 Hexagon nut M27x2
30 Threaded bolt M27x2
Figure 13: Mounting plate with fuel-injection pump inserted

Work Cards, classified into sub-assemblies

L48/60B;L51/60DF
2009-12-02

6704 200.03-03 EN 17 (17)

 MAN Diesel & Turbo 200.04

Fuel injection pump

Fuel injection pump

disassembly and assembly

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, ensure / restore operating safety.
Fuel injection pumps are to be dismounted in the course of the service and
maintenance work.
The work/work steps include:
disassembling components,
assembling components.
Tools/aids required
Quantity Designation Number Status
1 Mounting device 200.118 Standard
1 Assembly cone 200.118-1 Standard
1 Expanding sleeve 200.118-2 Standard
1 Sizing sleeve 200.118-5 Standard
1 Removal and fitting fixture 200.104 Standard
1 Threaded spindle 200.104-1 Standard
1 Lug 200.104-2 Standard
1 Spherical disc 200.104-4 Standard
1 Conical socket 200.104-5 Standard
1 Combination spanner (set) 009.231 Option
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
1 Cross handle 001.891 Option

Work Cards, classified into sub-assemblies

1 Socket spanner insert 24x12.5 001.757 Option
1 Eye bolt 001.404 Standard
1 Marker pen - Inventory
1 Screwdriver (Set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Side cutter - Inventory
1 Locking wire - Inventory
1 Pliers for locking wire - Inventory
1 Grease (acid-free) - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
2009-09-14

1 Lubricating oil, clean - Inventory

1 Special anti-seize agent (Molykote G Rapid, Moly- - Inventory
kote G-n)
48/60B

6704 200.04-03 EN 1 (17)

200.04 MAN Diesel & Turbo

Corresponding work cards

Fuel injection pump

Work card Work card Work card

000.30 000.32 055.05
200.03

Work sequence 1 - Dismantling the fuel injection pump

Starting position Fuel injection pump has been removed, clamped into the turning device and
cleaned externally.

Possibility of turning the fuel injection pump

When the locking lever is moved upwards, the fuel injection pump can
be brought into any desired position by turning the handwheel. It is
possible to fix the fuel injection pump at all 45° intervals by inserting the
locking lever into the groove of the ratchet disc (see Work Card 055.05).

Work on clamped fuel injection pump

When working on the clamped fuel injection pump, always insert the
locking lever into a groove in the ratchet disc!

Work steps 1. Remove securing wire (30) for throttle screws (28 and 31).

2. Unscrew throttle screws (28 and 31) for fuel supply and return flow.
3. Insert threaded spindle (200.104-1) into bore on housing (7) and fasten
with hexagon nut (54). See Fig. 5/I.
4. Place lug (200.104-2) over threaded spindle and rest on spring plate (19).
5. Fit conical socket (200.104-5) and spherical washer (200.104-4) through
threaded rod and on lug.

Ensure correct assembly of conical socket and spherical disc!

Work Cards, classified into sub-assemblies

6. Screw the hexagon nut (53) onto the threaded spindle.

7. Screw eye bolt (001.404) into supporting disc (18).
8. Tighten the hexagon nut (53) to compress the pressure spring (20) until
the supporting disc (18) is relieved. See Fig. 5/II.
9. Remove supporting disc (18) laterally. See Fig. 5/III.
10. Turn back hexagon nut (53) thus relieving compression spring (20). See
Fig. 5/IV.
11. Detach disassembly and assembly fixture (200.104).
2009-09-14

12. Remove spring plate (19) and compression spring (20).

13. Remove circlip (22), pull out spring plate (21).
48/60B

14. Pull out control sleeve (16).

15. Pull out pump piston (17) and place it on a clean surface.

2 (17) 6704 200.04-03 EN

 MAN Diesel & Turbo 200.04

Do not touch pump plunger with bare hands! Protect control edges on

Fuel injection pump

pump plunger from damage!

16. Remove securing wire (33) for baffle screws (34).

17. Unscrew both baffle screws (34).
18. Unscrew threaded pin (25) half way, release hexagon socket bolt (26)
and pull out clamping ring (27) from rack (24).
19. Mark relation of the flange (15) to housing (7).
20. Unscrew hexagon head bolts (14) and remove flange (15).
21. Remove rack (24).
22. Remove O-ring (37).
23. Unscrew countersunk screw (50) and detach pointer (51), including shim
rings (52).
24. Disassemble shaft seal (23).
25. Unscrew hexagon head bolts (2), remove valve carrier (1) and place on
a clean surface.
26. Unscrew hexagon head bolts (3) and remove thrust collar (4).
27. Disassemble monoblock cylinder (9).
28. Remove the sealing ring (6).
29. Remove O-rings (12 and 13) and sealing rings (10 and 11).
30. Check valve (40 to 44) in the monoblock cylinder (9) and valve (45 to 48)
in the valve support (1) for seal and mobility; dismantle valves if neces-
sary. See Fig. 2.
31. Clean all individual parts with clean diesel oil and check for wear and
damage.

Work Cards, classified into sub-assemblies

Monoblock cylinder and pump piston
A pump element (8) consists of the monoblock cylinder (9) and the pump
piston (17)! Monoblock cylinder and pump piston can only be changed
together because both parts are adapted to each other.

32. Blow all holes out with compressed air.

Work sequence 2 - Assembly of the fuel injection pump

Starting position All individual components are cleaned and checked for damage, replaced
if necessary. Valve in monoblock cylinder and in valve carrier are assembled.
See Fig. 2.
2009-09-14

Assembly of fuel injection pumps

The assembly of fuel injection pumps is to be executed with great care,
as smooth working and a good seal is possible only with undamaged and
48/60B

clean components. This applies especially to the monoblock cylinder

and the pump piston!

6704 200.04-03 EN 3 (17)

200.04 MAN Diesel & Turbo

Lightly oil all individual parts with thin lubricating oil before assembly.
Fuel injection pump

Exception:
Metallic sealing and contact faces must be absolutely dry at the time of
assembly.
Unless another lubricant is described in the work steps.

Housing is clamped into the turnover stand.

Possibility of turning the fuel injection pump

When the locking lever is moved upwards, the fuel injection pump can
be brought into any desired position by turning the handwheel. It is
possible to fix the fuel injection pump at all 45° intervals by inserting the
locking lever into the groove of the ratchet disc (see Work Card 055.05).

Work on clamped fuel injection pump

When working on the clamped fuel injection pump, always insert the
locking lever into a groove in the ratchet disc!

Work steps 1. Install new sealing ring (10) with assembly fixture (200.118) in ring
groove. See work sequence 3.

Ensure correct installation position when installing the sealing rings! See
Figs. 2 and 6.

2. Push new sealing ring (11) onto monoblock cylinder (9).

3. Insert new O-rings (12 and 13) into the ring groove,ensuring that they
are tensioned equally on the entire periphery and are not twisted.
4. Place new sealing ring (6) in housing (7).
5. Install monoblock cylinder (9) in housing (7), ensuring that cylinder pin
Work Cards, classified into sub-assemblies

(5) is installed between two cylinder pins (36) on the housing and that
the position of the monoblock cylinder is thus fixed. See Fig. 1.

Installing the monoblock cylinder

When installing the monoblock cylinder in the housing, ensure that it
does not tilt!

6. Apply MoS2 lubricant to threads and contact face of hexagon head bolts
(3).
7. Place thrust ring (4) on monoblock cylinder (9), insert hexagon head
bolts (3) and screw into monoblock cylinder.
2009-09-14

8. Position valve carrier (1) on monoblock cylinder (9), ensuring centring of

spring pin (32)/ bore in the monoblock cylinder. See Figs. 1 and 2.
9. Apply MoS2 lubricant to thread and contact face of the hexagon head
48/60B

bolts (2), screw them in and tighten them diagonally in three stages with
specified torque (see Work Card 000.30).

4 (17) 6704 200.04-03 EN

 MAN Diesel & Turbo 200.04

10. Tighten hexagon head bolts (3) diagonally with specified torque (see

Fuel injection pump

Work Card 000.30).
11. Insert a new O-ring (37) in the ring groove; in doing so, make sure that
it is evenly tensioned all around the circumference and that it is not
twisted.
12. Treat rack (24) with special lubricant.
13. Install rack (24) in the housing (7).
14. Insert flange (15) into bore, paying attention to the marking made on
flange and housing (7). See work sequence 1 / point 19.
15. Fit shaft seal (23) on rack (24) and push into the bore.
16. Fasten pointer (51) and shim rings (52) with countersunk bolt (50) onto
housing (7).
17. Fit clamping ring (27) on rack (24), screw in threaded pin (25) and lock
with prick punch.

Tip of the threaded pin

Ensure that the tip of the threaded pin engages when lowered onto the
rack! See Fig. 2.

18. Tighten cylinder screw (26), thus fastening clamping ring (27) on rack
(24).
19. Carefully push pump piston (17) into the monoblock cylinder (9).

Pump piston
Do not touch pump piston with bare hands! Protect control edges on
pump piston from damage!

20. Install control sleeve (16) such that markings (M) on rack (24) and control
sleeve match. See Fig. 2.

Work Cards, classified into sub-assemblies

21. Install spring plate (21) through control sleeve (16) in housing (7).

Marking on the control sleeve and rack

Before fitting the spring plate, check once again that the marks on the
control sleeve and rack line up.

22. Lightly grease circlip (22) and install it.

23. Insert threaded spindle (200.104-1) into bore on housing (7) and fasten
with hexagon nut (54). See Fig. 5.
24. Install compression spring (20) in spring plate (21).
25. Place spring plate (19) on compression spring (20).
2009-09-14

26. Place lug (200.104-2) over threaded spindle and rest on spring plate (19).
See Fig. 5/IV.
27. Fit ball cup (200.104-5) and spherical washer (200.104-4) through threa-
48/60B

ded rod and onto lug.

6704 200.04-03 EN 5 (17)

200.04 MAN Diesel & Turbo

Ball cup and spherical washer

Fuel injection pump

Ensure correct assembly of ball cup and spherical washer!

28. Screw the hexagon nut (53) onto the threaded spindle.
29. Compress/ press down compression spring / spring plate (20/19) by
tightening the hexagon nut (53) until supporting disc (18) can be instal-
led. See Fig. 5/III.
30. Thread eye bolt (001.404) into supporting disc (18).
31. Fit supporting disc (18) laterally onto pump piston base. See Fig. 5/II.
32. Turn back hexagon nut (53).

Supporting disc/Spring plate

While turning back the hexagon nut, check that supporting disc is
centred by spring plate and lies correctly! See Fig. 5/I.

33. Detach disassembly and assembly fixture (200.104), unscrew eye bolt.
34. Screw new baffle screws (34) including sealing rings (35) into housing
(7) and tighten.
35. Secure baffle screws (37) by means of securing wire (33). See Figs. 1
and 3.
36. Screw in throttle screws (28 and 31) including new sealing rings (29) in
housing (7). See Figs. 1 and 4.

Throttle screws
Ensure correct installation of the individual throttle screws! Markings on
throttle screw and the housing must match! Throttle screws and housing
are marked as follows:
Fuel return flow R
Work Cards, classified into sub-assemblies

Fuel supply Z
The fuel return flow is above, the fuel supply is below! See Figs. 1 and 4.

37. Secure throttle screws (28 and 31) by means of securing wire (30). See
Figs. 1 and 4.

Work sequence 3 - Assembly of the sealing ring (10)

Starting position Old sealing ring (10) is removed. Ring groove is cleaned and checked for
damage.

Ensure cleanliness of the mounting device (200.118) and the work place!
2009-09-14

The installation of the sealing ring in the ring groove (point 3 to 6) should
48/60B

be executed as quickly as possible in order to take the best possible

advantage of the elasticity of the sealing ring due to the heat!

6 (17) 6704 200.04-03 EN

 MAN Diesel & Turbo 200.04

Work steps 1. Fit assembly cone (200.118-1) on monobloc cylinder (9). See Fig. 6/I.

Fuel injection pump

2. Heat sealing ring (10) in oil bath to about 80 to 100°C.

Do not insert sealing ring in oil bath or take out from it with bare hands!
Danger of scalding!

The heating of the sealing rings should be done directly at work place,
as the sealing rings cool very quickly in air and lose their elasticity.

3. Take sealing ring (10) out from oil bath, dry it well and place on the
assembly cone.
4. Slide the sealing ring (10) consistently in the ring groove over the assem-
bly cone by means of the expanding sleeve (200.118-2). See Figs. 6/I
and 6/II.

Ensure correct installation position when installing the sealing rings! See
Figs. 2 and 6.

5. Remove expanding sleeve and assembly cone.

6. Fit sizing sleeve (200.118-5) on monobloc cylinder (9) and press the
sealing ring (10) in ring groove. See Fig. 6/IV. Pull out sizing sleeve after
about 2 minutes.

Work Cards, classified into sub-assemblies

2009-09-14

48/60B

6704 200.04-03 EN 7 (17)

 Work Cards, classified into sub-assemblies Fuel injection pump

8 (17)
48/60B
200.04

6704 200.04-03 EN
MAN Diesel & Turbo

2009-09-14
 MAN Diesel & Turbo 200.04

1 Valve support 21 Spring plate

Fuel injection pump

2 Hexagon bolt 22 Snap ring
3 Hexagon bolt 23 Shaft seal
4 Thrust ring 24 Rack
5 Parallel pin 25 Set screw
6 Sealing ring 26 Hexagon socket bolt
7 Casing 27 Locking ring
8 Pump element 28 Throttle screw (fuel inflow)
*9 Monobloc cylinder 29 Sealing ring
10 Sealing ring 30 Locking wire
11 Sealing ring 31 Throttle screw (fuel return flow)
12 O-ring seal 32 Dowel pin
13 O-ring seal 33 Locking wire
14 Hexagon bolt *34 Baffle screw
15 Flange 35 Sealing ring
16 Regulating sleeve 36 Parallel pin
17 Pump plunger 37 O-ring seal
18 Supporting disc R Fuel return
19 Spring plate Z Fuel supply
20 Compression spring
Figure 1: Fuel injection pump

Work Cards, classified into sub-assemblies

2009-09-14

48/60B

6704 200.04-03 EN 9 (17)

 Work Cards, classified into sub-assemblies Fuel injection pump

10 (17)
48/60B
200.04

6704 200.04-03 EN
MAN Diesel & Turbo

2009-09-14
 MAN Diesel & Turbo 200.04

1 Valve support 42 Compression spring

Fuel injection pump

7 Casing 43 Spacer sleeve
*9 Monobloc cylinder 44 Snap ring
10 Sealing ring 45 Snap ring
16 Regulating sleeve 46 Compression spring
24 Rack 47 Valve cone
25 Set screw 48 Spacer sleeve
26 Hexagon socket bolt 49 Hexagon socket bolt
27 Locking ring 50 Countersunk bolt
32 Dowel pin 51 Pointer
40 Ball 52 Shim ring
41 Spring plate M Mark
Figure 2: Fuel injection pump - Details of to figure 1

Work Cards, classified into sub-assemblies

2009-09-14

48/60B

6704 200.04-03 EN 11 (17)

200.04 MAN Diesel & Turbo
Fuel injection pump

1 Valve support 17 Pump plunger

2 Hexagon bolt 18 Supporting disc
Work Cards, classified into sub-assemblies

3 Hexagon bolt 19 Spring plate

4 Thrust ring 20 Compression spring
6 Sealing ring 21 Spring plate
7 Casing 22 Snap ring
8 Pump element 24 Rack
*9 Monobloc cylinder 33 Locking wire
10 Sealing ring *34 Baffle screw
11 Sealing ring 35 Sealing ring
12 O-ring seal 38 sealing screw on distribution block
13 O-ring seal 39 Sealing ring
16 Regulating sleeve
Figure 3: Fuel injection pump
2009-09-14
48/60B

12 (17) 6704 200.04-03 EN

 MAN Diesel & Turbo 200.04

Fuel injection pump

7 Casing 31 Throttle screw (fuel return flow)
28 Throttle screw (fuel inflow) R Fuel return
30 Locking wire Z Fuel supply
Figure 4: Fuel injection pump - Position of the throttle screws for fuel return flow
and inflow / Identification for fuel return flow and inflow on the casing and on
the throttle screws

Work Cards, classified into sub-assemblies

2009-09-14

48/60B

6704 200.04-03 EN 13 (17)

 Work Cards, classified into sub-assemblies Fuel injection pump

14 (17)
48/60B
200.04

6704 200.04-03 EN
MAN Diesel & Turbo

2009-09-14
 MAN Diesel & Turbo 200.04

17 Pump plunger 53 Hexagon nut M24

Fuel injection pump

18 Supporting disc 54 Hexagon nut M30
19 Spring plate
20 Compression spring I-IV Work steps
Figure 5: Fuel injection pump - Release/clamp the compression spring (removal/installation of the supporting
disc)

Work Cards, classified into sub-assemblies

2009-09-14

48/60B

6704 200.04-03 EN 15 (17)

200.04 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

2009-09-14

*9 Monobloc cylinder I-IV Work steps

10 Sealing ring
48/60B

Figure 6: Fuel injection pump - Assembly of the sealing ring (10)

16 (17) 6704 200.04-03 EN

 MAN Diesel & Turbo 200.04

* Shape of the baffle screws and the inlet ports in the monobloc cylinder can differ from the representation
in the figures.

Fuel injection pump

Work Cards, classified into sub-assemblies
2009-09-14

48/60B

6704 200.04-03 EN 17 (17)

 MAN Diesel & Turbo 200.05

Fuel injection pump

Fuel injection pump

Check and change baffle screws

Summary
Execute work on time according to the maintenance schedule, check com-
ponents for quality/wear condition, prevent operating problems/damages.
The baffle screws must be checked and/or changed at the times mentioned
in the service schedule at the latest.
The work / work steps include:
Removing components,
Checking parts/ components,
Installing components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Pliers for locking wire - Inventory

Preliminary remark
Baffle screws are subjected to high stresses caused by the pressure
changes in the flowing fuel. They should be regarded as wear parts, which
helps avoid problems on high value parts. Smaller wear particles are
removed by the fuel flow. Larger particles can cause damage to pump ele-
ment or on the seat of the injection valve.

Work sequence 1 - Disassemble baffle screws

Work steps 1. Block fuel inflow and return pipes (if possible).

Work Cards, classified into sub-assemblies

2. Remove wire locks (3) on the baffle screws (see figure 4).
3. Unscrew baffle screw (2) and collect the escaping fuel in a suitable tank.
4. Unscrew rear baffle screw (2).

Work sequence 2 - Check baffle screws for wear

Work steps 1. Baffle screws must be replaced if they are damaged on the outer cone
edge (see figure 1).
48/60;L40/54;L58/64
2007-11-07

6619 200.05-01 EN 1 (4)

200.05 MAN Diesel & Turbo
Fuel injection pump

Figure 1: Damaged nose-type baffle screws

1. Replace baffle screws if the inner cone contour has been affected to the
extent that the damage reached the edge of the cone (see Figure 2).
Work Cards, classified into sub-assemblies

Figure 2: Damaged nose-type baffle screws

1. Baffle screws showing only a light material removal can continue to be
used. They must however be replaced after 500 operating hours at the
48/60;L40/54;L58/64

latest or checked again after changing performance data or changed

(see figure 3).
2. Check baffle screws with friction welded MV6 nose design for cracks
2007-11-07

on the friction welded point and replace if necessary.

2 (4) 6619 200.05-01 EN

 MAN Diesel & Turbo 200.05

Fuel injection pump

Figure 3: Damaged nose-type baffle screws

In case of engines of the type L 58/64 the check should be carried out
after 1,500 operating hours, but latest after 2,000 operating hours.

Work Cards, classified into sub-assemblies

48/60;L40/54;L58/64
2007-11-07

1 Fuel injection pump 3 Wire lock 4 Wear area

2 Baffle screw (with external or internal hexagon socket)
Figure 4: Details of the injection pump of the engine type L 58/64 with nose-type baffle screws

6619 200.05-01 EN 3 (4)

200.05 MAN Diesel & Turbo
Fuel injection pump

Work sequence 3 - Installing baffle screws

Work steps 1. Clean sealing faces on the injection pump (1).

2. Thread in baffle screws with new copper seals.

When assembling the nose-type baffle screws, ensure that they are not
subjected to any impact or lateral pressure (e.g. due to harsh handling
and putting down).

3. Place new wire lock.

4. Open fuel inflow and return pipes.
Work Cards, classified into sub-assemblies
48/60;L40/54;L58/64

2007-11-07

4 (4) 6619 200.05-01 EN

 MAN Diesel & Turbo 200.06

Fuel injection pump

Fuel injection pump

Measure plunger lift

Summary
Enable/support economical operation.
Check injection timing.
The work extends to:
Determining plunger lift.
Safety requirements
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Measuring device 200.108 Standard
1 Bracket 200.108-1 Standard
1 Clamping piece 200.108-2 Standard
1 Clamping piece 200.108-3 Standard
1 Measuring gauge 200.108-4 Standard
1 Combination spanner (set) - Inventory
1 Pad - Inventory

Work sequence 1 - Measuring plunger lift

Starting position Cover of the camshaft casing is detached.

Work steps 1. Check whether position of the eccentric shaft matches the value in the
acceptance test record, set the eccentric shaft to the corresponding

Work Cards, classified into sub-assemblies

value if necessary (needed only for engine with fuel injection timer).
2. Turn back hexagon bolts (9), so that clamping piece (200.108-3) can
move freely.
3. Fit clamping piece (200.108-2) on cam follower of the fuel injection
pump (5) of a cylinder and clamp firmly on cam follower of the fuel injec-
tion pump by tightening the hexagon bolts (9). See Fig. 2.

Ensure that the clamping piece rests on and is in contact with cam
follower of the fuel injection pump!
48/60B;51/60DF

4. Fasten holder (200.108-1) on camshaft casing (4). See Fig. 2.

2007-05-07

5. Insert measuring gauge (200.108-4) in holder and fasten with knurled

screw (8).
6. Turn running gear in direction of engine rotation, until it reaches cam
base circle. Reset measuring gauge to "zero". See Fig. 2.

6704 200.06-01 EN 1 (5)

200.06 MAN Diesel & Turbo

Turn only in the direction of engine rotation, to equalise the existing

Fuel injection pump

clearance in the camshaft drive!

7. Turn running gear with turning device (electric motor), until piston is just
before ignition TDC.
8. Operate the turning gear by hand crank, until piston is in ignition TDC
(marking on flywheel).

If the ignition TDC is passed, repeat the turning operation! Turn only in
the direction of engine rotation!

9. Read off measuring gauge and note the value.

10. Detach the complete measuring tool (200.108).
11. Determine and note the value for the remaining cylinders in the same
manner.
12. Determine the mean value and compare with the mean value of Parent-
Engines in the Technical File, section 3 of the IMO Certification.
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2007-05-07

2 (5) 6704 200.06-01 EN

 MAN Diesel & Turbo 200.06

Fuel injection pump

Work Cards, classified into sub-assemblies
1 Fuel injection pump 4 Camshaft casing
2 Fuel injection pump drive 5 Cam follower of the fuel injection pump
3 Stud 6 Injection cam
Figure 1: Fuel injection pump drive and cam follower of the fuel injection pump
48/60B;51/60DF
2007-05-07

6704 200.06-01 EN 3 (5)

200.06 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

3 Stud 8 Knurled screw M5x18

4 Camshaft casing 9 Hexagon bolt M10x70
5 Cam follower of the fuel injection pump 10 Washer
7 Hexagon nut M12
Figure 2: Cam follower of the fuel injection pump with attached measuring device
48/60B;51/60DF

2007-05-07

4 (5) 6704 200.06-01 EN

 MAN Diesel & Turbo 200.06

Fuel injection pump

Figure 3: Cam follower of the fuel injection pump with attached measuring
device - Illustration shows measuring device with the highest cam rise

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2007-05-07

6704 200.06-01 EN 5 (5)

 MAN Diesel & Turbo 201.01

Cam follower

Fuel injection pump

removing and installing/checking

Summary
Carry out work on time according to the maintenance schedule, ensure
correct execution of work, check components for quality/wear status.
Clearance and components of cam followers are to be checked at regular
intervals.
The work / work steps include:
Removing components,
Checking parts/ components,
Installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Pin 201.018 Standard
1 Pilot rod 112.015 Standard
1 Holder 112.014 Standard
1 Removal and fitting fixture 112.013 Standard
1 Gripper 112.013-1 Standard
1 Guide tube 112.013-2 Standard
1 Mounting pin 112.012 Standard

Work Cards, classified into sub-assemblies

1 Screwdriver insert 009.167 Standard
1 Extension piece 12.5 x 575 009.166 Standard
1 Torque wrench 008.017 Standard
1 Torque wrench 008.016 Standard
2 Shackle A1.0 002.453 Standard
1 Adapter 12.5x20 001.927 Option
1 Extension piece 12.5x250 001.912 Option
1 Cross handle 001.891 Option
1 Socket spanner insert 30x12.5 001.759 Option
1 Ratchet 001.590 Standard
48/60B;51/60DF
2008-10-22

1 Combination spanner (set) - Inventory

1 Hexagon screwdriver (set) - Inventory
1 Lifting tackle with rope - Inventory
1 Oil stone - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory

6704 201.01-01 EN 1 (16)

201.01 MAN Diesel & Turbo

Quantity Designation Number Status

Fuel injection pump

1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30 112.01

Technical data
Designation Information
Cam follower with bearing blocks and shaft section 185 kg

Work sequence 1 - Inspection

Starting position Covers of the camshaft casing are detached.

Work steps 1. Check that hexagon bolts (1, 5 and 6) are tightened firmly with specified
torque (see Work Card 000.30).
2. Check that hexagon socket bolts (10) are tightened firmly with specified
torque (see Work Card 000.30).
3. Check running surface of all cam follower rollers for damage.
4. Check radial and axial clearance of the cam followers (3, 12 and 13) and
their rollers (see Volume 010.005 Engine - Operating Instructions).
5. Check that all lubricating points are supplied with adequate lubricating
oil.

Work sequence 2 - Disassembly of the cam follower

Starting position Covers of the camshaft casing are detached. Push rods are removed.

Work steps 1. Remove all obstructing piping.

2. Remove lube oil supply pipes (29) to the bearing blocks (4 and 9).
Work Cards, classified into sub-assemblies

3. Turn engine, until cam follower of the fuel injection pump (13) of the
concerned cylinder is at the highest cam rise. See Fig. 2.
4. Remove lock screw (26) including sealing ring (27) and thread in bolts
(201.018). See Fig. 2.

Type and source of danger

Insertion of bolts is allowed only for maintenance work with the engine
at rest (except for turning the engine)! Operating the engine with fuel
injection pumps thus shut off causes damage to the fuel injection pump
drive and is therefore prohibited!
48/60B;51/60DF

5. Turn the engine carefully, until roller (31) is on cam base circle of the
2008-10-22

injection cam (30). See Fig. 3.

6. Release and unscrew hexagon bolts (5 and 6). See Fig. 5.
7. Remove lock screw (7) including sealing ring (8).

2 (16) 6704 201.01-01 EN

 MAN Diesel & Turbo 201.01

8. Insert guide rods (112.015) through bearing blocks (4 and 9) and screw

Fuel injection pump

into camshaft bearing body. See Fig. 6.
9. Connect gripper (112.013-1) to the bearing blocks (4 and 9). See Figs.
7 and 8.
10. Adjust eccentric shaft (11) (see Work Card 202.01), such that hole in the
shaft section (21) and hole in the bearing block (9) match.
11. Release and unscrew nine hexagon socket bolts (10) each to the right
and left of the cam follower bearings. See Fig. 8.

Type and source of danger

Three hexagon socket bolts on each side (in the front area if possible)
remain screwed in.

12. Insert mounting pin (112.012) through hole in the bearing block (9) and
insert in hole on shaft section (21) thus fixing shaft section. See Fig. 6.
13. Thread three hexagon bolts (18 and 19) into gripper, screw them in until
they abut on the cam followers (3, 12 and 13) and thereby fix the cam
follower. See Fig. 8.
14. Release and unscrew remaining hexagon socket bolts (10) to the right
and left of the cam follower bearings.

Type and source of danger

Do not adjust the section pieces of the eccentric shaft remaining in the
engine after the removal of the last hexagon socket bolts!

15. Fix guide tube (112.013-2) to gripper. See Fig. 7.

16. Fasten cable with shackle (002.453) on gripper and suspend from lifting
tackle.
17. Release hexagon bolts (1) and unscrew. See Fig. 9.
18. Carefully remove cam followers (3, 12 and 13), bearing blocks (4 and 9)

Work Cards, classified into sub-assemblies

and shaft section (21) with disassembly and mounting device (112.013)
carefully, thus guiding complete unit with guide tube. See Fig. 10.

Type and source of danger

See that no parts are damaged during dismantling!

19. Fasten holder devices (112.014) to the right and left of shaft section (21).
See Fig. 10.

Holder devices are used for securing the butting disc during transport.
48/60B;51/60DF
2008-10-22

20. Place complete unit on clean workbench.

21. Detach the tool.

6704 201.01-01 EN 3 (16)

201.01 MAN Diesel & Turbo

Type and source of danger

Fuel injection pump

Hexagon bolts (18 and 19) remain in screwed-in position in the gripper.

22. Dismantle complete unit. See Fig. 11.

23. Clean all individual parts.
24. Clean oil bores using compressed air.
25. Check the running surface of the rollers for damage and smoothen with
oil stone if necessary.
26. Check radial and axial clearance of the rollers (see volume 010.005
Engine - Operating Instructions).
27. Measure hole of the bearing bushes in the cam followers (3, 12 and 13)
and shaft section (21) and calculate the clearance.

Type and source of danger

If the clearance has exceeded the permissible value, replace the bearing
bush.

Type and source of danger

It is advisable to have the installation executed at a MAN Service Support
point or by MAN Personnel.

Work sequence 3 - Installing the cam follower

Starting position Fuel injection pump drive is locked in TDC with bolts (201.018). Pilot rods
(112.015) are screwed in camshaft bearing bodies. Shaft section, running
surface and contact faces of all individual parts are completely clean. Oil
bores are free of dirt.
Work steps 1. Insert new O-ring seals (23) which have been oiled with clean lubricating
Work Cards, classified into sub-assemblies

oil in the ring grooves; in doing so, make sure that they are evenly ten-
sioned all around the circumference and that they are not twisted.
2. Lightly oil running surfaces and contact faces of all individual parts with
clean lubricating oil.
3. Fit all individual parts on shaft section (21). See Fig. 11.
4. Fasten holder devices (112.014) to the right and left of shaft section (21).
See Fig. 10.

Holder devices are used for securing the butting disc during transport.
48/60B;51/60DF

2008-10-22

5. Insert mounting pin (112.012) through hole in the bearing block (9) and
insert in hole on shaft section (21) thus fixing shaft section. See Fig. 6.
6. Connect gripper (112.013-1) to the bearing blocks (4 and 9). See Figs.
7 and 8.

4 (16) 6704 201.01-01 EN

 MAN Diesel & Turbo 201.01

7. Fix guide tube (112.013-2) to gripper. See Fig. 7.

Fuel injection pump

8. Fasten cable with shackle (002.453) on gripper and suspend from lifting
tackle.
9. Lift complete unit.
10. Clean contact faces on the part pieces of the eccentric shaft (11).
11. Detach holders (112.014).
12. Guide complete unit carefully into the engine, guiding with guide tube.
See Figs. 9 and 10.

See that no parts are damaged during installation! Pay attention to the
fixing of the bearing blocks by means of parallel pins (24) in the bearing
blocks and bores in the cylinder crankcase!

13. Apply MoS2- lubricant to threads and resting faces of the hexagon bolts
(1), insert through bearing blocks including washer (2) and screw in by
hand into cylinder crankcase. See Fig. 9.
14. Remove cable from gripper and detach guide tube.
15. Unscrew hexagon bolts (18 and 19). See Fig. 8.
16. Apply MoS2lubricant to threads and resting surfaces of the hexagon
socket bolts (10) -, insert through eccentric shaft (11) and screw into
shaft section (21). See Fig. 8.

You can use mounting pin (112.012) to move the shaft section a little for
better screw mounting.

17. Tighten hexagon socket bolts with specified torque (see Work Card
000.30).
18. Unscrew pilot rods (112.015). See Fig. 6.

Work Cards, classified into sub-assemblies

19. Apply MoS2- lubricant to threads and resting faces of the hexagon bolts
(6), insert through bearing blocks including washer (2) and screw in by
hand into cylinder crankcase. See Fig. 5.
20. Detach mounting pin and gripper.
21. Apply MoS2- lubricant to threads and resting faces of the hexagon bolts
(5), insert through bearing blocks including washer (2) and screw in by
hand into cylinder crankcase. See Fig. 5.
22. Tighten all hexagon bolts (1, 5 and 6) with specified torque (see Work
Card 000.30).
23. Check easy movement of all cam followers (3, 12 and 13).
48/60B;51/60DF

24. Turn engine, until cam follower of the fuel injection pump (13) rests on
2008-10-22

fuel injection pump drive (32) and lifts it (highest cam rise).
25. Remove bolt (201.018).
26. Screw locking bolt (26) including sealing ring (27) in.
27. Connect lube oil supply pipes (29) to the bearing blocks (4 and 9).

6704 201.01-01 EN 5 (16)

201.01 MAN Diesel & Turbo

28. Attach all detached pipelines again (see Work sequence 2/ point 1).
Fuel injection pump

29. Check that all lubricating points are supplied with adequate lubricating
oil.
30. With the engine running, compare exhaust temperature of the con-
cerned cylinder with the exhaust temperatures of the adjacent cylinder.
Work Cards, classified into sub-assemblies

1 Hexagon bolt 27 Sealing ring

2 Washer 28 Camshaft casing
48/60B;51/60DF

5 Hexagon bolt 29 Lube oil supply pipe

2008-10-22

6 Hexagon bolt 30 Injection cam

9 Bearing block 31 Roller
13 Cam follower of the fuel injection pump 32 Fuel injection pump drive
21 Shaft section 33 Cylinder crankcase
26 sealing screw on distribution block 34 Fuel injection pump
Figure 1: Fuel injection pump drive and injection cam with cam follower bearing

6 (16) 6704 201.01-01 EN

 MAN Diesel & Turbo 201.01

Fuel injection pump

Work Cards, classified into sub-assemblies
13 Cam follower of the fuel injection pump 32 Fuel injection pump drive
30 Injection cam 33 Cylinder crankcase
Figure 2: Fuel injection pump drive and injection cam with cam follower bearing
- Shutting off the fuel injection pump and the fuel injection pump drive
48/60B;51/60DF
2008-10-22

6704 201.01-01 EN 7 (16)

201.01 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

13 Cam follower of the fuel injection pump 32 Fuel injection pump drive
30 Injection cam
Figure 3: Fuel injection pump drive and injection cam with cam follower bearing
- Shutting off the fuel injection pump and the fuel injection pump drive
48/60B;51/60DF

2008-10-22

8 (16) 6704 201.01-01 EN

 MAN Diesel & Turbo 201.01

Fuel injection pump

1 Hexagon bolt 8 Sealing ring
2 Washer 9 Bearing block
3 Inlet cam follower 10 Hexagon socket bolt
4 Bearing block 11 Eccentric shaft

Work Cards, classified into sub-assemblies

5 Hexagon bolt 12 Exhaust cam follower
6 Hexagon bolt 13 Cam follower of the fuel injection pump
7 sealing screw on distribution block
Figure 4: Cam follower bearing
48/60B;51/60DF
2008-10-22

6704 201.01-01 EN 9 (16)

201.01 MAN Diesel & Turbo
Fuel injection pump

2 Washer 7 sealing screw on distribution block

4 Bearing block 8 Sealing ring
5 Hexagon bolt 9 Bearing block
6 Hexagon bolt
Work Cards, classified into sub-assemblies

Figure 5: Cam follower bearing - Removal/ installation of a complete unit, consisting of cam followers, bearing
blocks and shaft section
48/60B;51/60DF

2008-10-22

10 (16) 6704 201.01-01 EN

 MAN Diesel & Turbo 201.01

Fuel injection pump

4 Bearing block 9 Bearing block
Figure 6: Cam follower bearing - Removal/ installation of a complete unit, consisting of cam followers, bearing
blocks and shaft section

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2008-10-22

6704 201.01-01 EN 11 (16)

201.01 MAN Diesel & Turbo
Fuel injection pump

9 Bearing block 16 Hexagon bolt M12

14 Hexagon bolt M12x75 17 Rope
15 Hexagon bolt M12x45
Figure 7: Cam follower bearing - Removal/ installation of a complete unit, consisting of cam followers, bearing
Work Cards, classified into sub-assemblies

blocks and shaft section

48/60B;51/60DF

2008-10-22

12 (16) 6704 201.01-01 EN

 MAN Diesel & Turbo 201.01

Fuel injection pump

10 Hexagon socket bolt 19 Hexagon bolt M20x160
18 Hexagon bolt M20x90
Figure 8: Cam follower bearing - Removal/ installation of a complete unit, consisting of cam followers, bearing
blocks and shaft section

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2008-10-22

6704 201.01-01 EN 13 (16)

201.01 MAN Diesel & Turbo
Fuel injection pump

1 Hexagon bolt 2 Washer

Figure 9: Cam follower bearing - Removal/ installation of a complete unit, consisting of cam followers, bearing
blocks and shaft section
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2008-10-22

14 (16) 6704 201.01-01 EN

 MAN Diesel & Turbo 201.01

Fuel injection pump

20 Hexagon bolt M12x65
Figure 10: Cam follower bearing - Removal/ installation of a complete unit, consisting of cam followers, bearing
blocks and shaft section

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2008-10-22

6704 201.01-01 EN 15 (16)

201.01 MAN Diesel & Turbo
Fuel injection pump

3 Inlet cam follower 21 Shaft section

4 Bearing block 22 Butting disc
9 Bearing block 23 O-ring seal
12 Exhaust cam follower 24 Parallel pin
13 Cam follower of the fuel injection pump 25 Butting disc
Figure 11: Dismantle/ assemble a complete unit, consisting of cam followers,
bearing blocks and shaft section
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2008-10-22

16 (16) 6704 201.01-01 EN

 MAN Diesel & Turbo 201.02

Fuel injection pump drive

Fuel injection pump

removing and installing or disassembling and assembling

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for quality/wear condition.
The drive of the fuel injection pump is to be dismounted in the course of the
service and maintenance work.
The work / work steps include:
Disassembling components,
Separating parts/ components,
Installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 201.016 Standard
1 Thrust piece 201.016-1 Standard
1 Spindle 201.016-2 Standard
1 Thrust plate 201.016-3 Standard
1 Thrust plate 201.016-4 Standard
1 Combination spanner (set) 009.231 Option
2 Shackle A0.6 002.452 Standard

Work Cards, classified into sub-assemblies

1 Thickness gauges 0.05-1 000.451 Option
2 Lifting eye bolt M12 000.142 Standard
1 Lifting tackle - Inventory
1 Oil stone - Inventory
1 Hexagon screwdriver (set) - Inventory
2 Rope - Inventory
1 Depth gauge - Inventory
1 Locking ring pliers C125 - Inventory
1 Lubricating oil, clean - Inventory
48/60B;51/60DF

Corresponding Work Cards

2009-03-10

Work card Work card Work card

200.03

6704 201.02-03 EN 1 (13)

201.02 MAN Diesel & Turbo

Technical data
Fuel injection pump

Designation Information
Reference dimension (A) 207,8 mm
Fuel injection pump drive 84,5 kg
Flange 46,5 kg
Tappet 27 kg

Work sequence 1 - Removing and disassembling the fuel injection pump drive
Starting position Cover of camshaft casing and fuel injection pump are detached.

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work steps 1. Turn the engine so the roller of the cam follower of the fuel injection
pump (2) is on the cam base circle. See Fig. 1.
2. Detach the lubricating oil supply line (18), unscrew and remove the hex-
agon bolts and remove the threaded piece (17).
3. Place the thrust piece (201.016-1) on the tappet (5). See Fig. 2.
4. Insert both spindles (201.016-2) into the bores in the thrust piece and
screw into the tappet (5) until they make contact with the thrust piece.
Make sure both spindles are tightened evenly.
5. Insert the thrust plate (201.016-4) over the thrust piece and fit on the
flange (11). See Fig. 2.
6. Screw the hexagon nut (20) onto the thrust piece until it makes contact
with the thrust plate.
7. Fasten the rope (19) with the shackle (002.452) to the thrust piece and
Work Cards, classified into sub-assemblies

attach to lifting tackle.

8. Carefully unscrew and remove three hexagon socket bolts (10) crosswise
in several steps. See Fig. 2.

Fuel injection pump drive is under spring tension!

9. Carefully remove the fuel injection pump drive, taking care to avoid
damaging the stud bolts (14). Set the fuel injection pump drive down on
the support. See Fig. 3.
48/60B;51/60DF

10. Cover the opening in the cylinder crankcase (16).

2009-03-10

11. Remove shackle.

12. Unscrew the hexagon nut (20) carefully, until compression spring (9) is
completely released.
13. Detach disassembly and mounting device (201.016).

2 (13) 6704 201.02-03 EN

 MAN Diesel & Turbo 201.02

14. Dismantle fuel injection pump drive.

Fuel injection pump

15. Clean all individual components and check for damage.
16. Blow out oil bores with compressed air.
17. Check running surfaces of rollers (3) for damage, smooth with oil stone
if required.
18. Measure and make a note of the axial and radial clearance of the rollers
(3) and compare with the permissible values (see Volume 010.005
Engine - Operating Instructions).

If one of the measured clearances is greater than the allowable value,

install a new tappet.

It is advisable to change the rollers and roller pin at a MAN service

support location or have it done by MAN personnel.

Work sequence 2 - removing and disassembling the fuel injection pump drive
(disassembling at the engine)
Starting position Cover of camshaft casing and fuel injection pump are detached.

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work steps 1. Turn the engine so the roller of the cam follower of the fuel injection
pump (2) is on the cam base circle. See Fig. 1.

Work Cards, classified into sub-assemblies

2. Detach the lubricating oil supply line (18), unscrew and remove the hex-
agon bolts and remove the threaded piece (17).
3. Place the thrust piece (201.016-1) on the tappet (5). See Fig. 4.
4. Insert both spindles (201.016-2) into the bores in the thrust piece and
screw into the tappet (5) until they make contact with the thrust piece.
Make sure both spindles are tightened evenly.
5. Push the thrust plate (201.016-3) over the thrust piece and spindles and
fit on the spring plate (12). See Fig. 4.
6. Screw the hexagon nut (20) onto the thrust piece until it makes contact
with the thrust plate.
48/60B;51/60DF

7. Tighten the hexagon nut (20) and push the compression spring (9) down.
2009-03-10

See Fig. 5.
8. Remove locking ring (13).
9. Turn back the hexagon nut (20) and release the compression spring (9).
See Fig. 6.
10. Unscrew and remove the hexagon nut (20) and remove the thrust plate.

6704 201.02-03 EN 3 (13)

201.02 MAN Diesel & Turbo

11. Remove the spring plate (12) and compression spring (9).
Fuel injection pump

12. Unscrew and remove three hexagon socket bolts (10).

13. Screw the lifting eye bolts (000.142) into the flange (11).
14. Attach the ropes (19) with the shackle (002.452) to the lifting eye bolts
and suspend from the lifting tackle.
15. Remove the flange (11), taking care not to damage the studs (14). Set
the flange down on the support.
16. Detach the tool.
17. Fasten the rope (19) with the shackle (002.452) to the thrust piece and
attach to lifting tackle. See Fig. 7.
18. Remove the tappet (5) and set it down on the support. See Fig. 8.
19. Cover the opening in the cylinder crankcase (16).
20. Detach the tool.
21. Remove spring plate (6).
22. Remove the O-ring seal (8) from the flange (11).
23. Clean all individual components and check for damage.
24. Blow out oil bores with compressed air.
25. Check running surfaces of rollers (3) for damage, smooth with oil stone
if required.
26. Measure and make a note of the axial and radial clearance of the rollers
(3) and compare with the permissible values (see Volume 010.005
Engine - Operating Instructions).

If one of the measured clearances is greater than the allowable value,

install a new tappet.
Work Cards, classified into sub-assemblies

It is advisable to change the rollers and roller pin at a MAN service

support location or have it done by MAN personnel.

Work sequence 3 - Assembly and installation of fuel injection pump drive

Starting position Turn the engine so the roller of the cam follower of the fuel injection pump
is on the cam base circle. All individual parts have been cleaned, oil bores
are free of contamination.
48/60B;51/60DF

Danger of death when lifting and moving loads!

2009-03-10

Unless absolutely necessary, do not enter or remain in the area below

suspended loads!

Work steps 1. Clean contact face and bore in cylinder crankcase (16).

2. Lightly oil all individual parts with clean lubricating oil.

4 (13) 6704 201.02-03 EN

 MAN Diesel & Turbo 201.02

3. Insert the spring plate (6) into the tappet (5).

Fuel injection pump

4. Place the thrust piece (201.016-1) on the tappet (5).
5. Insert both spindles (201.016-2) into the bores in the thrust piece and
screw into the tappet (5) until they make contact with the thrust piece.
Make sure both spindles are tightened evenly.
6. Fasten the rope (19) with the shackle (002.452) to the thrust piece and
attach to lifting tackle.
7. Lift tappet (5) and move over bore in cylinder crankcase (16). See Fig.
8.
8. Lower tappet (5) carefully into the bore; in doing so, note the position of
the groove for the threaded piece (17) which must be pointing towards
the control side (ST). See Fig. 7.
9. Lower the tappet (5) until the rollers (3) are resting on the cam follower
of the fuel injection pump (2).
10. Detach the lifting tackle, remove rope (19) and shackle.
11. Screw the lifting eye bolts (000.142) into the flange (11).
12. Attach the ropes (19) with the shackle (002.452) to the lifting eye bolts
and suspend from the lifting tackle.
13. Lift the flange (11).
14. Insert a new O-ring seal (8) in the ring groove; in doing so, make sure
that it is evenly tensioned all around the circumference and that it is not
twisted.
15. Move flange (11) over bore in cylinder crankcase (16).
16. Lower flange (11) carefully into the bore, paying attention to the fixing
of the parallel pin (15, in flange) and bore (in the cylinder crankcase). Do
not damage the studs (14) when installing the flange. See Fig. 1.
17. Screw in and tighten three hexagon socket bolts (10).
18. Detach the lifting tackle, remove rope (19), shackle and lifting eye bolts.

Work Cards, classified into sub-assemblies

19. Install the compression spring (9) in the tappet (5) and fit spring plate
(12) on compression spring.
20. Push the thrust plate (201.016-3) over the thrust piece and spindles and
fit on the spring plate (12). See Fig. 6.
21. Screw the hexagon nut (20) onto the thrust piece until it makes contact
with the thrust plate.
22. Tighten the hexagon nut (20) and push the compression spring (9) down.
23. Install the locking ring (13) in the ring groove. See Fig. 5.
24. Turn back hexagon nut (20).
48/60B;51/60DF

25. Detach disassembly and mounting device (201.016).

2009-03-10

26. Check the control dimension (A) when installing new parts. See Fig. 1.
27. Install threaded piece (17) in cylinder crankcase (16).
28. Attach lube oil supply pipe (18).

6704 201.02-03 EN 5 (13)

201.02 MAN Diesel & Turbo
Fuel injection pump

1 Camshaft 11 Flange
2 Cam follower of the fuel injection pump 12 Spring plate
3 Roller 13 Locking ring
4 Roller pin 14 Stud
Work Cards, classified into sub-assemblies

5 Tappet 15 Parallel pin

6 Spring plate 16 Cylinder crankcase
7 Thrust piece 17 Threaded piece
8 O-ring seal 18 Lube oil supply pipe
9 Compression spring
10 Hexagon socket bolt A Control dimension
Figure 1: Fuel injection pump drive (picture shows in-line engine)
48/60B;51/60DF

2009-03-10

6 (13) 6704 201.02-03 EN

 MAN Diesel & Turbo 201.02

Fuel injection pump

Work Cards, classified into sub-assemblies
48/60B;51/60DF

5 Tappet 14 Stud
2009-03-10

7 Thrust piece 16 Cylinder crankcase

10 Hexagon socket bolt 19 Rope
11 Flange 20 Hexagon nut M20x2
Figure 2: Removing the fuel injection pump drive

6704 201.02-03 EN 7 (13)

201.02 MAN Diesel & Turbo
Fuel injection pump
Work Cards, classified into sub-assemblies

Figure 3: Removing the fuel injection pump drive

48/60B;51/60DF

2009-03-10

8 (13) 6704 201.02-03 EN

 MAN Diesel & Turbo 201.02

Fuel injection pump

Work Cards, classified into sub-assemblies

5 Tappet 12 Spring plate

7 Thrust piece 13 Locking ring
11 Flange 20 Hexagon nut M20x2
Figure 4: Removing/fitting the fuel injection pump drive - releasing/tensioning
the compression spring
48/60B;51/60DF
2009-03-10

6704 201.02-03 EN 9 (13)

201.02 MAN Diesel & Turbo
Fuel injection pump

9 Compression spring 13 Locking ring

11 Flange 20 Hexagon nut M20x2
12 Spring plate
Figure 5: Removing/fitting the fuel injection pump drive - releasing/tensioning
the compression spring
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2009-03-10

10 (13) 6704 201.02-03 EN

 MAN Diesel & Turbo 201.02

Fuel injection pump

9 Compression spring 14 Stud
11 Flange 20 Hexagon nut M20x2
12 Spring plate
Figure 6: Removing/fitting the fuel injection pump drive - releasing/tensioning
the compression spring

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2009-03-10

6704 201.02-03 EN 11 (13)

201.02 MAN Diesel & Turbo
Fuel injection pump

5 Tappet 16 Cylinder crankcase

14 Stud 19 Rope
Figure 7: Removing/fitting the fuel injection pump drive - removing/fitting the
tappet
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2009-03-10

12 (13) 6704 201.02-03 EN

 MAN Diesel & Turbo 201.02

Fuel injection pump

Work Cards, classified into sub-assemblies
Figure 8: Removing/fitting the fuel injection pump drive - removing/fitting the
tappet
48/60B;51/60DF
2009-03-10

6704 201.02-03 EN 13 (13)

MAN Diesel & Turbo 202

Fuel injection timer

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.21-1 EN 1 (2)

 MAN Diesel & Turbo
Fuel injection timer

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.21-1 EN

 MAN Diesel & Turbo 202.01

Fuel injection timer

Fuel injection timer

adjusting

Summary
Ensure correct execution of work.
It may be necessary to displace the eccentric shaft for maintenance work
on cam follower of the fuel injection pump.
The work/work steps include:
Release hydraulic brake(s),
Stagger fuel injection timer by hand,
Activate hydraulic brake(s).
Work sequence - Adjusting the fuel injection timer
Work steps 1. Switch off engine circuit breaker of the fuel injection timer.

2. Adjust manual actuation (2) on brake valve (1) up to contact, hydraulic

brake (11 or 13) will release. See figure 1/right.

The engine has one hydraulic brake each including brake valve on the
fuel injection timer and possibly one at the end of the eccentric shaft
(depending on the number of cylinders).

It should be ensured that both are released in case of an engine with two
hydraulic brakes!

3. Release spring brakes by operating the lever (5) on the electrical adjust-
ment motor (6). See Fig. 2.

Work Cards, classified into sub-assemblies

Keep the lever pulled during the adjustment procedure (lever is spring-
loaded)!

4. Adjust eccentric shaft (3) by rotating the manual setting wheel (7) on the
electrical setting motor.
5. Release lever, spring brake is activated.
6. Turn back manual actuation on the brake valve up to contact, hydraulic
brake is activated. See figure 1/left.
48/60;L40/54;51/60DF

The engine has one hydraulic brake each including brake valve on the
fuel injection timer and possibly one at the end of the eccentric shaft
2007-11-09

(depending on the number of cylinders).

The fuel injection timer returns automatically to its initial position on engine start!

6644 202.01-02 EN 1 (3)

202.01 MAN Diesel & Turbo
Fuel injection timer

1 Brake valve
2 Manual actuation A Adjustment travel activated/released
Figure 1: Position of the manual actuation on brake valve for: Hydraulic brake
activated (left) / hydraulic brake released (right)
Work Cards, classified into sub-assemblies
48/60;L40/54;51/60DF

2007-11-09

2 (3) 6644 202.01-02 EN

 MAN Diesel & Turbo 202.01

Fuel injection timer

Work Cards, classified into sub-assemblies
48/60;L40/54;51/60DF

1 Brake valve 7 Manual setting wheel 12 Pointer on adjustment motor

3 Eccentric shaft 8 Scale ring 13 Fuel injection timer with inte-
grated hydraulic brake
2007-11-09

4 Fuel - cam follower 9 Fuel cam B Spring brake activated

5 Lever (spring loaded) 10 Camshaft C Spring brake released
6 electrical adjustment motor 11 Hydraulic brake (dependent on
number of cylinders)
Figure 2: Fuel injection timer with hydraulic brakes

6644 202.01-02 EN 3 (3)

MAN Diesel & Turbo 203

Governor control linkage

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.22-1 EN 1 (2)

 MAN Diesel & Turbo
Governor control linkage

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.22-1 EN

 MAN Diesel & Turbo 203.01

Governor control linkage

Governor control linkage

servicing and checking

Summary
Execute the work in time according to the maintenance schedule, ensure
the correct execution of work, ensure / restore operational safety.
Check the governor control linkages at regular intervals and lubricate.
The work includes:
Checking parts/components.
Safety requirements
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Grease gun 003.005 Standard
1 Combination spanner (set) - Inventory
1 Lubricating grease, acid-free - Inventory

Preliminary remark
The control rod was set precisely at the time of commissioning of the engine and
needs only changing individual parts and possibly correction on attachment of a new
fuel injection pump!
At the ZERO position of the control rod, the control rod of all fuel injection pumps
must be on the ZERO position, otherwise it may not be possible to shut off the engine
because individual fuel injection pumps are still pumping!
Work sequence - Servicing and inspection

Work Cards, classified into sub-assemblies

Work steps 1. Check the entire governor control linkage for attrition.

2. Check governor control linkage for correct setting.

3. Check joints of the governor control linkage for easy movement.
4. Check hexagon bolts and nuts for firm fit.
5. Check buckling lever (4) for free mobility.
6. Lubricate all jointed heads on control rods and connecting rods with
lubricating grease.
2007-06-15

L48/60

6644 203.01-02 EN 1 (2)

203.01 MAN Diesel & Turbo
Governor control linkage

1 Fuel injection pump

2 Rack
3 Connecting rod
4 Buckling lever
5 Control shaft
6 Bearing block

Figure 1: Governor control linkage

Work Cards, classified into sub-assemblies

2007-06-15
L48/60

2 (2) 6644 203.01-02 EN

MAN Diesel & Turbo 209

Camshaft
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.23-1 EN 1 (2)

 MAN Diesel & Turbo
Camshaft

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.23-1 EN

 MAN Diesel & Turbo 209.01

Camshaft

Camshaft
inspecting

Summary
Carry out the work in good time in accordance with the maintenance sched-
ule; check the components’ quality/wear condition. The running surfaces of
the cams and bearing points must be checked at regular intervals.
The work includes: Checking parts /components.
Safety requirements
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Oil stone - Inventory

Corresponding Work Cards

Work card Work card Work card
102.01

Preliminary remark

Setting of the inlet and exhaust cams

The setting of the inlet and exhaust cams was executed at MAN Diesel
& Turbo SE and must not be changed (distance between intake/exhaust
valves and piston)! The setting of the injection cams was also defined at
MAN Diesel & Turbo SE. Any change in the injection cam setting may be

Work Cards, classified into sub-assemblies

executed only in exceptional cases, by trained personnel!

Change of cams or camshaft

The change of cams or of camshaft should be carried out at a customer
service support location with the special tools available there.

Work sequence - Inspection

48/60;48/60B;51/60DF

Work steps 1. Remove cover from camshaft casing.

2. Inspect running surface of the exhaust cam (1), injection cam (3) and
intake cam (4) for damage.
2008-10-08

Checking the cams

Turn the running gear over using the turning gear and check the
individual cams over the entire circumference. Smooth over small rough
points with an oilstone.

6644 209.01-01 EN 1 (2)

209.01 MAN Diesel & Turbo

3. Inspect camshafts bearing bolts (2) and hexagon bolts (5) for correct
Camshaft

tightening or firm fit (see Work Card 102.01).

4. Check whether all bearing positions are supplied with adequate oil.
5. Attach cover of the camshaft casing.
6. Check the remaining cams in the same manner (see point 1 to 5).
Work Cards, classified into sub-assemblies

1 Exhaust cam 4 Inlet cam

2 Camshaft bearing bolt 5 Hexagon bolt
3 Injection cam
Figure 1: Camshaft with cams (illustration shows in-line engine 48/60)
48/60;48/60B;51/60DF

2008-10-08

2 (2) 6644 209.01-01 EN

MAN Diesel & Turbo 221

Fuel injection valve

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.24-1 EN 1 (2)

 MAN Diesel & Turbo
Fuel injection valve

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.24-1 EN

 MAN Diesel & Turbo 221.01

Fuel injection valve

Fuel injection valve

removal and installation

Summary
Execute work on time according to the maintenance schedule, enable/ sup-
port economic operation, prevent operational problems/damage.
Fuel injection valves affect the loading of the injection system and the engine
operating data. They are to be checked if there are deviations in the oper-
ating data, overhauled if necessary or replaced.
The work/work steps include:
Removing components,
installing components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Support fixture 434.047 Standard
1 Pin spanner 434.029 Standard
1 Support plate 221.192 Standard
1 Suspension device 221.189 Standard
1 Threaded pipe 221.189-1 Standard
1 Pilot rod 221.189-2 Standard

Work Cards, classified into sub-assemblies

1 Setting device 221.180 Standard
1 Removal and fitting fixture 221.179 Standard
1 Extractor sleeve 221.179-1 Standard
1 Threaded spindle 221.179-2 Standard
1 Deep groove thrust ball bearing 221.179-5 Standard
1 Cap 221.179-6 Standard
1 Extractor 221.128 Standard
1 Cleaning tool 055.133 Standard
1 Combination spanner (set) 009.231 Option
1 Torque wrench 008.017 Standard
1 Shackle A1.6 002.454 Standard
2009-02-25

1 Adapter 20x12.5 001.923 Option

2 Extension piece 20x400 001.914 Standard
48/60B

1 Extension piece 20x200 001.913 Standard

1 Cross handle 001.891 Option

6707 221.01-04 EN 1 (18)

221.01 MAN Diesel & Turbo

Quantity Designation Number Status

Fuel injection valve

1 Universal joint 20 001.877 Standard

1 Socket spanner insert 36x20 001.771 Standard
1 Wire brush - Inventory
1 Lifting tackle - Inventory
1 Rope - Inventory
1 Wooden spatula - Inventory
1 Depth gauge - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricant "Optimoly White-T" - Inventory
1 Lubricating oil, clean - Inventory
1 Securing compound, Loctite 638 - Inventory

Corresponding Work Cards

Work card Work card Work card
000.19 000.30 055.03
221.02 221.03 221.05
434.01

Technical data
Designation Information
Fuel injection valve 16,5 kg
Thrust flange 7 kg
Bolt projection (A) 188 mm

Work sequence 1 - Removing the fuel injection valve

Work Cards, classified into sub-assemblies

If the engine normally operates with heavy fuel, it must be operated

briefly with diesel oil before the fuel injection valves are removed.

Starting position Cooling water for fuel injection valve cooling system is drained completely.
Shut-off valves on fuel pipes are closed. Cylinder head cover and indicator
valve are open.

Remove fuel injection valve only when engine is absolutely at standstill and
indicator valve is open! The combustion chamber can be under high
pressure when the indicator valve is closed!
2009-02-25

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
48/60B

suspended loads!

2 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.01

Work steps 1. Unscrew pipe line for cooling water supply from cylinder head (6), drain

Fuel injection valve

cooling channels of the fuel injection valve (9) by blowing with com-
pressed air. Screw the pipe line on again.
2. Push the support plate (221.192) over the hexagon socket bolt (14) and
fasten to rocker arm bracket (16) with hexagon bolt (15). See Fig. 2.
3. Unscrew and remove the hexagon nut on the exhaust side (1). See Fig.
2.
4. Detach the tool.
5. Unscrew and remove the hexagon nut on the control side (1). See Fig.
3.
6. Remove the fuel injection pipe (see Work Card 434.01).
7. Fasten suspension device (434.047) with hexagon bolt (18) to rocker arm
casing (17). See Fig. 4.
8. Undo the threaded piece (7), screw it right out and remove it from the
cylinder head (6). See Fig. 4.
9. Screw the extractor (221.128) into the thrust flange (3). See Fig. 5/I.
10. Remove the thrust flange (3) and place it to one side. See Fig. 5/II.

Sufficient free access when removing the thrust flange

When removing the last third of the thrust flange, turn it slightly and hold
it at an angle to allow sufficient access to the rocker arm (13).
When removing the thrust flange, avoid damaging the studs (2).

11. Screw on the threaded spindle (221.179-2) until it makes contact with
the fuel injection valve (9). See Fig. 6/I.
12. Place the extractor sleeve (221.179-1) on the sleeve (5).

Locating the extractor sleeve

Fit the extractor sleeve in such a way that it is fixed by a stud (2) on the
control side. See Fig. 6/I.

Work Cards, classified into sub-assemblies

13. Push the deep groove thrust ball bearing (221.179-5) over the threaded
spindle and insert it in the extractor sleeve.

Make sure the deep groove thrust ball bearing is correctly

installed
Make sure the deep groove thrust ball bearing is correctly installed. See
Fig. 6.

14. Place the cap (221.179-6) on the extractor sleeve.

15. Screw the hexagon nut (19) onto the threaded spindle.
16. Detach the fuel injection valve (9) by turning the hexagon nut (19). See
2009-02-25

Fig. 6/II.

Detaching the fuel injection valve

48/60B

Only detach the fuel injection valve using the removal and fitting fixture
(221.179).

6707 221.01-04 EN 3 (18)

221.01 MAN Diesel & Turbo

17. Detach disassembly and mounting device (221.179).

Fuel injection valve

18. Screw on the threaded pipe (221.189-1) until it makes contact with the
fuel injection valve (9). See Fig. 7/I.
19. Fasten the rope (20) with the shackle (002.454) to the lifting eye bolt (22)
and attach it to lifting tackle.
20. Screw the pilot rod (221.189-2) into the threaded pipe.
21. Remove the fuel injection valve (9) carefully from the cylinder head (6)
and place to one side on the workbench. See Fig. 7/II.

In order to ensure sufficient access to rocker arm (13) when removing

the fuel injection valve, rotate fuel injection valve slightly in the last one
third of removal and hold it at an angle.
When removing, see that sealing ring (8) is also removed and the studs
(2) are not damaged.

22. Clean the locating hole with the cleaning tool (055.133). See Fig. 8.

During cleaning, make sure that no foreign bodies are allowed to drop
into the combustion chamber!

23. Check the valve seating surface (B) and grind in if required (see Work
Card 055.03). See Fig. 1.
24. Cover the opening in the cylinder head (6).
25. Remove suspension fixture (221.189).
26. Remove the sealing ring (8) and O-ring seals (4, 11 and 21).
27. Clean the fuel injection valve (9) from the outside, dismantle it if neces-
sary (see Work Card 221.03).

Clean the fuel injection valve away from the workbench.

Work Cards, classified into sub-assemblies

Remove carbon residue with a wire brush. Proceed with particular care
when cleaning the cylindrical shoulder of the nozzle body.

Scrape fuel injection nozzle only with a wooden spatula, so as not to

damage nozzle apertures!

28. Clean the threaded piece (7).

29. Check the sealing face at the threaded piece (7) for damage, rework
sealing face if required (see Work Card 221.05).

Work sequence 2 - Installing the fuel injection valve

2009-02-25

Starting position The fuel injection valve, in particular the cylindrical shoulder of the nozzle
body, has been carefully cleaned. The opening pressure, tightness and
48/60B

nozzle bores have been checked (see Work Card 221.02).

4 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.01

Fuel injection valve from reserve stock or spare parts supply

Fuel injection valve

Fuel injection valve from reserve stock or spares supply cleaned and
checked externally.

The locating hole in the cylinder head and valve seating surface in the insert
have been cleaned. The supporting device (434.047) has been attached to
the rocker arm casing.

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work steps 1. Mount new sealing ring (8) on the fuel injection valve (9).

Make sure that sealing ring fits tightly on nozzle body.

2. Insert new O-ring seals (11, green colour), lubricated with clean lubricating
oil, in the ring grooves (I to IV) , ensuring that they are tensioned equally
on the entire periphery and are not twisted. See Fig. 9.
3. Insert new O-ring seal (21, black in colour), lubricated with clean lubricating
oil, in the ring groove (V) , ensuring that it is tensioned equally on the entire
periphery and is not twisted. See Fig. 9.

Installing O-ring seals

You must ensure that the O-ring seals are installed in the correct ring
grooves!
Ring groove I –IV Sealing ring item 11 / Colour green
Ring groove V sealing ring item 21 / black in colour.

Work Cards, classified into sub-assemblies

4. Screw on the threaded pipe (221.189-1) until it makes contact with the
fuel injection valve (9). See Fig. 10/I.
5. Fasten the rope (20) with the shackle (002.454) to the threaded pipe and
attach it to lifting tackle.
6. Lift up the fuel injection valve (9).
7. Screw the pilot rod (221.189-2) into the threaded pipe.
8. With the fuel injection valve (9) suspended vertically, fill interior (spring
chamber) with clean fuel through the bore for the threaded piece (7).

Damping of the compression spring

This is important for the damping of the compression spring during
2009-02-25

commissioning.
48/60B

9. Remove cover from locating hole in the cylinder head (6).

6707 221.01-04 EN 5 (18)

221.01 MAN Diesel & Turbo

10. Drive fuel injection valve (9) over cylinder head (6) and install carefully in
Fuel injection valve

locating hole, guiding fuel injection valve using the pilot rod. See Fig. 10/
II.
11. Push the fuel injection valve (9) into place.
12. Detach the tool.
13. Apply the lubricant "Optimoly White-T" to the threads of the threaded
piece (7).
14. Fit setting device (221.180) on fuel injection valve (9), paying attention
to fixing hole in setting device /dowel pin (12) on fuel injection valve. See
Fig. 11.
15. Align fuel injection valve (9) by rotating on setting device, simultaneously
inserting threaded piece (7) in cylinder head (6) and screwing into fuel
injection valve. See Fig. 11.
16. Tighten threaded piece (7) with specified torque (see Work Card 000.30).
See Fig. 4.
17. Remove the setting device (221.180) and detach support fixture
(434.047).
18. Attach the fuel injection pipe (see Work Card 434.01).
19. Insert a new O-ring seal (4) oiled with clean lubricating oil in the ring
groove, making sure that it is evenly tensioned all around the circum-
ference and is not twisted.
20. Screw the extractor (221.128) into the thrust flange (3). See Fig. 5/II.
21. Install thrust flange (3). See Fig. 5/I.

Fitting the flange bearing

In order to ensure sufficient access to rocker arm (13) when installing the
thrust flange, rotate thrust flange in the initial one third of installation and
hold it at an angle.
When installing, see that studs (2) are not damaged.
Work Cards, classified into sub-assemblies

22. Detach the tool.

23. Coat thread and contact face of hexagon nuts (1) with MoS2 lubricant
and screw hand-tight onto studs (2).

Installation of the fuel injection valve in a cylinder head at

operating temperature
If the fuel injection valve is installed in a cylinder head at operating
temperature, tighten the hexagon nut initially just by hand (point 23) and
with the specified torque only after temperature equalisation (point 24 to
26)!

24. Tighten hexagon nut on control side (1) to the prescribed torque (see
2009-02-25

Work Card 000.30). See Fig. 3.

25. Push the support plate (221.192) over the hexagon socket bolt (14) and
fasten to rocker arm bracket (16) with hexagon bolt (15). See Fig. 2.
48/60B

26. Tighten hexagon nut on exhaust side (1) to the prescribed torque (see
Work Card 000.30). See Fig. 2.

6 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.01

27. Detach the tool.

Fuel injection valve

28. Close the indicator valve.
29. Fill cooling water into fuel injection valve cooling system.
30. Open the shut-off valves on the fuel pipes.
31. Close the cylinder head cover.

Work sequence 3 - Installing the studs (2)

Starting position Fuel injection valve has been removed and cleaned; studs have been
removed and threaded holes cleaned.
Work steps 1. Install the fuel injection valve (9). See work sequence 2, points 1 to 17.

2. Attach the fuel injection pipe (see Work Card 434.01).

3. Prepare thrust flange (3) for installation. See work sequence 2, points
19 and 20.
4. Coat the screw-in thread of the stud bolts (2) with Loctite 638 securing
compound and screw them in until the specified bolt protrusion (A) is
reached. See Fig. 1.
5. Install thrust flange (3). See work sequence 2, points 21 and 22.
6. Coat thread and contact face of hexagon nuts (1) with MoS2 lubricant,
screw hand-tight onto studs (2) and tighten to prescribed torque. See
work sequence 2, points 23 to 27.

Rapid installation
Steps 5 and 6 need to be performed quickly! Hexagon nuts (1) should be
tightened with the specified torque before the securing compound
Loctite 638 on the screwed-in stud (2) has hardened (about 10 min.)!

Work Cards, classified into sub-assemblies

2009-02-25

48/60B

6707 221.01-04 EN 7 (18)

221.01 MAN Diesel & Turbo
Fuel injection valve
Work Cards, classified into sub-assemblies

1 Hexagon nut 6 Cylinder head 11 O-ring seal

2 Stud 7 Threaded piece 12 Dowel pin
3 Thrust flange 8 Sealing ring 21 O-ring seal
4 O-ring seal 9 Fuel injection valve A Bolt projection
5 Sleeve 10 Insert B Valve seating surface
Figure 1: Fuel injection valve and threaded piece
2009-02-25
48/60B

8 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.01

Fuel injection valve

Work Cards, classified into sub-assemblies
2009-02-25

1 Hexagon nut 13 Rocker arm 16 Rocker arm bracket

2 Stud 14 Hexagon socket bolt
48/60B

3 Thrust flange 15 Hexagon bolt M16x30

Figure 2: Releasing/tightening the hexagon nut on the exhaust side - illustration shows hexagon nut being
tightened

6707 221.01-04 EN 9 (18)

221.01 MAN Diesel & Turbo
Fuel injection valve

1 Hexagon nut 3 Thrust flange 13 Rocker arm

2 Stud
Figure 3: Releasing/tightening the hexagon nut on the control side - illustration shows hexagon nut being
tightened
Work Cards, classified into sub-assemblies

2009-02-25
48/60B

10 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.01

Fuel injection valve

Work Cards, classified into sub-assemblies
6 Cylinder head 9 Fuel injection valve 18 Hexagon bolt M10x20
7 Threaded piece 17 Rocker arm casing
Figure 4: Releasing/tightening of threaded piece - illustration shows threaded piece being tightened
2009-02-25

48/60B

6707 221.01-04 EN 11 (18)

221.01 MAN Diesel & Turbo
Fuel injection valve
Work Cards, classified into sub-assemblies

2 Stud 9 Fuel injection valve

3 Thrust flange 12 Dowel pin
4 O-ring seal I - II Work steps
2009-02-25

6 Cylinder head
Figure 5: Removal/installation of the thrust flange
48/60B

12 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.01

Fuel injection valve

Work Cards, classified into sub-assemblies
2009-02-25

2 Stud 11 O-ring seal ST Control side

8 Sealing ring 19 Hexagon nut M24 I - II Work steps
48/60B

9 Fuel injection valve 21 O-ring seal

Figure 6: Detaching the fuel injection valve

6707 221.01-04 EN 13 (18)

221.01 MAN Diesel & Turbo
Fuel injection valve
Work Cards, classified into sub-assemblies

2009-02-25

5 Sleeve 9 Fuel injection valve 22 Lifting eye bolt

6 Cylinder head 10 Insert I - II Work steps
48/60B

8 Sealing ring 20 Rope

Figure 7: Removing the fuel injection valve

14 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.01

Fuel injection valve

5 Sleeve
6 Cylinder head
10 Insert

Figure 8: Cleaning the locating hole in the cylinder head

Work Cards, classified into sub-assemblies

2009-02-25

48/60B

6707 221.01-04 EN 15 (18)

221.01 MAN Diesel & Turbo
Fuel injection valve

9 Fuel injection valve

11 O-ring seal
21 O-ring seal
I-V Ring groove

Figure 9: O-ring seal/ring groove

Work Cards, classified into sub-assemblies

2009-02-25
48/60B

16 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.01

Fuel injection valve

Work Cards, classified into sub-assemblies
2009-02-25

6 Cylinder head 11 O-ring seal 22 Lifting eye bolt

8 Sealing ring 20 Rope I - II Work steps
48/60B

9 Fuel injection valve 21 O-ring seal

Figure 10: Installation of fuel injection valve

6707 221.01-04 EN 17 (18)

221.01 MAN Diesel & Turbo
Fuel injection valve
Work Cards, classified into sub-assemblies

2009-02-25

6 Cylinder head 9 Fuel injection valve 12 Dowel pin

7 Threaded piece
48/60B

Figure 11: Aligning the fuel injection valve/installing the threaded piece

18 (18) 6707 221.01-04 EN

 MAN Diesel & Turbo 221.02

Fuel injection valve

Fuel injection valve

inspecting

Summary
Check components for state/wear condition, ensure/ restore operational
safety. Fuel injection valves affect the loading of the injection system and
the engine operating data. They are to be checked if there are deviations in
the operating data, overhauled if necessary or replaced.
The work includes: Checking parts /components.
Personnel and time required
Number Qualification Duration in h
1 Technician 2

Tools/aids required
Quantity Designation Number Status
1 Nozzle tester L58/64 221.202 Standard
1 Connecting piece 221.202-22 Standard
1 Nozzle tester L,V48/60 + B + CR 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201-18 Standard
1 Connecting piece 221.201-23 Standard
1 Nozzle tester 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 tester L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197-21 Standard

Work Cards, classified into sub-assemblies

1 Connecting piece 221.197-26 Standard
1 Nozzle tester 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 tester L,V32/40 CR 221.195 Standard
32/40;48/60B;48/60CR;51/60DF

1 Reducing jaw for injection valve (set) 221.195-21 Standard

1 Connecting piece 221.195-26 Standard
1 Receptacle for slushing oil - Inventory
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Compressed air, max. 15 bar - Inventory
2007-11-05

1 Slushing oil - Inventory

6629 221.02-03 EN 1 (7)

221.02 MAN Diesel & Turbo

Corresponding Work Cards

Fuel injection valve

Work card Work card Work card

221.03 221.04

Observation
The tool numbers of the individual parts of the pressure-testing set are
composed of the tool number of the pressure-testing set and the item num-
ber of the individual part. See Figs. 1 and 2.
Example: Tool number of the high-pressure hose for engine type
L 58/64: 221.202-6.
Preliminary remarks
Functional performance and setting of the injection valve affect the com-
bustion process, the operating data and the loading of the injection system.
If there are changes in the operating data (ignition pressure, exhaust gas
temperature) the valves concerned should be checked for opening pressure
and leakages. The pressure-testing set enables pressing off using a hydro-
pneumatic high-pressure pump. The device ensures comfortable working
under reproducible conditions.
Note
In the testing of injection valves of modern 4-stroke engines the atomisation
is no longer a test criterion, because the behaviour of the nozzle in engine
operation cannot be verified by using the pressure-testing set.
An inferior spray pattern does not provide any indication of the functioning
of the nozzle in the engine. It is fully functional if it fulfils the criteria for
opening pressure, tightness and free nozzle apertures.
Construction and schematics of the pressure-testing set
Work Cards, classified into sub-assemblies
32/40;48/60B;48/60CR;51/60DF

2007-11-05

2 (7) 6629 221.02-03 EN

 MAN Diesel & Turbo 221.02

Fuel injection valve

1 Pressure gauge 0-600 bar 6 High-pressure hose 14 Nozzle jet collection receptacle
2 Air tap 10 Hydraulic pump 15 Receptacle cover
3 Filter pressure controller 11 Pressure limiting valve 16 Adapter head
4 Air coupling 12 Oil tank
5 Pressure relief valve 13 Oil collecting pan
Figure 1: Pressure-testing set

Work Cards, classified into sub-assemblies

32/40;48/60B;48/60CR;51/60DF
2007-11-05

6629 221.02-03 EN 3 (7)

221.02 MAN Diesel & Turbo
Fuel injection valve

Key as in figure 1 23 Connecting piece

9 Connecting piece 24 Connecting piece
22 Connecting piece 26 Connecting piece
Figure 2: Schema of the pressure-testing set

Work sequence 1 - Preparation for the inspection

Heavy oil residues in injection valves

Heavy oil residues in injection valves can adversely affect test results
and make cleaning more difficult. It is therefore recommended to run the
engine on diesel fuel for around an hour before removing injection valves.
If this is not possible, and if the engine is shut down in heavy fuel mode,
the injection valve must be dismantled and cleaned before carrying out
the tests described here.
Work Cards, classified into sub-assemblies

Starting position Injection valve is dismantled and cleaned externally.

Inspection of the injection valve

Use slushing oil for checking the injection valves, since this acts as a
32/40;48/60B;48/60CR;51/60DF

preservation treatment at the same time. Only absolutely clean slushing

oil must be used in the pressure-testing set, otherwise problems could
arise in the pump or in the injection valve to be tested. The oil level in the
oil tank (12) must be monitored.

Work steps 1. Depending on the engine type, place the correct reducing jaws in the
adapter head (16) (no reducing jaws are needed for engine type 58/64).
Insert injection valve in the adapter head and tighten uniformly with
2007-11-05

holder.
2. Depending on the engine type, screw in suitable connecting piece (9,
22, 23, 24, 26) on the pressure hose connection of the injection nozzle
and screw on high-pressure hose (6) to connecting piece.

4 (7) 6629 221.02-03 EN

 MAN Diesel & Turbo 221.02

3. Place the nozzle jet receptacle (13-15) under the injection nozzle and

Fuel injection valve

push it up until the required jets impact on the outer walls of the nozzle
jet receptacle.

Fuel injection nozzle

Never allow the injection nozzle to spray into the open air, only into the
receptacle! Do not touch fuel jets, as they penetrate skin tissue and
cause painful inflammation! Do not use open flames at the workplace!
Smoking is strictly prohibited! An oil mist extractor should be used
wherever possible!

The checking and setting of the injection valves includes the following steps:
▪ Check opening pressure,
▪ Check nozzle orifices,
▪ Set target pressure,
▪ Check tightness.

Work sequence 2 - Checking opening pressure

Work steps 1. Rotate knob on filter pressure controller (3) completely to left (minus -)
and set air tap (2) on "On".
2. Close pressure relief valve (5).
3. Run the hydraulic pump (10) by rotating the knob on filter pressure con-
troller (3) to the right (plus +) and raise the pressure slowly until injection
valve opens. Note opening pressure and compare with the reference
value (for reference value see operating instructions sheet 2.5.2). Let the
pressure-testing set run for a minimum of 20 seconds, thereby flushing
the injection valve.

Opening pressure
The hydraulic pressure must be taken slowly past the opening pressure,
since there are otherwise errors when reading the opening pressure. The

Work Cards, classified into sub-assemblies

test pressure must not exceed 400 bar! In case of new nozzle elements,
the nozzle needle may stick during the first spray test and must be
released by intensive flushing. In the case of injection nozzles already
used, collect the slushing oil contaminated with fuel and do not use it in
the pressure-testing set again.
In case of new nozzles, there can be a drop in the opening pressure of
32/40;48/60B;48/60CR;51/60DF

up to 50 to 90 bar after just a few operating hours.

This pressure drop does not imply any functional deficiency and is
characteristic of all fuel injection valves.

Decision Opening pressure drop less /greater than 90 bar?

Opening pressure drop less than 90 bar continue to the next step
Opening pressure drop greater than 90 bar ▪ Dismantle injection valve (in accordance with Work Card 221.03)
2007-11-05

▪ Carry out visual inspection (spring breakage)

▪ if component is in order, continue to the next step

6629 221.02-03 EN 5 (7)

221.02 MAN Diesel & Turbo

Work sequence 3 - Check nozzle openings

Fuel injection valve

Work steps 1. Rotate filter pressure controller completely to the left (minus -), open
pressure relief valve (5) and proceed as follows (for position details see
Work Card 221.03).
2. Release hexagon nut (44) and turn back adjusting screw (45) until com-
pression spring (49) is released.
3. Close pressure relief valve. Run the hydraulic pump by using the knob
on the filter pressure controller and set the opening pressure to 30 bar
by using the adjusting screw (45).
Decision All nozzle orifices open? See Fig. 3.

Yes continue to the next step

No - Dismantle injection valve (in accordance with Work Card 221.03)

Figure 3: Assessment of the nozzle orifices. Left - open, right - partly blocked
Work sequence 4 - Adjust opening pressure to the set value
Work steps 1. Raise hydraulic pressure by using the knob on the filter pressure con-
troller (3), at the same time tension the compression spring (49) a little
by using adjusting screw (45). Repeat the process until the required
value (tolerance ±20 bar) is reached (for required value see Operating
Work Cards, classified into sub-assemblies

Instructions sheet 2.5.2).

Compression spring
Do not set a higher pressure than indicated, otherwise the compression
spring will be deformed. Adjust to the indicated higher spray pressure
32/40;48/60B;48/60CR;51/60DF

value only after assembling a new compression spring to compensate

for the initial setting of the compression springs.

2. If the set value is adjusted as repeatable, lock the adjusting screw (45)
with a hexagon nut (44) and check the opening pressure again.

Work sequence 5 - Checking for leakage

Work steps To check for leakage, set the pressure to 250 bar by using the knob on the
2007-11-05

filter pressure controller (3) and let it stand. The injection nozzle is consid-
ered tight if no drops fall within 5 seconds.
Decision Tightness OK? See Fig. 4.

Yes The injection valve can be made available for use!

6 (7) 6629 221.02-03 EN

 MAN Diesel & Turbo 221.02

No - The injection valve must be sent to MAN Diesel & Turbo SE in Augsburg
for regeneration.

Fuel injection valve

Figure 4: Assessment of the tightness. Left - tight, right - drips

Work Cards, classified into sub-assemblies

32/40;48/60B;48/60CR;51/60DF
2007-11-05

6629 221.02-03 EN 7 (7)

 MAN Diesel & Turbo 221.03

Fuel injection valve

Fuel injection valve

dismantling

Summary
Check components for condition/wear condition, prevent operating prob-
lems/damage.
Fuel injection valves affect the loading of the injection system and the oper-
ating values of the engine. They are to be checked if there are deviations in
the operating data, overhauled if necessary or replaced.
The work/work steps include:
Dismantling of components,
Inspection of parts/ components.
Personnel and time required
Number Qualification Duration in h
1 Technician 1

Tools/aids required
Quantity Designation Number Status
1 Nozzle tester L,V48/60 + B + CR 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201-18 Standard
1 Socket spanner 221.127 Standard
1 Combination spanner (set) 009.231 Option
1 Torque wrench 008.005 Standard
1 Chuck 002.701 Standard
1 Eye bolt 001.412 Standard
1 Tank with fuel - Inventory

Work Cards, classified into sub-assemblies

1 Wire brush - Inventory
1 Wooden spatula - Inventory
1 Paper towels - Inventory
1 Cleaning medium (wool) - Inventory
1 Cleaning wires (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
48/60B;48/60CR;51/60DF

1 Depth gauge - Inventory

Corresponding Work Cards

Work card Work card Work card
2010-03-03

221.02 221.04

6707 221.03-02 EN 1 (6)

221.03 MAN Diesel & Turbo

Preliminary remarks
Fuel injection valve

Dismantling the fuel injection valves

Dismantle fuel injection valves if errors are detected during the tests
specified in Work Card 221.02, or if the fuel injection nozzle has reached
the end of its service life and needs to be replaced.
This is carried out at the nozzle tester.

Work sequence 1 - Dismantling of a fuel injection valve

Work steps 1. Wash fuel injection valve in fuel and remove adhering carbon residue
with a wire brush.
2. Swivel receptacle (13 to 15) to the side and place reducing jaw
(221.201-18) in the adapter head (16) of the clamping device. See Fig.
1.
3. Insert fuel injection valve, with injection nozzle facing down, in the
adapter head (16) and tighten uniformly.
4. Loosen hexagon nut (44) and turn back adjusting screw (45) until com-
pression spring (49) is released. See Fig. 2.
5. Unscrew hexagon bolts (60), rotate adapter head (16) with fuel injection
valve by 180° and screw in the hexagon bolt again.
6. Release nozzle clamping nut (52) carefully.

If there is heavy resistance when releasing the nozzle clamping nut, try
to release the threads by soaking them in fuel and rotating them to and
fro. Do not release nozzle clamping nut with force, as otherwise threads
can seize and parts can become useless.

7. Unscrew nozzle clamping nut (52) and remove nozzle body (42), ensur-
ing that nozzle needle (43) does not fall out.
8. Extract nozzle needle (43) from nozzle body (42) and place it in fuel for
Work Cards, classified into sub-assemblies

cleaning.

Never interchange nozzle needles from one nozzle body to another. They
are manufactured in pairs.

9. Unscrew hexagon bolts (60), rotate back adapter head (16) with fuel
48/60B;48/60CR;51/60DF

injection valve by 180° and screw in the hexagon bolt again.

10. Remove fuel injection valve from adapter head (16) and place on work-
bench.
11. Unscrew adjusting screw (45).
2010-03-03

12. If internal parts are not loose, screw in eye bolt (001.412) in thrust piece
(48) and extract thrust piece. Then remove compression spring (49) and
spring plate (50).
13. Place all parts for cleaning in diesel oil and wash them. Then blow with
compressed air.

2 (6) 6707 221.03-02 EN

 MAN Diesel & Turbo 221.03

Work sequence 2 - Checking components

Fuel injection valve

The inspection of the components includes:
▪ the nozzle bores,
▪ the quality of fitting surfaces,
▪ the mobility of the nozzle needle,
▪ traces of corrosion on the nozzle clamping nut and valve body,
▪ the nozzle specifications,

Pay particular attention to sources of such faults, which have led to

unsatisfactory results in the inspection of the injection valve.

1. Clamp a suitable cleaning wire in chuck (002.701) and push through

nozzle orifices to clean them; subsequently blow out with compressed
air. See Fig. 3.
2. Examine all components, especially sealing faces for damage/traces of
wear.

Seat and fitting surfaces should not be machined manually or

mechanically, as the requisite accuracies cannot be achieved by either
means.

3. Check if nozzle needle (43) can be moved in the valve body (42) easily
and without perceivable resistance. See Fig. 4.
4. Examine valve bodies (42) for traces of corrosion. These can be 2.5 mm
deep at the most. Check nozzle cooling water outlet temperature,
increase temperature up to 90°C at the most if necessary.
5. Read off nozzle specifications on the collar of the valve body (42) and
compare with reference specifications. See Fig. 5.

Work Cards, classified into sub-assemblies

Original specification - see acceptance test record of the engine.
6. Change damaged parts, replacing nozzle needle (43) and valve body
(42) together; if necessary, have both parts reconditioned by MAN Diesel
& Turbo SE, Augsburg or Hamburg. Other workshops are not authorised
to do this!

Rebuilt nozzle elements are identified with RA or RH and the rebuilding

48/60B;48/60CR;51/60DF

date. It is not possible to regenerate several times.

2010-03-03

6707 221.03-02 EN 3 (6)

221.03 MAN Diesel & Turbo
Fuel injection valve

6 High-pressure hose 16 Adapter head

13-15 Receptacle 60 Hexagon bolt
Figure 1: Nozzle tester
Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2010-03-03

4 (6) 6707 221.03-02 EN

 MAN Diesel & Turbo 221.03

Fuel injection valve

42 Valve body
43 Nozzle needle
44 Hexagon nut
45 Adjusting screw
46 Holder
48 Thrust piece
49 Compression spring
50 Spring plate
51 Parallel pin
52 Nozzle clamping nut
55 Dowel pin

Figure 2: Fuel injection valve

Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

41 Cleaning wire
42 Nozzle body
2010-03-03

Figure 3: Cleaning the nozzle orifices

6707 221.03-02 EN 5 (6)

221.03 MAN Diesel & Turbo
Fuel injection valve

42 Nozzle body
43 Nozzle needle

Figure 4: Checking the mobility of the nozzle needle

Figure 5: Nozzle element - figure at left –Nozzle specification / figure at right -

Identification of the regeneration
Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2010-03-03

6 (6) 6707 221.03-02 EN

 MAN Diesel & Turbo 221.04

Fuel injection valve

Fuel injection valve

assembling

Summary
Impart necessary knowledge, ensure correct execution of work.
Fuel injection valves affect the loading of the injection system and the oper-
ating values of the engine. They are to be checked if there are deviations in
the operating data, overhauled if necessary or replaced.
The work includes:
Assembling components.
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Nozzle tester L,V48/60 + B + CR 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201-18 Standard
1 Socket spanner 221.127 Standard
1 Torque wrench 008.005 Standard
1 Eye bolt 001.412 Standard
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Depth gauge - Inventory
1 Paper towels - Inventory
1 Lubricant (Molykote "D") - Inventory

Work Cards, classified into sub-assemblies

1 Lubricant (Optimol "Paste White T") - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30 221.02

Work sequence - Assembling a fuel injection valve

48/60B;48/60CR;51/60DF

Check before the assembly whether specification of the injection nozzle

matches with the required specification! The original specification can
be referred from the acceptance test record (no., number of nozzle
2008-10-22

orifices, orifice diameter, spraying angle)!

Starting position Fuel injection valve is dismantled, all individual parts are cleaned carefully,
damaged parts are replaced.
Work steps 1. Screw eye bolt (001.412) into thrust piece (48), hold holder (46) at an
angle (with sealing face facing up) and guide in thrust piece including

6707 221.04-02 EN 1 (4)

221.04 MAN Diesel & Turbo

compression spring (49) and spring plate (50). Pay attention to the posi-
Fuel injection valve

tion of the opening for threaded piece. See Fig. 1.

After installation, check that spring plate is positioned properly.

2. Unscrew eye bolt.

3. Screw in adjusting screw (45), do not yet tighten compression spring
(49).
4. Place reducing jaw (221.213-18) in adapter head (16) of the clamping
device. See Fig. 2.
5. Insert holder (46) in the adapter head (16) so that the sealing face for
nozzle body (42) faces down. Tighten holder evenly in adapter head.
6. Unscrew hexagon bolts (60), rotate adapter head (16) with holder (46)
by 180° and screw in the hexagon bolt again.
7. Dip nozzle needle (43) in clean fuel and guide into the nozzle body (42).
Check that the movement of the nozzle needle.
8. Check nozzle needle stroke between top edge of nozzle body (42) and
offset on nozzle needle (43). Target value see Volume 010.005 Engine -
Work Instructions.
9. Rub the sealing face on holder (46) and valve body (42) dry using a paper
napkin.
10. Check that sealing face on holder (46) and valve body (42) is perfectly
clean (no lint etc.).
11. Insert nozzle body (42) with nozzle needle (43) on holder (46), paying
attention to the position of the two parallel pins (51).

See that nozzle needle does not slip out from nozzle body!
Work Cards, classified into sub-assemblies

12. Apply lubricant "Optimol Paste White T" on pressure shoulder (G) on
nozzle body (42). See Fig. 1.
13. Apply lubricant "Optimol Paste White T" to screw threads of holder (46)
and nozzle clamping nut (52) as well as pressure shoulder (G) on nozzle
clamping nut. See Fig. 1.
48/60B;48/60CR;51/60DF

14. Screw nozzle clamping nut (42) onto holder (42) and tighten it hand-tight.

If several fuel injection valves have been dismantled, ensure during

assembly that nozzle clamping nut and holders are not swapped over!
Nozzle clamping nut and holders of a fuel injection valve are identified
2008-10-22

together!

15. Tighten nozzle clamping nut (42) with specified torque (see Work Card
000.30).

2 (4) 6707 221.04-02 EN

 MAN Diesel & Turbo 221.04

16. Unscrew hexagon bolts (60), rotate back adapter head (16) with holder

Fuel injection valve

(46) by 180° and screw in the hexagon bolts again.
17. Screw hexagon nut (44) loosely on adjusting screw (45) and tighten only
after adjusting the spray pressure (see Work Card 221.02).

Work Cards, classified into sub-assemblies

48/60B;48/60CR;51/60DF

42 Nozzle body 49 Compression spring

43 Nozzle needle 50 Spring plate
44 Hexagon nut 51 Parallel pin
45 Adjusting screw 52 Nozzle clamping nut
2008-10-22

46 Holder 55 Dowel pin

48 Thrust piece D Pressure shoulder
Figure 1: Fuel injection valve

6707 221.04-02 EN 3 (4)

221.04 MAN Diesel & Turbo
Fuel injection valve

6 High-pressure hose 16 Adapter head

13-15 Receptacle 60 Hexagon bolt
Figure 2: Nozzle tester
Work Cards, classified into sub-assemblies
48/60B;48/60CR;51/60DF

2008-10-22

4 (4) 6707 221.04-02 EN

 MAN Diesel & Turbo 221.05

Fuel injection valve

Fuel injection valve

Grind sealing faces on threaded piece

Summary
Check components for state/wear condition, ensure/ restore operational
safety. The sealing faces on the threaded piece to the fuel injection valve
are to be checked for damage every time it is removed and reworked if
necessary.
The work includes: Creating a correct contact image.
Tools/aids required
Quantity Designation Number Status
1 Pressure pipe grinding device 434.044 Option
1 Adapter plate 434.044-1 Option
1 Threaded ring 434.044-2 Option
1 Bearing ring 434.044-3 Option
1 Bearing flange 434.044-4 Option
1 Spacer ring 434.044-8 Option
1 Stop gauge (threaded piece) 434.044-9 Option
2 Bearing block 434.044-10 Option
1 Swivel arm 434.044-11 Option
1 Bracket 434.044-12 Option
1 Stop 434.044-13 Option
1 Grinding wheel 434.044-16 Option
1 Baseplate 434.044-17 Option
1 Carriage 434.044-18 Option

Work Cards, classified into sub-assemblies

1 Shaft 434.044-19 Option
1 Stop 434.044-20 Option
1 Counter flange (threaded piece) 434.044-21 Option
1 Adapter flange (threaded piece) 434.044-22 Option
2 Ball bearing 434.044-24 Option
2 Ball bearing 434.044-25 Option
1 Hook wrench 434.044-37 Option
1 Face spanner 434.044-38 Option
2 Clamping lever 434.044-41 Option
1 Clamping piece 434.044-42 Option
5 Emery paper 434.044-44 Option
2007-12-10

1 Hexagon screw driver 5 000.294 Option

1 Hexagon screw driver 4 000.293 Option
L48/60B

1 Tommy bar, 8 000.262 Option

1 electric angle grinder - Option

6707 221.05-01 EN 1 (6)

221.05 MAN Diesel & Turbo

Quantity Designation Number Status

Fuel injection valve

1 Safety goggles - Inventory

1 Cleaning medium - Inventory

Corresponding Work Cards

Work card Work card Work card
221.01

Work sequence 1 - Attachment of the threaded piece to the pressure pipe grinding device
Starting position Threaded piece is disassembled and cleaned externally (see Work Card
221.01).

Pressure pipe grinding device and threaded piece

The pressure pipe grinding fixture must be installed and/or operated on
a firm base. Vibration of the fixture affects the surface quality of the
sealing faces to be ground.
The threaded pieces to be ground must be absolutely free from
lubricating oils and greases. Contamination of any kind, especially
lubricants, reduces the service life of the emery paper considerably.

Work steps 1. Release both clamping levers (434.044-41) and swivel out electrical
angle grinder (3) with bracket (434.044-12) up to the stop.
2. Screw on and tighten adapter flange (434.044-22) with hexagon socket
bolts (2) on threaded ring (434.044-2). See Fig. 1.
3. Fasten stop gauge (434.044-9) on adapter flange with two hexagon
socket bolts (6). See Fig. 3.

Fastening the stop gauge

When fixing the stop gauge on adapter flange, support with tommy bar
(000.262) on the threaded ring.
Work Cards, classified into sub-assemblies

4. Screw counter flange (434.044-21) on the threaded piece (1).

Threaded piece
There is a left hand thread on the threaded piece on the injection valve
side!

5. Screw the threaded piece (1) in the adapter flange by using counter
flange, until cone of the threaded piece is in contact with the stop gauge.
6. Screw on counter flange on adapter flange and tighten by using face
spanner (434.044-38) and hook wrench (434.044-37).
7. Place clamping piece (434.044-42) at the end of the threaded piece (1).
2007-12-10

See Fig. 1.
8. Detach stop gauge (434.044-9).
L48/60B

9. Insert tommy bar (000.262) radially in threaded ring (434.044-2) and

screw it in on adapter place (434.044-1) up to the stop.

2 (6) 6707 221.05-01 EN

 MAN Diesel & Turbo 221.05

Threaded ring

Fuel injection valve

It is important that for every new threaded piece to be ground, the
threaded ring be threaded in until it is comes to rest on the adapter plate!

10. Press the yellow arresting head on the electrical angle grinder (3), set up
grinding wheel (434.044-16) with emery paper (434.044-44) on electrical
angle grinder and fasten using fastening nuts.
11. Pull back slide (434.044-18) with support adjusting crank (4).
12. Swing the bracket (434.044-12) up to the stop and fix on the slide with
two clamping levers (434.044-41).

Work sequence 2 - Regrinding the sealing face on threaded piece

Starting position Threaded piece is attached correctly to the pressure pipe grinding device.
Grinding wheel is mounted with new emery paper on electric angle grinder.

Reworking of the sealing face

The reworking of the sealing face is difficult and requires special care! It
is advisable to have this work executed at a service support location or
by MAN Diesel & Turbo staff!

Work steps 1. Swing the swivel arm (434.044-11) with electric angle grinder (3) up to
the right hand stop (5). See Fig. 2.
2. Drive grinding wheel (434.044-16) with support adjusting crank (4) on
the sealing face of the threaded piece (1), until the grinding wheel
touches the sealing face.
3. Move swivel arm up to the left stop (434.044-13), such that the grinding
wheel faces the threaded piece (1). See Fig. 4.

Wear safety goggles

Wear safety goggles for grinding threaded pieces!

Work Cards, classified into sub-assemblies

4. Connect voltage supply for the electric angle grinder (3) and switch it
on.
5. Rotate threaded piece (1) uniformly on clamping piece (434.044-42) and
move the swivel arm at the same time with the electrical angle grinder
(3) around the sealing face contour.

Grinding wheel
The grinding wheel must not touch the adapter flange!

6. The advance on the threaded ring (434.044-2) is effected by means of

2007-12-10

the tommy bar (000.262). Maximum advance per work sequence is one
division of the scale on the threaded ring.
L48/60B

6707 221.05-01 EN 3 (6)

221.05 MAN Diesel & Turbo

Advance
Fuel injection valve

The advance is not on the support adjusting crank (4)! The adjusted
position remains unchanged during the entire grinding sequence!
Lightly rework the sealing faces, only smoothen removing as little
material as possible!

7. Move swivel arm up to the left hand stop, so that the grinding wheel
faces the threaded piece (1). Switch off electric angle grinder (3).
8. Evaluate the result of the grinding process. Repeat the grinding process
until the sealing face has a uniform polished appearance.

Contact pattern
If the required contact pattern cannot be realised with the pressure pipe
grinding device, it must be given for repairs to a MAN Diesel & Turbo
Customer Service workshop!

Used emery paper

Pull out used emery paper immediately and replaced by a new one.

9. Remove threaded piece (1) from pressure pipe grinding device and
remove counter flange.
Work Cards, classified into sub-assemblies

2007-12-10
L48/60B

1 Threaded piece 3 electric angle grinder 4 Support adjusting crank

2 Hexagon socket bolt M5x10
Figure 1: Pressure pipe grinding device with attached threaded piece

4 (6) 6707 221.05-01 EN

 MAN Diesel & Turbo 221.05

Fuel injection valve

2 Hexagon socket bolt M5x10 5 Stop
Figure 2: Pressure pipe grinding tool

Work Cards, classified into sub-assemblies

2007-12-10

1 Threaded piece 4 Hexagon socket bolt M6x35

Figure 3: Attachment of the threaded piece on the pressure pipe grinding
L48/60B

device

6707 221.05-01 EN 5 (6)

221.05 MAN Diesel & Turbo
Fuel injection valve

5 Stop
Figure 4: Right and left hand stop for the swivel arm
Work Cards, classified into sub-assemblies

2007-12-10
L48/60B

6 (6) 6707 221.05-01 EN

MAN Diesel & Turbo 280-289

Charge air and exhaust pipe

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.25-1 EN 1 (2)

 MAN Diesel & Turbo
Charge air and exhaust pipe

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.25-1 EN

 MAN Diesel & Turbo 280.01

Charge air and exhaust pipe for emergency operation

Charge air and exhaust pipe

converting

Summary
Ensure correct execution of work, enable emergency operation.
To enable emergency operation of an engine in the event of failure of a tur-
bocharger, refitting must be done on the charge air and exhaust gas sys-
tems.
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Cover 280.033 Standard
1 Blind flange 280.037 Standard
1 Torque wrench 008.017 Standard
1 Socket spanner insert 30x12.5 001.759 Option
1 Receptacle - Inventory
1 Lifting tackle with rope - Inventory
1 Combination spanner (set) - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory

Work Cards, classified into sub-assemblies

Corresponding Work Cards
Work card Work card Work card
000.30

Technical data
Designation Information
Axial compensator 25,5 kg
Pipe section 36,5 kg
Annular sealing flap 43,5 kg
2008-10-22

Pipe section with cover 118,5 kg

Work sequence 1 - Refit charge air and exhaust pipe for emergency operation
L48/60B

Preliminary remark For suction of the combustion air during emergency operation, the charge
air bypass pipe must be removed, the opening at the end of the charge air

6704 280.01-03 EN 1 (9)

280.01 MAN Diesel & Turbo

pipe protected by wire mesh and the exhaust pipe closed with a blind flange.
Charge air and exhaust pipe

Ensure cleanliness in the suction area.

For instructions during emergency operation with failed turbocharger see Volume
010.005 Engine - Operating Instructions/010.200 Turbocharger.
Achievable performance In engine operation with variable speed, only engine operation with constant speed
is possible after removing the charge air bypass pipe!
During emergency operation, a maximum output of 20% of the rated power can be
obtained in the engine operation with constant speed!
The limiting criteria for the achievable engine output during emergency operation are
▪ the maximum exhaust gas temperature after the cylinder,
▪ the maximum exhaust temperature in front of the turbocharger,
▪ Exhaust clouding!
Starting position Turbocharger is refitted for emergency operation (see Volume 010.200 Tur-
bocharger), lubricating oil to the turbocharger is interrupted. Charge air
bypass pipe and control air pipes to the solenoid valve are pressureless.
Work steps 1. Place receptacle under charge air pipe section (1), unscrew screw plug
and drain condensed water from charge air pipe section.
2. Screw in sealing screw including seal in charge air pipe section (1),
remove receptacle.
3. Remove axial compensator (4) and place on support surface. See Fig.
2.
4. Remove pipe section (5) and place on support surface. See Fig. 3.
5. Remove pipe section (2) and place on support surface. See Fig. 4.
6. Detach air pipes (32 and 33) and block openings on the annular sealing
flap (3) and on solenoid valve (34) with suitable means. See Fig. 5.
7. Remove annular sealing flap (3) and place it carefully on the support.
See Fig. 5.
8. Set blind flange (280.037) including seal (16) on flange (18), screw hex-
Work Cards, classified into sub-assemblies

agon nut (15) on stud (17) and tighten. See Fig. 6.

9. Set cover (280.033) on charge air pipe section (1), screw in hexagon bolt
(19) and tighten. See Fig. 7.
10. Remove O-ring seal (25).
11. Clean all parts externally.

Work sequence 2 - Refitting the charge air and exhaust pipe

Starting position Return fitting of the charge air and exhaust pipe is done in respectively
reverse sequence to Work sequence 1. Observe the following points:
1. Assemble all engine parts only loosely at first and tighten hexagon bolts
or nuts only after aligning all parts.
2008-10-22

2. Ensure correct connection of the air pipes (32 and 33). See Fig. 5.
3. Oil new O-ring seal (25) with clean lubricating oil and place it in ring
L48/60B

groove, ensuring that it is not twisted.

2 (9) 6704 280.01-03 EN

 MAN Diesel & Turbo 280.01

4. Brush the threads and the contact surface of the hexagon bolts (2) with

Charge air and exhaust pipe

MoS2 lubricant, screw them in and tighten them using the specified
torque (see Work Card 000.30).
5. Ensure correct fitting of the axial compensator (4) (observe flow direc-
tion!). See Fig. 2.

Work Cards, classified into sub-assemblies

1 Charge air pipe section 3 Annular sealing flap 5 Pipe section
2 Pipe section 4 Axial compensator 6 Exhaust pipe section
Figure 1: Charge air bypass pipe
2008-10-22

L48/60B

6704 280.01-03 EN 3 (9)

280.01 MAN Diesel & Turbo
Charge air and exhaust pipe
Work Cards, classified into sub-assemblies

2 Pipe section 8 Hexagon bolt 13 Perforated disc

3 Annular sealing flap 9 Hexagon nut 14 Seal
4 Axial compensator 10 Hexagon bolt I - II Work steps
5 Pipe section 11 Seal
7 Hexagon nut 12 Flange
2008-10-22

Figure 2: Charge air deflection pipe - Detach/attach the axial compensator

L48/60B

4 (9) 6704 280.01-03 EN

 MAN Diesel & Turbo 280.01

Charge air and exhaust pipe

5 Pipe section 16 Seal
6 Exhaust pipe section 17 Stud
15 Hexagon nut 18 Flange
Figure 3: Charge air deflection pipe - Detach/attach the pipe section (exhaust)

Work Cards, classified into sub-assemblies

2008-10-22

L48/60B

6704 280.01-03 EN 5 (9)

280.01 MAN Diesel & Turbo
Charge air and exhaust pipe
Work Cards, classified into sub-assemblies

1 Charge air pipe section 20 Holder 24 Holder

2 Pipe section 21 Hexagon nut 25 O-ring seal
3 Annular sealing flap 22 Washer 26 Seal
19 Hexagon bolt 23 Hexagon bolt I-III Work steps
Figure 4: Charge air deflection pipe - Detach/attach the pipe section (exhaust)
2008-10-22
L48/60B

6 (9) 6704 280.01-03 EN

 MAN Diesel & Turbo 280.01

Charge air and exhaust pipe

Work Cards, classified into sub-assemblies

3 Annular sealing flap 30 Hexagon bolt 34 Solenoid valve

27 Holder 31 Washer I-III Work steps
28 Hexagon nut 32 Air pipe
29 Washer 33 Air pipe
Figure 5: Charge air bypass pipe - Removing/ fitting of annular sealing flap
2008-10-22

L48/60B

6704 280.01-03 EN 7 (9)

280.01 MAN Diesel & Turbo
Charge air and exhaust pipe
Work Cards, classified into sub-assemblies

6 Exhaust pipe section 16 Seal 18 Flange

15 Hexagon nut 17 Stud I - II Work steps
Figure 6: Charge air deflection pipe - Attach/detach the blind flange (exhaust)
2008-10-22
L48/60B

8 (9) 6704 280.01-03 EN

 MAN Diesel & Turbo 280.01

Charge air and exhaust pipe

Work Cards, classified into sub-assemblies

1 Charge air pipe section 19 Hexagon bolt I - II Work steps

Figure 7: Charge air deflection pipe - Attach/detach the cover (charge air)
2008-10-22

L48/60B

6704 280.01-03 EN 9 (9)

 MAN Diesel & Turbo 280.02

Charge air bypass device

Charge air and exhaust pipe

disassemble and assemble, renew sealing elements

Summary
Execute the work in time according to the maintenance schedule, ensure
the correct execution of work, ensure / restore operational safety. 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/work steps include: Disassembling /separating components,
Renewing sealing rings/sealing elements, Assembling/refitting compo-
nents.
Safety requirements
- Engine secured against starting
- Engine shut down
Personnel and time required
Number Qualification Duration in h
1 Technician 2

Tools/aids required
Quantity Designation Number Status
1 Pliers for locking rings A 10-25 002.121 Option
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Grease (acid-free) - Inventory

Work Cards, classified into sub-assemblies

Work sequence 1 - Detaching the deflection flap with drive head
Starting position Control pipes (22) and bypass pipes of the charge air bypass device are
pressureless.
Work steps 1. Disconnect control pipes (22) from the drive head (21).

2. Remove flange bolts (23) (see figure 1).

3. Dismantle any supports on the adapter flange (25).
4. Pull out deflection flap (20) with drive head from the flange connection,
taking care not to damage the seals (24).

Work sequence 2 - Replacing the sealing and wear part sets on the drive head
2007-11-15

Work steps 1. Remove deflection flap (20) and drive head (21) from the adapter flange
(25).
General

2. Unscrew hexagon socket bolts (8) of both covers (7).

3. Remove cover (7) with cover packing (6) and pay attention to any exist-
ing reset springs (16). Remove reset springs (16) (see figure 2).

6682 280.02-01 EN 1 (4)

280.02 MAN Diesel & Turbo

4. Run both pistons (5) from the casing (10) of the drive head by rotating
Charge air and exhaust pipe

the pinion shaft (11). When removing the two pistons, pay attention to
guide segments (9).

Work on the drive head

The two pistons of the drive head must never be run from the casing by
using compressed air!
Valid in general: Disconnect the connection to the compressed air network during
work on the drive head!

5. Disassemble guide rings (4) and O-ring seals (3).

6. Remove locking ring (1) with pliers for locking rings (002.121), pay atten-
tion to the backing ring (2).
7. Press pinion shaft (11) from the casing (10).
8. Remove upper and lower slide ring (14 and 15) with O-ring seals (12 and
13).
9. Clean all components and check for wear.
10. The assembly is done in reverse order of the dismantling. Use new set
of seals consisting of items 3, 6, 12, 13 and 17, as well as a wear parts
set consisting of items 4 ,9 , 14 and 15.

Locking ring
Do not overextend locking ring (1) when fitting.

When inserting the piston (5) into the casing (10) ensure that the piston racks
engage correctly in the pinion shaft teeth (11) and travel symmetrically
together.
Attach the cover (7) with cover packing (6) in the correct position on the
casing (10). Observe identification "UP" on cover.
Work sequence 3 - Attaching the deflection flap with drive head
Work Cards, classified into sub-assemblies

Starting position Tightness test for deflection flap and drive head carried out. Deflection flap
and drive head mounted on adapter flange.
Work steps 1. Insert deflection flap (20) with drive head (21) in the correct position
between the flange connection of the bypass pipes, taking care not to
damage the seals (24).
2. Insert flange bolts (23) and tighten them crosswise.
3. Mount any existing holders on the adapter flange (25).
4. Attach control pipes (22) to the drive head (21) and check system for
tightness.
2007-11-15

Faulty or leaky bypass flap

If bypass flap (20) is faulty or leaky, replace it completely!
General

2 (4) 6682 280.02-01 EN

 MAN Diesel & Turbo 280.02

Charge air and exhaust pipe

20 Bypass flap 23 Flange bolt
21 Drive head 24 Seal
22 Control pipes 25 Adapter flange
Figure 1: Charge air bypass device

Work Cards, classified into sub-assemblies

2007-11-15

General

6682 280.02-01 EN 3 (4)

280.02 MAN Diesel & Turbo
Charge air and exhaust pipe

1 Locking ring 8 Hexagon socket bolt 15 lower slide ring

2 Backing ring 9 Guide segment 16 Reset spring
3 O-ring seal 10 Casing 17 O-ring seal
4 Guide ring 11 Pinion shaft 18 Cap nut
Work Cards, classified into sub-assemblies

5 Piston 12 O-ring seal 19 Set screw

6 Cover packing 13 O-ring seal
7 Cover 14 upper slide ring
Figure 2: Drive head
2007-11-15
General

4 (4) 6682 280.02-01 EN

 MAN Diesel & Turbo 289.01

Exhaust pipe

Charge air and exhaust pipe

checking, detaching and attaching

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, ensure / restore operational safety.
The exhaust pipe is to be checked at regular intervals for tightness of the
flanged connections and compensators.
The work/work steps include:
Checking parts/components,
Removing parts/components,
Refitting parts/components.
Safety requirements
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Torque wrench 10-60 Nm 008.029 Standard
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
2 Shackle A0.6 002.452 Standard
1 Adapter 12.5x10 001.922 Standard
1 Extension piece 12.5x250 001.912 Option
1 Cross handle 001.891 Option
1 Socket spanner insert 30x12.5 001.759 Option
1 Socket spanner insert 17x12.5L 001.754 Option

Work Cards, classified into sub-assemblies

2 Lifting eye bolt M16 000.143 Standard
1 Lifting tackle with rope - Inventory
1 Molykote HSC - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30

Technical data
Designation Information
2007-05-07

Quick-fitting coupling half 8 kg

Axial compensator 13,5 kg
L48/60B

Pipe section 67,5 kg

6704 289.01-01 EN 1 (9)

289.01 MAN Diesel & Turbo

Preliminary remark
Charge air and exhaust pipe

Check the exhaust pipe for external objects after damage to piston or
valve! Broken pieces can be drawn from the exhaust flow into the turbine
and cause serious damage!

Work sequence 1 - Inspection

Starting position Engine has cooled down.

Work steps 1. Check exhaust pipe for tightness on flanged connections and axial
compensators at intervals specified in the maintenance schedule.
2. Check covering insulation for dark colouration.

Leaky exhaust pipes can be seen by the black colouring at the

corresponding places on the insulation.

Remove covering if necessary, disassemble exhaust pipe and clean.

Work sequence 2 - Removing
Starting position Engine has cooled down, casing is removed.

Work steps 1. Release nuts (7) and unscrew alternately. See Fig. 3.

2. Remove upper quick-acting coupling half (5).

3. Screw in lifting eye bolts (000.143) into the pipe section (2). See Fig. 4.
4. Attach the ropes (10) with the shackle (002.452) to the lifting eye bolts
and suspend from the lifting tackle. Lightly tension the rope.
5. Release nuts (12), unscrew alternately and remove clamps (11 and 14).
Work Cards, classified into sub-assemblies

See Fig. 5/II.

6. Remove second pipe clamp in the same manner (see point 5) and
remove axial compensator (4) carefully.

Do not damage axial compensator during disassembly!

7. Place axial compensator on support.

8. Disassemble second axial compensator (4) in the same way (see point
5 and 6). See Fig. 5/III.
2007-05-07

9. Lift up pipe section (2) carefully and remove. See Fig. 6.

10. Clean all parts, check axial compensators (4) for damage.
L48/60B

2 (9) 6704 289.01-01 EN

 MAN Diesel & Turbo 289.01

Work sequence 3 - Fitting

Charge air and exhaust pipe

Starting position Refitting of the pipe section is done in reverse order from work sequence 2.
Observe the following points:
1. Clean contact face on flange (6) and on the adjacent pipe sections or
on exhaust turbocharger (3) carefully.
2. Assemble all engine parts only loosely at first and tighten hexagon bolts
or nuts only after aligning all parts (see part 4 and 5).
3. Ensure correct fitting of the axial compensator (4) (correct flow direc-
tion!). See Fig. 2.
4. Coat screw thread and contact surface of the nuts (12) with lubricant
Molykote HSC, screw on threaded bolt (13) and tighten with specified
torque (see Work Card 000.30).
5. Apply lubricant Molykote HSC on thread and resting surface of the nuts
(7), screw on stud (8) and tighten with specified torque (see Work Card
000.30).

Work Cards, classified into sub-assemblies

2007-05-07

L48/60B

6704 289.01-01 EN 3 (9)

289.01 MAN Diesel & Turbo
Charge air and exhaust pipe
Work Cards, classified into sub-assemblies

1 Cylinder head 3 Exhaust turbocharger

2 Pipe section
Figure 1: Exhaust pipe
2007-05-07
L48/60B

4 (9) 6704 289.01-01 EN

 MAN Diesel & Turbo 289.01

Charge air and exhaust pipe

2 Pipe section 4 Axial compensator

Work Cards, classified into sub-assemblies

Figure 2: Exhaust pipe
2007-05-07

L48/60B

6704 289.01-01 EN 5 (9)

289.01 MAN Diesel & Turbo
Charge air and exhaust pipe
Work Cards, classified into sub-assemblies

2007-05-07

2 Pipe section 8 Stud

L48/60B

5 top quick-acting coupling half 9 lower quick acting coupling half

6 Flange I - II Work steps
7 Nut
Figure 3: Exhaust pipe - Detach/attach the quick-fitting coupling

6 (9) 6704 289.01-01 EN

 MAN Diesel & Turbo 289.01

Charge air and exhaust pipe

2 Pipe section 10 Rope

Work Cards, classified into sub-assemblies

Figure 4: Exhaust pipe - Suspending the pipe section
2007-05-07

L48/60B

6704 289.01-01 EN 7 (9)

289.01 MAN Diesel & Turbo
Charge air and exhaust pipe
Work Cards, classified into sub-assemblies

2 Pipe section 13 Threaded bolt

4 Axial compensator 14 lower pipe clamp half
11 upper pipe clamp half I-III Work steps
2007-05-07

12 Nut
Figure 5: Exhaust pipe - Detach/attach the quick-acting coupling
L48/60B

8 (9) 6704 289.01-01 EN

 MAN Diesel & Turbo 289.01

Charge air and exhaust pipe

Work Cards, classified into sub-assemblies
2007-05-07

2 Pipe section I - II Work steps

L48/60B

10 Rope
Figure 6: Exhaust pipe - Removing/assembling the pipe section

6704 289.01-01 EN 9 (9)

 MAN Diesel & Turbo 289.02

Exhaust gas blow-off device

Charge air and exhaust pipe

disassemble and assemble, renew sealing elements

Summary
Execute the work in time according to the maintenance schedule, ensure
the correct execution of work, ensure / restore operational safety. Check
control elements in the exhaust gas system in the course of the service and
maintenance work and overhaul if necessary.
The work/work steps include: Disassembling /separating components,
Renewing sealing rings/sealing elements, Assembling/refitting compo-
nents.
Safety requirements
- Engine secured against starting
- Engine shut down
Personnel and time required
Number Qualification Duration in h
1 Technician 2

Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Screwdriver (Set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 High temperature grease XOMOX REINM 050 - Inventory

Work sequence 1 - Detaching the blow-off flap with drive head

Work Cards, classified into sub-assemblies

Starting position Control lines (3) and blow-off pipes of the exhaust gas blow-off device
pressureless. For position details refer to figure 1.
Work steps 1. Disconnect control pipes (3) from the drive head (2).

2. Remove bolted flange connections (4).

48/60;48/60B;L58/64;V48/60CR

3. Dismantle any supports on the adapter flange (6).

4. Pull blow-off flap with drive head from flange joint. Pay attention to seals
(5) and do not damage them.

Work sequence 2 - Exchange of the flap shank seal on the blow-off flap
For position details refer to figure 2.
2009-07-20

Work steps 1. Detach blow-off flap and drive head from adapter flange.

2. Remove clamping sleeve (24) from flap shank (3).

3. Unscrew hexagon nut (20) with spring washers (21), remove thrust plate
(17) with thrust ring (16) and flap shank seal (14).

6707 289.02-01 EN 1 (6)

289.02 MAN Diesel & Turbo

Seal support ring and flap shank bearing

Charge air and exhaust pipe

The seal support ring (15) as well as the flap shank bearing (13) need not
be dismounted.

4. Push new flap valve shank seal (14) over the flap shank (3) in bore on
flap housing (1).
5. Fix thrust ring and thrust plate and screw down with hexagon nuts (20).
Do not forget spring washers (21).
6. Install clamping sleeve (24) in flap shank (3).
7. Check flap shank seal for tightness and retighten hexagon nuts (20).

Work sequence 3 - Exchange of the flooring seal on the blow-off flap

For position details refer to figure 2.
Work steps 1. Loosen and remove locking bolt (25) on flap housing (1).

2. Replace sealing ring (26) and replace by a new sealing ring.

3. Screw sealing screws (25) in flap casing (1) and tighten.

Work sequence 4 - Exchange of the seat ring with seat ring seal on the blow-off flap
For position details refer to figure 2.
Work steps 1. Unscrew hexagon socket bolts (11) on seat retaining ring (10).

2. Bring flap plate (2) in a lightly opened position (flap plate opened facing
flap housing by about 30 degrees).
3. Press seat retaining ring (10) from flap housing. Thread-in two hexagon
bolts in the tapped holes on the seat retaining ring and press it uniformly.
4. Check seat ring sealing (8) and replace if necessary. Groove for sealing
ring to be cleaned before fitting a new sealing ring.
5. Bring flap plate (2) to a completely opened position (flap plate opened
Work Cards, classified into sub-assemblies

facing flap housing by 90 degrees).

6. Clean and check sealing face of the flap plate (2).
7. Bring flap plate (2) to closed position
8. Place new seat ring (6) in the flap housing (1).
48/60;48/60B;L58/64;V48/60CR

Inserting the seat ring

Pay attention to the recess on flap housing when inserting the seat ring
(6).

9. Place seat retaining ring (10) and screw in hexagon socket bolts (11)
evenly, crosswise. Ensure that the seat retaining ring rests flat, at a
2009-07-20

maximum projection of 0.2 mm, on the flap housing.

10. Carry out leak test at nominal pressure in preferred throughput direction.

2 (6) 6707 289.02-01 EN

 MAN Diesel & Turbo 289.02

Work sequence 5 - Changing of the shank seals and of the rotating wing sealing ring on

Charge air and exhaust pipe

drive head
For position details refer to figure 3.
Work steps 1. Unscrew fitting bolts (8) and hexagon socket bolts (10).

2. Separate the casing top part (1) from casing bottom part (7) and remove
shank (4) with rotating wing (3).
3. Remove the O-ring seals (5), clean the sealing ring grooves and insert
new O-ring seals.
4. Remove rotating wing sealing ring (6), clean sealing ring groove on
rotating wing (3) and insert new rotating wing sealing ring.
5. Clean sealing faces on casing upper part and lower part, check bearing
bushes (2) in the casing halves.
6. Insert shank (4) with rotating wing (3) in casing lower part. Pay attention
to O-ring seals (5) and do not damage them.
7. Apply high-temperature grease XOMOX REINM 050 to sealing faces of
the two halves of the casing.

High-temperature grease XOMOX REINM 050

Use only high-temperature grease XOMOX REINM 050 to join the two
halves of the casing! Other sealing compounds could damage the drive
head!

8. Fit casing upper part. Pay attention to O-ring seals (5) and do not dam-
age them.
9. Screw in fitting bolts (8) with hexagon nuts (9). Screw on hexagon socket
bolts (10) with hexagon nuts (9) and tighten crosswise.

Work sequence 6 - Attaching the blow-off flap with drive head

Starting position Leakage test for blow-off flap and drive head carried out. Blow-off flap and

Work Cards, classified into sub-assemblies

drive head mounted on adaptor flange.
For position details refer to figure 1.
Work steps 1. Insert blow-off flap with drive head in the correct position between
flange connection of the blow-off pipes. Pay attention to seals (5) and
do not damage them.
48/60;48/60B;L58/64;V48/60CR

2. Insert flange bolts (4) and tighten them crosswise.

3. Assemble braces between blow-off pipe and adapter flange (6) if any.
4. Attach control pipes (3) to the drive head (2) and check system for tight-
ness.
2009-07-20

6707 289.02-01 EN 3 (6)

289.02 MAN Diesel & Turbo
Charge air and exhaust pipe

1 Blow-off flap 4 Flange bolt

2 Drive head 5 Seal
3 Control pipes 6 Adapter flange
Figure 1: Exhaust gas blow-off device
Work Cards, classified into sub-assemblies
48/60;48/60B;L58/64;V48/60CR

2009-07-20

4 (6) 6707 289.02-01 EN

 MAN Diesel & Turbo 289.02

Charge air and exhaust pipe

Work Cards, classified into sub-assemblies
1 Flap housing 11 Hexagon socket bolt 19 Set screw
2 Flap plate 12 Plate centring ring 20 Hexagon nut
48/60;48/60B;L58/64;V48/60CR

3 Flap shank 13 Flap shank bearing 21 Spring washer

6 Seat ring 14 Flap shank seal 24 Clamping sleeve
8 Seat ring seal 15 Seal support ring 25 sealing screw on distribution block
9 Taper pin 16 Thrust ring 26 Sealing ring
10 Seat retaining ring 17 Thrust plate
Figure 2: Blow-off flap
2009-07-20

6707 289.02-01 EN 5 (6)

289.02 MAN Diesel & Turbo
Charge air and exhaust pipe

1 Casing upper part 5 O-ring seal 10 Hexagon socket bolt

2 Bearing bush 6 Rotating wing sealing ring 11 Stop screw
3 Rotating wing 7 Casing lower part 12 Sealing washer
3a Safety ball bearing 8 Fitting bolt 13 Washer
4 Shank 9 Hexagon nut 14 Hexagon nut
Figure 3: Drive head
Work Cards, classified into sub-assemblies
48/60;48/60B;L58/64;V48/60CR

2009-07-20

6 (6) 6707 289.02-01 EN

MAN Diesel & Turbo 300/350

Lubricating oil and cooling water pump

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.26-1 EN 1 (2)

 MAN Diesel & Turbo
Lubricating oil and cooling water pump

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.26-1 EN

 MAN Diesel & Turbo 300.01

Lubricating oil pump

Lubricating oil and cooling water pump

removing and refitting

Summary
Ensure correct execution of work, carry out work in accordance with the
maintenance schedule in good time, prevent operational problems/damage.
The lube oil pump(s) are to be removed within the scope of maintenance
and repair work.
The work/work steps include: Removing components, Assembling compo-
nents.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
2 Shackle A1.0 002.453 Standard
1 Thickness gauges 0.05-1 000.451 Option
2 Lifting eye bolt M20 000.155 Standard
3 Forcing-off bolt M16 - Inventory
1 Lifting tackle with rope - Inventory
1 Combination spanner (set) - Inventory
1 Hylomar SQ/M - Inventory

Technical data

Work Cards, classified into sub-assemblies

Designation Information
Lube oil pump with gearwheel 640 kg

Preliminary remark
The Work Card describes the detachment/attachment of a lubricating oil
pump attached to the control.
The sequence for the detachment/attachment of a lubricating oil pump
attached on the exhaust takes place in the same manner as on the control.
Work sequence 1 - Removal of lubricating oil pump
2008-10-22

Starting position Lubricating oil is drained from lubricating oil pump and pipes (pressure and
suction side). Pressure and suction side pipes as well as all piping and
engine parts obstructing the detachment of the lube oil pump have been
L48/60B

removed/detached.
Work steps 1. Screw lifting eye bolts (000.155) in lubricating oil pump (4). See Fig. 2.

6704 300.01-01 EN 1 (5)

300.01 MAN Diesel & Turbo

2. Attach the ropes (5) with the shackle (002.453) to the lifting eye bolts
Lubricating oil and cooling water pump

and suspend from the lifting tackle. Lightly tension the rope.
3. Unscrew hexagon nuts (2).
4. Screw three forcing-off bolts into the lubricating oil pump (4). Press
lubricating oil pump off casing (1).
5. Remove lubricating oil pump (4) carefully, not damaging the studs (1).
See Fig. 3.
6. Transport off lubricating oil pump (4) and place aside on underlay.
7. Detach the tool.
8. Clean the lubricating oil pump (4) externally.

Work sequence 2 - Attachment of lubricating oil pump

Starting position Outside of lubricating oil pump has been cleaned. >Contact face on casing
and lube oil pump are cleaned.
Work steps 1. Screw lifting eye bolts (000.155) in lubricating oil pump (4).

2. Attach the ropes (5) with the shackle (002.453) to the lifting eye bolts
and suspend from the lifting tackle. Lightly tension the rope.
3. Coat the contact face on the lube oil pump (4) with "Hylomar SQ/M"
sealing compound.
4. Lift lube oil pump (4) and transport up to engine.
5. Attach the lubricating oil pump (4) carefully, making sure you do not
damage the studs (3).
6. Screw the hexagon nuts (2) on to the stud bolts (3) and tighten.
7. Detach the tool.
8. Measure torsional backlash with thickness gauges (000.451) and com-
pare with prescribed value (see Volume 010.005 Engine - Operating
Instructions).
Work Cards, classified into sub-assemblies

9. Fill lubricating oil pump (4) on the pressure side with clean lubricating
oil.
10. Attach all removed engine parts and piping.
11. Before commissioning, vent the pressure line at the highest point until
lubricating oil is discharged bubble-free at the breather element.
12. Check lubricating oil pump (4) and pipes for leakages and noises when
starting the engine. Loud noises show that the lubricating oil pump is
sucking air, so the lubricating oil pump cannot deliver the full capacity
and cavitation can occur.
2008-10-22
L48/60B

2 (5) 6704 300.01-01 EN

 MAN Diesel & Turbo 300.01

Lubricating oil and cooling water pump

1 Casing 3 Stud
2 Hexagon nut 4 Lubricating oil pump

Work Cards, classified into sub-assemblies

Figure 1: Lubricating oil pump
2008-10-22

L48/60B

6704 300.01-01 EN 3 (5)

300.01 MAN Diesel & Turbo
Lubricating oil and cooling water pump
Work Cards, classified into sub-assemblies

1 Casing 4 Lubricating oil pump

2 Hexagon nut 5 Rope
3 Stud
Figure 2: Detaching/attaching the lubricating oil pump 2008-10-22
L48/60B

4 (5) 6704 300.01-01 EN

 MAN Diesel & Turbo 300.01

Lubricating oil and cooling water pump

1 Casing 4 Lubricating oil pump
3 Stud 5 Rope
Figure 3: Detaching/attaching the lubricating oil pump

Work Cards, classified into sub-assemblies

2008-10-22

L48/60B

6704 300.01-01 EN 5 (5)

 MAN Diesel & Turbo 300.02

Lubricating oil pump

Lubricating oil and cooling water pump

dismantling and assembling

Summary
Ensure correct execution of work. The lubricating oil pump should be regen-
erated at regular intervals.
The work/work steps include: Removal of components, dismantling and
assembly, installation of components.
Tools/aids required
Quantity Designation Number Status
1 Torque wrench 10-60 Nm 008.029 Standard
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.011 Standard
1 Adapter 12.5x10 001.922 Standard
1 Cross handle 001.891 Option
1 Screwdriver insert 8x12.5 001.854 Standard
1 Ratchet tool 001.521 Option
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.30 000.32

Technical data
Designation Information

Work Cards, classified into sub-assemblies

Gear wheel 25,5 kg

Work sequence 1 - Removing the gearwheel

Starting position Lubricating oil pump is detached.

Work steps 1. Thread off all hexagon socket bolts (13) by a few thread pitches. See
Fig. 2.
2. Unscrew four hexagon socket bolts (screws 5 - 6 - 7 - 8) and screw into
forcing-off tap holes. See figure 1, 3 and 4.
3. Push thrust rings (16 to 19) away from each other by alternately tight-
ening the hexagon socket bolts (screws 5 - 6 - 7 - 8).
4. Pull out gear wheel (11) and clamping set (12) of driving spindle (14) and
2007-12-10

place on support surface. See Fig. 5.

5. Remove clamping set (12) from gear wheel (11). See Fig. 6.
L48/60B

6. Unscrew and remove the hexagon socket bolts (13). See Fig. 7.
7. Dismantle clamping set (12), clean it and check for damage. See Fig. 7.

6707 300.02-01 EN 1 (7)

300.02 MAN Diesel & Turbo

8. Clean locating hole in the gearwheel.

Lubricating oil and cooling water pump

9. Clean lubricating oil pump externally.

10. Dismantle lubricating oil pump (see work sequence 2).

Work sequence 2 - Dismantling and assembling lubricating oil pump

The dismantling and assembly of the lube oil pump shall be carried out in
accordance with the manufacturer's specifications (see "Technical Docu-
mentation E 185 . . . ." ."and "Assembly instructions E 185. . . ." ."in section
4).
Work sequence 3 - Refitting the gearwheel
Starting position Lubricating oil pump is assembled (see Work sequence 2).

Lube oil pump, gearwheel and clamping set are cleaned.

Work steps 1. Oil the thrust ring (16 to 19) lightly with clean thin lubricating oil.

2. Assemble clamping set (12).

Thrust rings
Note the position of the parting lines (M and N)! The parting line (N) for
the internal and external thrust ring (17 and 19) must be offset with
respect to the parting line (M) for the front and rear thrust ring (16 and
18) by 180°! See Fig. 8/I.
Undrilled points in the rear thrust ring (18) must be assigned to the
forcing-off tap holes in the front thrust ring (16)! See Fig. 8/II.

3. Oil threads and resting surfaces of the hexagon socket bolts (13) lightly
with clean, thin lubricating oil and screw into clamping set (12).
4. Oil locating hole in the gearwheel (11) and locating pin of the driving
spindle (14) lightly with clean, thin lubricating oil.
5. Insert clamping set (12) in locating hole of the gearwheel (11) and push
it together to driving spindle (14).
Work Cards, classified into sub-assemblies

6. Tighten hexagon socket bolts (13) lightly, align gearwheel (11) on the
drive spindle shoulder.
7. Tighten hexagon socket bolts (13) evenly in three stages with specified
torque (see Work Card 000.30) - For tightening order see figure 1.
8. Check hexagon socket bolts (13) in the sequence of their arrangement
(bolt 1-5-3-7-2-6-4-8) with torque (3rd stage, see Work Card 000.30),
retighten hexagon socket bolts if necessary.

Pressure limiting valve

After attaching the lubricating oil pump to the engine, the pressure
limiting valve shall be adjusted according to the manufacturer's
specifications (see "Technical Documentation E 185 . . . ." ."in section 4)!
2007-12-10
L48/60B

2 (7) 6707 300.02-01 EN

 MAN Diesel & Turbo 300.02

Lubricating oil and cooling water pump

1-8 Bolt number/Tightening order 11 Gear wheel 13 Hexagon socket bolt
10 Lubricating oil pump 12 Clamping set 14 Driving spindle
Figure 1: Lubricating oil pump

Work Cards, classified into sub-assemblies

2007-12-10

13 Hexagon socket bolt

Figure 2: Lube oil pump - Removing the gearwheel
L48/60B

6707 300.02-01 EN 3 (7)

300.02 MAN Diesel & Turbo
Lubricating oil and cooling water pump

13 Hexagon socket bolt

Figure 3: Lube oil pump - Removing the gearwheel
Work Cards, classified into sub-assemblies

2007-12-10
L48/60B

4 (7) 6707 300.02-01 EN

 MAN Diesel & Turbo 300.02

Lubricating oil and cooling water pump

Work Cards, classified into sub-assemblies

12 Clamping set 13 Hexagon socket bolt I - II Work steps

Figure 4: Lube oil pump - Removing the gearwheel
2007-12-10

L48/60B

6707 300.02-01 EN 5 (7)

300.02 MAN Diesel & Turbo
Lubricating oil and cooling water pump

11 Gear wheel 14 Driving spindle

Figure 5: Lube oil pump - Removing the gearwheel
Work Cards, classified into sub-assemblies

11 Gear wheel 12 Clamping set

Figure 6: Lubricating oil pump - Removing the clamp ring
2007-12-10
L48/60B

6 (7) 6707 300.02-01 EN

 MAN Diesel & Turbo 300.02

Lubricating oil and cooling water pump

13 Hexagon socket bolt
16 Thrust ring, front
17 Thrust ring, outer
18 Thrust ring, rear
19 Thrust ring, inner

Figure 7: Lubricating oil pump - Dismantling the clamp ring (12)

13 Hexagon socket bolt 18 Thrust ring, inner

16 Thrust ring, front M Parting line (item 16 and 18)
17 Thrust ring, outer N Parting line (item 17 and 19)
18 Thrust ring, rear

Work Cards, classified into sub-assemblies

Figure 8: Lube oil pump - Assembly of the clamp set (illustration I: Position of
the parting lines / illustration II: Position of the forcing-off tap hole to rear thrust
ring)
2007-12-10

L48/60B

6707 300.02-01 EN 7 (7)

MAN Diesel & Turbo 322

Charge air cooler

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.27-1 EN 1 (2)

 MAN Diesel & Turbo
Charge air cooler

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.27-1 EN

 MAN Diesel & Turbo 322.01

Charge air cooler

Charge air cooler

checking and cleaning

Summary
Carry out the work in accordance with the maintenance plan in good time,
enable/support economic working, prevent operational problems/damage.
The charge air cooler has a significant effect on the performance data and
thus also on the engine performance. It is therefore necessary to check it at
regular intervals and clean it.
The work/work steps include:
Checking operating data,
Removing components,
Cleaning parts chemically/ mechanically,
Fitting components.
Safety requirements
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Digital pressure gauge "Digima-Premo" 009.090 Option
1 Ratchet tool 008.023 Standard
1 Torque wrench 008.017 Standard
1 Torque wrench 008.011 Standard
2 Shackle A1.6 002.454 Standard
1 Extension piece 12.5x250 001.912 Option

Work Cards, classified into sub-assemblies

1 Screwdriver insert 14x12.5 001.858 Standard
1 Socket spanner insert 18x12.5 001.798 Option
1 Socket spanner insert 30x12.5 001.759 Option
1 Socket spanner insert 24x12.5 001.757 Option
1 Thickness gauges 0.05-1 000.451 Option
1 Receptacle - Inventory
1 Lifting tackle - Inventory
1 Combination spanner (set) - Inventory
1 Cleaning trough - Inventory
2 Ring nut M16 - Inventory
2010-03-17

1 Pipe brush - Inventory

2 Shackle A0.6 - Inventory
48/60B

2 Washer B17 - Inventory

1 Safety goggles - Inventory

6704 322.01-02 EN 1 (18)

322.01 MAN Diesel & Turbo

Quantity Designation Number Status

Charge air cooler

1 Protective gloves - Inventory

2 Hexagon bolt M16x50 - Inventory
1 Hexagon screwdriver (set) - Inventory
2 Rope - Inventory
1 Sealing compound (Silicone) - Inventory
1 Cleaning medium - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
000.08 000.40

Technical data
Designation Information
Cooler bundle 1050 kg
Cover 210 kg
Test pressure of cooler bundle (water) 9 bar

Work sequence 1 - Checking the charge air cooler

The degree of contamination dictates how often the charge air cooler should
be cleaned. You should therefore regularly connect a digital pressure gauge
(009.090) upstream and downstream of the charge air cooler and take
measurements (see Work Card 000.40).

Cleaning the charge air cooler

The charge air cooler needs to be cleaned on the air side if the differential
pressure in the upper load range has reached 50 mbar.
Work Cards, classified into sub-assemblies

Check the cooling water inlet and outlet temperature during operation, and
continuously monitor the output of the charge air cooler by recording the
upstream and downstream charge air temperature.
Check the pipe connections for leaks.
Check that the connection between the cooler housing (6) and cooler bundle
(1) is airtight.
Inspect the charge air cooler for leaks.
Work sequence 2 - Removing the cooler bundle
Starting position Cooling water has cooled down to at least 50°C. Casing and safety guard
have been removed (if installed).
2010-03-17

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
48/60B

suspended loads!

2 (18) 6704 322.01-02 EN

 MAN Diesel & Turbo 322.01

Work steps 1. Drain cooling water from cooling water supply and drain line.

Charge air cooler

2. Place a container underneath the charge air cooler to trap the liquid.
3. Remove two covers (12) on the underside of the cooler housing. See
Fig. 2.
4. Unscrew screw plug (10) on the deflection chambers (9 and 14) and
drain cooling water from the cooler bundle (1) (approx. 130 litres).

Charge air cooler without continuous ventilation

In charge air coolers without continuous ventilation, open drain plugs (2)
on the connection chamber (4).

5. Screw the screw plug (10) including seal (11) back into the deflection
chambers (9 and 14) and reinstall the covers (12) on the underside of
the cooler housing.
6. Detach the cooling water supply and discharge pipe and also the ven-
tilation pipe (if installed) from the connection chamber (4).
7. Unscrew four hexagon bolts (16) on the underside of the cooler housing.
See Fig. 3.
8. Unscrew hexagonal socket screws (19) on the top of the charge air
cooler. See Fig. 4.
9. Fasten ring nuts (23) to cover (7). See Fig. 5/I.
10. Fasten the rope (21) with the shackle (22) to the ring nuts (23) and attach
it to lifting gear. Lightly tension the rope.
11. Unscrew hexagon bolts (26 and 28) and remove cover (7). Set cover
down on support and remove tool. See Fig. 5.
12. Unscrew the hexagonal socket screws (30) next to the suspension
brackets. See Fig. 6/I.
13. Attach rope (21) with shackle (002.454) to suspension straps and sus-
pend from lifting gear. See Fig. 5/II.

Work Cards, classified into sub-assemblies

Cast-on suspension brackets
The sole purpose of the cast-on suspension brackets on the connection
chamber (4) is to attach the cooler bundle – they must not be used to
remove the whole charge air cooler!
If you wish to remove the whole charge air cooler, use the separate
suspension devices provided on the side of the cooler housing!

14. Carefully lift the cooler bundle (1) and take it sideways out of the cooler
housing (6). See Figs. 6 and 7.
15. Set the cooler bundle down in the cleaning tank.
16. Clean the inner face of the cooler housing to remove deposits.
2010-03-17

Work sequence 3 - Cleaning the cooler bundle (air side)

Brush finned tubes with cleaning fluid or rinse in undiluted solvent. See Table
48/60B

1.

6704 322.01-02 EN 3 (18)

322.01 MAN Diesel & Turbo

Some cleaning media have a burning effect on the skin when undiluted,
Charge air cooler

so wear safety goggles and plastic gloves when using them!

Follow instructions issued by the manufacturing company!

Cleaning in the event of heavy soiling or encrustation

If the finned pipes are heavily soiled or encrusted, the coating must be
immersed in cleaning fluid for several hours to allow it to soften. To do
this, place the cooler bundle upright in the cleaning tank and seal the
opening for the cooling water pipes on the connection chamber (4) to
stop cleaning fluid from entering the interior of the cooler bundle.
When using a water-soluble cleaning agent, rinse the cooler bundle with
plenty of water or blow through with compressed air once you have
finished cleaning.

The recommended cleaning agents include the following:

Designation Manufacturer
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 ACC-9 Drew Chemical Corp.
Boonton
New Jersey/USA
Air Cooler Cleaner ACC/ME Drew Chemical Corp.
Boonton
New Jersey/USA
Atlas D.G. Cleaner Atlas Mc Alpine LTD
Erith
Work Cards, classified into sub-assemblies

Kent/England
Air Cooler Cleaner Nalfleet Marine Chemicals
"Sea Shield" ACC 79101 Northwich, Cheshire
CW8 4DX/U.K.
Norus Degreaser Norus Sales Co.
Stabekk/Norway
Table 1: Cleaning agent/Manufacturer
Work sequence 4 - Cleaning the cooler bundle (water side)

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!
2010-03-17

Work steps 1. Lift cooler bundle (1).

48/60B

2. Unscrew hexagonal socket screws (32) and remove retainer plate (15).
See Fig. 9.

4 (18) 6704 322.01-02 EN

 MAN Diesel & Turbo 322.01

3. Unscrew the hexagon nuts (34) and remove the hexagon bolts (38). See

Charge air cooler

Fig. 10/I.
4. Unscrew hexagonal socket screws (36) and remove deflection chamber
(9) including graphite seal (33). See Fig. 10/I.
5. Remove the second deflection chamber (14) in the same manner. See
Item 3 and 4 / see Fig. 10/II.
6. Set down cooler bundle (1).
7. Unscrew hexagonal socket screws (30 and 40) and remove connection
chamber (4) including graphite seal (39). Place connection chamber on
support. See Fig. 11.
8. Remove the tool.
9. Loosen deposits in finned tubes with wire brush and rinse with strong
water jets.
For the removal of lime deposits, see Work Card 000.08.
Work sequence 5 - Installing the cooler bundle
Starting position Inside of the cooler housing and cooler bundle have been cleaned.

Danger of death when lifting and moving loads!

Unless absolutely necessary, do not enter or remain in the area below
suspended loads!

Work steps 1. Clean and degrease all sealing surfaces on cooler housing (6), cover (7),
cooler bundle (1), connection chambers (4) and deflection chambers (9
and 14).
2. Attach rope (21) with shackle (002.454) to suspension straps and sus-
pend from lifting gear. Lift the connection chamber (4).
3. Place connection chamber (4) including new graphite seal (39) on cooler

Work Cards, classified into sub-assemblies

bundle (1). See Fig. 11.
4. Oil thread and contact surfaces of the hexagonal socket screws (40) with
clean lube oil, screw on and tighten with the specified torque in three
steps:
1st Step. . . 100 Nm
2nd Step. . . 160 Nm
3rd Step. . . 200 Nm.
Tighten the hexagonal socket screws alternately, towards the outside
starting from the centre.
5. Oil thread and contact surfaces of the hexagonal socket screws (30) with
clean lube oil, then screw in position, including extending sleeves (31)
and tighten with the specified torque in three steps:
1st Step. . . 100 Nm
2010-03-17

2nd Step. . . 160 Nm

3rd Step. . . 200 Nm.
Tighten the hexagonal socket screws alternately, across the diagonals,
48/60B

towards the outside starting from the centre.

6. Lift cooler bundle (1).

6704 322.01-02 EN 5 (18)

322.01 MAN Diesel & Turbo

7. Place deflection chamber (9) including new graphite seal (33) on cooler
Charge air cooler

bundle (1). See Fig. 10/I.

8. Oil thread and contact surfaces of the hexagonal socket screws (36) with
clean lube oil, then screw in position, including extending sleeves (37)
and tighten with the specified torque in three steps:
1st Step. . . 100 Nm
2nd Step. . . 160 Nm
3rd Step. . . 200 Nm.
Tighten the hexagonal socket screws alternately, across the diagonals,
towards the outside starting from the centre.
9. insert hexagon screws (38) in holes, oil thread and contact surfaces of
the hexagon nuts (34) with clean lube oil, then screw on, including
washers (35) and tighten with the specified torque in three steps:
1st Step. . . 100 Nm
2nd Step. . . 160 Nm
3rd Step. . . 200 Nm.
Tighten the hexagon nuts alternately.
10. Fit the second deflection chamber (14) in the same manner. See Items
7 to 9 / see Fig. 10/II.
11. Place retainer plate (15) on deflection chambers (9 and 14), oil thread
and contact surfaces of the hexagonal socket screws (32) with clean
lube oil and tighten with the specified torque in three steps:
1st Step. . . 100 Nm
2nd Step. . . 160 Nm
3rd Step. . . 200 Nm.
Tighten the hexagonal socket screws alternately, across the diagonals,
towards the outside starting from the centre. See Fig. 9.
12. Carry out a pressure test on the cooler bundle (1).
13. Check that there are no loose parts in the cooler housing (6).
14. Move the cooler bundle (1) along the side of the cooler housing (6). See
Fig. 8.
Work Cards, classified into sub-assemblies

15. Apply temperature-resistant silicone to the sealing surface on the top of

the cooler housing.
16. Install the cooler bundle (1) carefully into the cooler housing (6) from the
side. Lower the cooler bundle until the top tube plate is roughly 20 mm
above the cooler housing. See Fig. 7.
17. Oil thread and contact surface of the hexagon bolts (16) with clean lube
oil, then screw locking washers (17) and washers (18) into retainer plate
(15). See Fig. 3.

Installing the locking washers

Ensure correct installation of the locking washers.
2010-03-17

18. Lower the cooler bundle (1) completely into the cooler housing (6).
48/60B

6 (18) 6704 322.01-02 EN

 MAN Diesel & Turbo 322.01

Gap between the top tube plate and top of the cooler housing

Charge air cooler

After the cooler bundle has been lowered all the way down, the gap
between the top tube plate and the top of the cooler housing must not
be more than 1 mm. This gap is closed when the retainer plate is screwed
in position.

19. Align the cooler bundle (1) in the cooler housing (6). To do this, push the
top and bottom end of the cooler bundle towards the air inlet.
20. Detach the tool.
21. Fasten ring nuts (23) to cover (7). See Fig. 5/I.
22. Fasten the rope (21) with the shackle (22) to the ring nuts (23) and attach
it to lifting gear. Lift cover (7).
23. Apply temperature-resistant silicone to the sealing surfaces on the cover
(7).
24. Attach cover (7) carefully to the cooler housing (6). See Fig. 5.
25. Oil thread and contact surfaces of the hexagon bolts (26 and 28) with
clean lube oil, then screw locking washers (27 and 29) into the cooler
housing (6). See Fig. 5.

Installing the locking washers

Ensure correct installation of the locking washers.

26. Tighten hexagon bolts (26) with a torque of 220 Nm.

Tighten the hexagon bolts alternately and crosswise, starting from the
centre and working outwards.
27. Tighten hexagon bolts (28) with a torque of 90 Nm.
Tighten the hexagon bolts alternately towards the outside starting from
the centre.
28. Oil thread and contact surfaces of the hexagonal socket screws (19) with

Work Cards, classified into sub-assemblies

clean lube oil, then screw in, including the washers (20) and tighten with
a torque of 180 Nm.
Tighten the hexagonal socket screws alternately, across the diagonals,
towards the outside starting from the centre.
29. Screw hexagon head bolts (16) all the way in and tighten with a torque
of 430 Nm.
Tighten the hexagon head bolts alternately towards the outside starting
from the centre.
30. Install cooling water inlet and discharge pipes and the ventilation pipes
(if present) on the connection chamber (4).
31. Open screw plugs (2) after opening the inlet and outlet of the cooling
water pipes.
2010-03-17

Bleeding the cooler bundle

Keep screw plugs open until the air has completely escaped from the
48/60B

cooling bundle.

6704 322.01-02 EN 7 (18)

322.01 MAN Diesel & Turbo

32. Check all pipe connections for tightness after commissioning.

Charge air cooler

33. Check air tightness between cooler housing (6) and cooler bundle (1).
34. Examine charge air cooler for leaks.
Work Cards, classified into sub-assemblies

1 Cooler bundle 5 Air intake housing

2 Screw plug 6 Cooler housing
3 Seal 7 Cover
4 Connection chamber 8 Housing
Figure 1: Charge air cooler
2010-03-17
48/60B

8 (18) 6704 322.01-02 EN

 MAN Diesel & Turbo 322.01

6 Cooler housing 11 Seal 14 Deflection chamber

Charge air cooler
Work Cards, classified into sub-assemblies
9 Deflection chamber 12 Cover I-II Work steps
10 Screw plug 13 Hexagon bolt
Figure 2: Charge air cooler - Removal/installation of the cooler bundle
2010-03-17

48/60B

6704 322.01-02 EN 9 (18)

322.01 MAN Diesel & Turbo
Charge air cooler

6 Cooler bundle 17 Locking washer

15 Retaining plate 18 Washer
Work Cards, classified into sub-assemblies

16 Hexagon bolt I-II Work steps

Figure 3: Charge air cooler - Removal/installation of the cooler bundle

2010-03-17
48/60B

10 (18) 6704 322.01-02 EN

 MAN Diesel & Turbo 322.01

Charge air cooler

1 Cooler bundle 19 Hexagonal socket screw
6 Cooler housing 20 Washer
7 Cover
Figure 4: Charge air cooler - Removal/installation of the cooler bundle

Work Cards, classified into sub-assemblies

2010-03-17

48/60B

6704 322.01-02 EN 11 (18)

322.01 MAN Diesel & Turbo
Charge air cooler
Work Cards, classified into sub-assemblies

1 Cooler bundle 23 Ring nut M16 28 Hexagon bolt

6 Cooler housing 24 Washer B17 29 Locking washer
7 Cover 25 Hexagon bolt M16x50 I-II Work steps
21 Rope 26 Hexagon bolt
22 Shackle A0.6 27 Locking washer
2010-03-17

Figure 5: Charge air cooler - Removal/installation of the cooler bundle

48/60B

12 (18) 6704 322.01-02 EN

 MAN Diesel & Turbo 322.01

Charge air cooler

Work Cards, classified into sub-assemblies
2010-03-17

4 Connection chamber 31 Extending sleeve

21 Rope I-II Work steps
48/60B

30 Hexagonal socket screw

Figure 6: Charge air cooler - Removal/installation of the cooler bundle

6704 322.01-02 EN 13 (18)

322.01 MAN Diesel & Turbo
Charge air cooler

1 Cooler bundle 6 Cooler housing

Work Cards, classified into sub-assemblies

Figure 7: Charge air cooler - Removal/installation of the cooler bundle

2010-03-17
48/60B

14 (18) 6704 322.01-02 EN

 MAN Diesel & Turbo 322.01

1 Cooler bundle 6 Cooler housing

Charge air cooler
Work Cards, classified into sub-assemblies
Figure 8: Charge air cooler - Removal/installation of the cooler bundle
2010-03-17

48/60B

6704 322.01-02 EN 15 (18)

322.01 MAN Diesel & Turbo
Charge air cooler

9 Deflection chamber 15 Retaining plate

14 Deflection chamber 32 Hexagonal socket screw
Work Cards, classified into sub-assemblies

Figure 9: Charge air cooler - Removing/refitting the retainer plate

2010-03-17
48/60B

16 (18) 6704 322.01-02 EN

 MAN Diesel & Turbo 322.01

1 Cooler bundle 34 Hexagon nut 38 Hexagon bolt

Charge air cooler
Work Cards, classified into sub-assemblies
9 Deflection chamber 35 Washer I-II Work steps
14 Deflection chamber 36 Hexagonal socket screw
33 Graphite seal 37 Extending sleeve
Figure 10: Charge air cooler - Removing/refitting the deflection chambers
2010-03-17

48/60B

6704 322.01-02 EN 17 (18)

322.01 MAN Diesel & Turbo
Charge air cooler
Work Cards, classified into sub-assemblies

1 Cooler bundle 31 Extending sleeve

4 Connection chamber 39 Graphite seal
21 Rope 40 Hexagonal socket screw
30 Hexagonal socket screw
Figure 11: Charge air cooler - Removing/refitting the connection chamber
2010-03-17
48/60B

18 (18) 6704 322.01-02 EN

MAN Diesel & Turbo 419

Indicating device
000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.28-1 EN 1 (2)

 MAN Diesel & Turbo
Indicating device

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.28-1 EN

 MAN Diesel & Turbo 419.01

Indicator valve

Indicating device
open and close

Summary
Ensure correct execution of work. Open and close the indicator valve by
using a tool for determining the ignition and compression pressure.
The work includes: Opening the indicator valve, Collect performance data
and Closing the indicator valve.
Tools/aids required
Quantity Designation Number Status
1 Box spanner 419.011 Standard
1 Protective gloves - Inventory

Corresponding Work Cards

Work card Work card Work card
000.25

Work sequence - Open/close indicator valve

Starting position Engine at desired performance level in stable operation. Steady state con-
dition of operational values is reached.
Work steps 1. Unscrew the handwheel and remove the protection cap (2). See Fig. 2.

2. Fit box spanner (419.011) on indicator valve (6). See Fig. 3.

Danger of injury from jet of fire!

Do not step in front of the fire jet!

Work Cards, classified into sub-assemblies

3. Open the indicator valve (6) with socket spanner and keep it open for 2
to 3 ignition strokes to remove soot or combustion particles which have
lodged themselves in the indicator pipe (4).
4. Close indicator valve (6) using a box spanner.
5. Screw the pressure sensor of the ignition pressure measuring unit
(419.019 or 419.015) on indicator valve (6), open indicator valve and
carry out the measurement (see Work Card 000.25).
6. Close indicator valve (6) again after the measurement is complete and
unscrew pressure sensor.
48/60B;L48/60CR

7. Remove box spanner.

2009-04-27

8. Fit the protection cap (2) and screw the handwheel onto the indicator
valve (6). See Fig. 1.

6725 419.01-01 EN 1 (4)

419.01 MAN Diesel & Turbo
Indicating device

1 Cylinder head cover 4 Indicator pipe

2 Protection cap 5 Cylinder head
3 Casing
Figure 1: Indicator valve with protection cap fitted
Work Cards, classified into sub-assemblies
48/60B;L48/60CR

2009-04-27

2 (4) 6725 419.01-01 EN

 MAN Diesel & Turbo 419.01

Indicating device
1 Cylinder head cover 3 Casing
2 Protection cap 6 Indicator valve
Figure 2: Removal and fitting of the protection cap

Work Cards, classified into sub-assemblies

48/60B;L48/60CR
2009-04-27

6725 419.01-01 EN 3 (4)

419.01 MAN Diesel & Turbo
Indicating device

3 Casing 6 Indicator valve

Figure 3: Indicator valve with fitted box spanner
Work Cards, classified into sub-assemblies
48/60B;L48/60CR

2009-04-27

4 (4) 6725 419.01-01 EN

MAN Diesel & Turbo 434

Fuel injection pipe /Buffer piston/Fuel pipe

000 Sub-assembly overview
009 Foundations/Bearings
012 Cylinder crankcase/tie rod
020 Crankshaft/Coupling bolts
021 Crankshaft bearing/main thrust bearing
027 Torsional vibration damper
030 Connecting rod/Big-end bearing
034 Piston/Piston rings
050 Top land ring/cylinder liner
055 Cylinder head/Valve seat rings/Safety valve
073 Covering/Crankcase cover
100 Control device operating mechanism
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/control arm
112 Push rods

6704 3.29-1 EN 1 (2)

 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe

113/114Inlet and exhaust valves

125 Operating device
140 Speed regulation
160-162Starting air pilot valve/Starting valve/Main
starting valve
200 Fuel injection pump
202 Fuel injection timer
203 Governor control linkage
209 Camshaft
221 Fuel injection valve
280-289Charge air and exhaust pipe
300/350Lubricating oil and cooling water pump
322 Charge air cooler
419 Indicating device
434 Fuel injection pipe /Buffer piston/Fuel pipe

2 (2) 6704 3.29-1 EN

 MAN Diesel & Turbo 434.01

Fuel injection pipe

Fuel injection pipe /Buffer piston/Fuel pipe

removing and refitting

Summary
Execute work on time according to the maintenance schedule, check com-
ponents for quality/wear condition, ensure / restore operating reliability.
Fuel injection pipes must be removed to perform maintenance and repair
work.
The work/work steps include:
removing the components,
refitting the components.
Safety requirements
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Plate for adjustable wrench 41 009.074 Standard
1 Torque wrench 008.017 Standard
1 Cross handle 001.891 Option
1 Combination spanner (set) - Inventory
1 Lubricant (containing molybdenum disulphide) - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work Cards, classified into sub-assemblies

Work card Work card Work card
000.30 221.01 434.02
434.03

Technical data
Designation Information
Fuel injection pipe 4,5 kg

Work sequence 1 - Removing fuel injection pipe

Work steps 1. Close shut-off valve on fuel admission pipe.
48/60B;51/60DF
2007-12-10

2. Release hexagon nuts on fuel injection valve and thread off (see Work
Card 221.01).
3. Loosen nut (9).
4. Release hexagon bolts (7) and unscrew.

6707 434.01-01 EN 1 (5)

 434.01 MAN Diesel & Turbo

5. Loosen and unscrew hexagon bolts (3), watching out for cup springs (5).
Fuel injection pipe /Buffer piston/Fuel pipe

6. Push back flange (4 and 6).

7. Unscrew nut (9) and slide back.
8. Pull off pressure tube (8) from threaded piece (2).
9. Remove fuel injection pipe.

Removing several fuel injection pipes

If several fuel injection pipes are detached, identify them such that each
fuel injection pipe will again be installed on the same cylinder.

10. Remove flange (4).

11. Remove the O-ring seals (10 and 15).
12. Clean fuel injection pipe externally.
13. Clean sealing faces on the pressure pipe (8) and check for damage, if
necessary dismantle fuel injection pipe and rework sealing faces (see
Work Card 434.02 and 434.03).

Work sequence 2 - Attachment of fuel injection pipe pipe

Starting position Fuel injection pipe is cleaned.

Installing several fuel injection pipes

If several fuel injection pipes were detached, pay attention to the
markings made on them when reassembling (see work sequence 1), so
that each fuel injection pipe will be attached to the same cylinder.

Work steps 1. Clean the sealing face on threaded piece (2) and on fuel injection pump
(11) and check for damage.
2. Insert new O-ring seals (10 and 15), oiled with clean lubricating oil, in
ring groove,ensuring that they are tensioned equally on the entire
Work Cards, classified into sub-assemblies

periphery and are not twisted.

3. Slide flange (4) over flange (6).
4. Apply MoS2 lubricant on threads of the nut (9).
5. Check that nuts (12 and 14) are screwed on to pressure tube (8) to the
extent that snap ring (13) is in contact with the pressure tube. See Fig.
1.

Leakage on the pressure pipe connections

If the nuts are not screwed up to make contact between the snap ring
and the pressure tube, this can cause leakages on the pressure tube
connections!
48/60B;51/60DF

2007-12-10

6. Insert pressure pipe (8) into fuel injection pump (11) and screw the nut
(9) in further by two or three turns.
7. Insert pressure tube (8) in the adapter on the threaded piece (2).
8. Slide flange (6) further until it rests on the nut (14).

2 (5) 6707 434.01-01 EN

 MAN Diesel & Turbo 434.01

9. Thread in hexagon bolts (7) in threaded piece (2) and tighten.

Fuel injection pipe /Buffer piston/Fuel pipe

10. Screw in nut (9) completely and tighten with specified torque (see Work
Card 000.30).
11. Tighten hexagon nut on fuel injection valve with specified torque (see
Work Card 221.01).
12. Slide flange (4) forward up to stop.
13. Screw in hexagon bolts (3) including new cup springs (5) in cylinder head
(1) and tighten.

Hexagon bolts and cup springs

Two cup springs are to be used per hexagon bolt.

14. Open shut-off valve on fuel admission pipe.

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2007-12-10

6707 434.01-01 EN 3 (5)

 434.01 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe
Work Cards, classified into sub-assemblies

1 Cylinder head 6 Flange 11 Fuel injection pump

2 Threaded piece 7 Hexagon bolt 12 Nut
48/60B;51/60DF

3 Hexagon bolt 8 Pressure tube 13 Snap ring

2007-12-10

4 Flange 9 Nut 14 Nut

5 Cup spring 10 O-ring seal 15 O-ring seal
Figure 1: Fuel injection pipe

4 (5) 6707 434.01-01 EN

 MAN Diesel & Turbo 434.01

Fuel injection pipe /Buffer piston/Fuel pipe

Work Cards, classified into sub-assemblies
9 Nut 11 Fuel injection pump
Figure 2: Fuel injection pipe - Tightening the nuts with torque 48/60B;51/60DF
2007-12-10

6707 434.01-01 EN 5 (5)

 MAN Diesel & Turbo 434.02

Fuel injection pipe

Fuel injection pipe /Buffer piston/Fuel pipe

dismantling and assembling

Summary
Execute work on time according to the maintenance schedule, check com-
ponents for quality/wear condition, ensure / restore operating safety. Fuel
injection pipes must be dismantled for inspection and rework on the pres-
sure pipe sealing faces.
The jobs/ work steps extend to: Dismantling and assembling components.
Tools/aids required
Quantity Designation Number Status
1 Combination spanner (set) - Inventory
1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
434.03

Work sequence 1 - Dismantling of fuel injection pipe

Starting position Fuel injection pipe is detached.

Work steps 1. Slide nut (6) back and unscrew nut (7).

Left-hand threads
Nut (7) has left hand threads!

Work Cards, classified into sub-assemblies

2. Pull out nut (6).
3. Slide back flange (3), until nut (1) is accessible.
4. Unscrew nut (1).

Left-hand threads
Nut (1) has left hand threads!

5. Take off flange (3).

6. Remove the O-ring seals (5 and 8).
7. Clean all the components and check for damage. Replace if necessary.
2007-06-15

8. If necessary, rework sealing faces on pressure tube (4) (see Work Card
434.03).
L48/60B

6707 434.02-01 EN 1 (2)

 434.02 MAN Diesel & Turbo

Work sequence 2 - Assembling the fuel injection pipe

Fuel injection pipe /Buffer piston/Fuel pipe

Starting position Individual parts are cleaned, damaged sealing faces on pressure tube, if
any, are reworked.
Work steps 1. Insert new O-ring seals (5 and 8), oiled with clean lubricating oil, in ring
groove,ensuring that they are tensioned equally on the entire periphery
and are not twisted.
2. Slide flange (3) and nut (6) up on pressure tube (4).
3. Screw the nuts (1 and 7) on pressure tube (4), until snap ring (2) is in
contact with pressure tube. See Fig. 1.

Left-hand threads
Nuts (1 and 7) have left hand threads!

Leakage on the pressure pipe connections

If the nuts are not screwed in up to contact of the snap ring on the
pressure pipe, this can cause leakages in the pressure pipe connections
after the attachment of the fuel injection pipe!
Work Cards, classified into sub-assemblies

1 Nut 5 O-ring seal

2 Snap ring 6 Nut
3 Flange 7 Nut
4 Pressure tube 8 O-ring seal
2007-06-15

Figure 1: Fuel injection pipe

L48/60B

2 (2) 6707 434.02-01 EN

 MAN Diesel & Turbo 434.03

Fuel injection pipe

Fuel injection pipe /Buffer piston/Fuel pipe

Grind sealing faces on pressure tube

Summary
Check components for state/wear condition, ensure/ restore operational
safety.
The sealing faces on the pressure pipe of the fuel injection pipe are to be
checked for damage at every deinstallation and reworked if necessary.
The work includes:
Creating a correct contact pattern.
Tools/aids required
Quantity Designation Number Status
1 Pressure pipe grinding device 434.044 Option
1 Adapter plate 434.044-1 Option
1 Threaded ring 434.044-2 Option
1 Bearing ring 434.044-3 Option
1 Bearing flange 434.044-4 Option
1 Adapter flange (pressure pipe) 434.044-5 Option
1 Spacer ring 434.044-8 Option
2 Bearing block 434.044-10 Option
1 Swivel arm 434.044-11 Option
1 Bracket 434.044-12 Option
1 Stop 434.044-13 Option
1 Stop gauge (Pressure tube) 434.044-14 Option
1 Grinding wheel 434.044-16 Option
1 Baseplate 434.044-17 Option

Work Cards, classified into sub-assemblies

1 Carriage 434.044-18 Option
1 Shaft 434.044-19 Option
1 Stop 434.044-20 Option
1 Counter flange (threaded piece) 434.044-21 Option
2 Ball bearing 434.044-24 Option
2 Ball bearing 434.044-25 Option
1 Hook wrench 434.044-37 Option
48/60;48/60B;51/60DF

1 Face spanner 434.044-38 Option

2 Clamping lever 434.044-41 Option
5 Emery paper 434.044-44 Option
2007-06-15

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 - Option

6707 434.03-02 EN 1 (6)

 434.03 MAN Diesel & Turbo

Quantity Designation Number Status

Fuel injection pipe /Buffer piston/Fuel pipe

1 Safety goggles - Inventory

1 Cleaning medium - Inventory

Corresponding Work Cards

Work card Work card Work card
434.02

Work sequence 1 - Attachment of the pressure pipe to the pressure pipe grinding device
Starting position Fuel injection pipe is disassembled and cleaned (see Work Card 434.02).

Installation of the pressure pipe grinding device and

contamination of the pressure pipe
The pressure pipe grinding fixture must be installed and/or operated on
a firm base. Vibration of the fixture affects the surface quality of the
sealing faces to be ground.
The pressure pipe to be ground must be absolutely free from lubricating
oils and greases. Contamination of any kind, especially lubricants,
reduces the service life of the emery paper considerably.

Work steps 1. Release both clamping levers (434.044-41) and swivel out electrical
angle grinders (3) with bracket (434.044-12) up to the stop.
2. Screw on and tighten adapter flange (434.044-5) with hexagon socket
bolts (2) on threaded ring (434.044-2). See Fig. 1.
3. Fasten stop gauge (434.044-14) on adapter flange with two hexagon
socket bolts (6). See Fig. 3.

Fastening the stop gauge

When fixing the stop gauge on adapter flange, support with tommy bar
(000.262) on the threaded ring.
Work Cards, classified into sub-assemblies

4. Screw-on counter flange (434.044-21) on the pressure tube (1).

Threads on pressure pipe

The threads on pressure tube are left hand threads!

5. Screw in the pressure tube (1) in the adapter flange by using counter
flange, until pressure tube taper is in contact with the stop gauge.
48/60;48/60B;51/60DF

6. Screw on counter flange on adapter flange and tighten by using face

spanner (434.044-38) and hook wrench (434.044-37).
7. Detach stop gauge (434.044-14).
2007-06-15

8. Insert tommy bar (000.262) radially in threaded ring (434.044-2) and

screw it in on adapter place (434.044-1) up to the stop.

2 (6) 6707 434.03-02 EN

 MAN Diesel & Turbo 434.03

Screw in the threaded ring.

Fuel injection pipe /Buffer piston/Fuel pipe

It is important that for every new pressure tube to be ground, the
threaded ring be screwed in until it is comes to rest on the adapter plate!

9. Press the yellow arresting head on the electrical angle grinder (3), set up
grinding wheel (434.044-16) with emery paper (434.044-44) on electrical
angle grinder and fasten using fastening nuts.
10. Pull back slide (434.044-18) with support adjusting crank (4).
11. Swing the bracket (434.044-12) up to the stop and fix on the slide with
two clamping levers (434.044-41).

Work sequence 2 - Regrinding the sealing faces on pressure pipe

Starting position pressure pipe is attached correctly to the pressure pipe grinding device.
Grinding wheel is mounted with new emery paper on electric angle grinder.

Rework of the sealing faces

The reworking of the sealing face is difficult and requires special care! It
is advisable to have this work executed at a service support location or
by MAN Diesel & Turbo staff!

Work steps 1. Swing the swivel arm (434.044-11) with electric angle grinder (3) up to
the right hand stop (5). See Fig. 2.
2. Drive grinding wheel (434.044-16) with support adjusting crank (4) on
the sealing face of the pressure pipe (1), until the grinding wheel touches
the sealing face.
3. Move swivel arm up to the left stop (434.044-13), such that the grinding
wheel faces the pressure pipe (1). See Fig. 4.

Wear safety goggles!

Wear safety goggles for grinding pressure tubes!

Work Cards, classified into sub-assemblies

4. Connect voltage supply for the electric angle grinder (3) and switch it
on.
5. Rotate pressure pipe (1) uniformly and move the swivel arm at the same
time with the electrical angle grinder (3) around the sealing face contour.

Do not touch!
The grinding wheel must not touch the adapter flange!
48/60;48/60B;51/60DF

6. The advance on the threaded ring (434.044-2) is effected by means of

the tommy bar (000.262). Maximum advance per work sequence is one
2007-06-15

division of the scale on the threaded ring.

6707 434.03-02 EN 3 (6)

 434.03 MAN Diesel & Turbo

Advance
Fuel injection pipe /Buffer piston/Fuel pipe

The advance is not on the support adjusting crank (4)! The adjusted
position remains unchanged during the entire grinding sequence!
Lightly rework the sealing faces, only smoothen removing as little
material as possible!

7. Move swivel arm up to the left stop, such that the grinding wheel faces
the pressure pipe (1). Switch off electric angle grinder (3).
8. Evaluate the result of the grinding process. Repeat the grinding process
until the sealing face has a uniform polished appearance.

Unrealisable contact pattern

If the required contact pattern cannot be realised with the pressure pipe
grinding device, it must be given for repairs to a MAN Diesel & Turbo
Customer Service workshop!

Used emery paper

Pull out used emery paper immediately and replaced by a new one.

9. Remove pressure pipe (1) from pressure pipe grinding device and
remove counter flange.
Work Cards, classified into sub-assemblies
48/60;48/60B;51/60DF

2007-06-15

1 Pressure tube 3 electric angle grinder

2 Hexagon socket bolt M5x10 4 Support adjusting crank
Figure 1: Pressure pipe grinding device with attached pressure pipe

4 (6) 6707 434.03-02 EN

 MAN Diesel & Turbo 434.03

Fuel injection pipe /Buffer piston/Fuel pipe

2 Hexagon socket bolt M5x10 5 Stop
Figure 2: Pressure pipe grinding tool

Work Cards, classified into sub-assemblies

48/60;48/60B;51/60DF
2007-06-15

1 Fuel injection pipe 6 Hexagon socket bolt M6x35

Figure 3: Attachment of the pressure pipe on the pressure pipe grinding device

6707 434.03-02 EN 5 (6)

 Work Cards, classified into sub-assemblies Fuel injection pipe /Buffer piston/Fuel pipe

6 (6)
48/60;48/60B;51/60DF
434.03

5 Stop

6707 434.03-02 EN
Figure 4: Right and left hand stop for the swivel arm
MAN Diesel & Turbo

2007-06-15
 MAN Diesel & Turbo 434.04

Buffer piston

Fuel injection pipe /Buffer piston/Fuel pipe

dismantling and assembling

Summary
Execute work on time according to the maintenance schedule, ensure cor-
rect execution of work, check components for state/wear condition.
Remove buffer piston at regular intervals. Renew the set of piston seals.
The work/work steps include: Dismantling components, renewing sealing
rings/packing elements, assembling components.
Safety requirements
- Operating media systems closed/depressurised
- Engine secured against starting
- Engine shut down
Personnel and time required
Number Qualification Duration in h
1 Technician 0,5

Tools/aids required
Quantity Designation Number Status
1 Thickness gauges 0.05-1 000.451 Option
1 Eye bolt 000.028 Standard
1 Combination spanner (set) - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Lubricant (Copa Slip) - Inventory
1 Lubricating oil, clean - Inventory

Work Cards, classified into sub-assemblies

Preliminary remark
If there are impact noises on the buffer piston during the operation, this is
an indication of a break in the compression spring (9). Spill pressure waves
of the fuel injection pumps in the fuel inflow and outflow systems can occur
even with a tight piston (6). Higher leakage fuel occurrence can be attributed
to damaged set of seals (8) or wear of piston (6) and bush (7). The buffer
piston must be dismantled without delay under such circumstances.
Work sequence 1 - Disassembling the buffer piston
Starting position Engine is stopped, fuel pipes are blocked and without pressure. Leak fuel
pipe is removed from the leak fuel connection (13). Buffer piston is detached.
2008-10-22

Work steps 1. Loosen and thread off hexagon socket bolts (3) evenly.
L48/60B

6707 434.04-01 EN 1 (5)

 434.04 MAN Diesel & Turbo

Existing tension due to compression spring

Fuel injection pipe /Buffer piston/Fuel pipe

The compression spring (9) is normally slack after loosening the hexagon
socket bolts (3)! With the piston (6) firmly at the end position however,
there are still spring forces on the cover (2) even on removing the cylinder
screws! It is therefore advisable to avoid anybody's presence in the axial
direction of the buffer piston when opening! Risk of injury!

2. Remove cover (2). See Fig. 2/A.

3. Screw eye bolt (000.028) in piston (6) and remove it.
4. Remove or remove washer (4), compression spring (9) and washer (10).
See Image 2/B.
5. Remove bush (7).
6. Remove O-ring seal (5), refer to figure 2/C.
7. Cut profile ring (11) and remove it, Remove O-ring seal (12) See figure
2/D.

Renew profile ring and O-ring seal

Renew profile ring and O-ring seal on each inspection of the buffer
piston.

8. Check piston (6) and bush (7) for movement, measure wear with thick-
ness gauges (000.451).

Exceeding the maximum clearance

When the maximum clearance (see Volume 010.005 Engine – Operating
Instructions) is exceeded, install new parts (piston and bush). A bush with
score-marks should be replaced due to the high leakage of fuel.

9. Examine compression spring (9) for cracks or fractures.

10. Clean all individual parts.
Work Cards, classified into sub-assemblies

Work sequence 2 - Assembly of the buffer piston

Starting position All individual parts are cleaned and checked for damages.

Work steps 1. Compress new O-ring seal (12) in the shape of a kidney and insert it into
the corresponding groove of the bush (7), ensuring that it is not twisted.
See Fig. 3.
2. Put new profile ring (11) in boiling water for five minutes, remove, dry,
press it into kidney shape and insert into appropriate groove of the bush
(7).

Danger of scalding!
Do not use bare hands to insert profile ring into boiling water or to take
2008-10-22

it out! Danger of scalding!

L48/60B

2 (5) 6707 434.04-01 EN

 MAN Diesel & Turbo 434.04

Installation of the profile ring

Fuel injection pipe /Buffer piston/Fuel pipe

Ensure correct installation position when installing the profile ring. See
figure 2/D.

3. Insert new O-ring seal (5) oiled with clean lubricating oil into the corre-
sponding groove of the cylinder (1), ensuring that it is not twisted.
4. Apply the lubricant Copaslip on the running surface of the bush (7).
5. Insert bush in the cylinder (1).
6. Insert washer (10) and compression spring (9) in cylinder (1), place
washer (4) on compression spring.
7. Apply the lubricant (Copa Slip) to the running surface of the piston (6).
8. Install piston (6) in bush (7).
9. Attach cover (2) to cylinder (1) by means of hexagon socket bolts (3).
Screw in and tighten hexagon socket bolts alternately.
10. Attach buffer piston with leakage fuel pipe.

Work Cards, classified into sub-assemblies

1 Cylinder 7 Sleeve
2 Cover 8 Set of seals, consisting of items 11 and 12
3 Hexagon socket bolt 9 Compression spring
4 Washer 10 Washer
5 O-ring seal 11 Profile ring
6 Piston 12 Washer
Figure 1: Buffer piston
2008-10-22

L48/60B

6707 434.04-01 EN 3 (5)

 434.04 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe
Work Cards, classified into sub-assemblies

1 Cylinder 6 Piston 11 Profile ring

2008-10-22

2 Cover 7 Sleeve 12 O-ring seal

3 Hexagon socket bolt 8 Set of seals 13 Connection for leakage fuel
4 Washer 9 Compression spring
L48/60B

5 O-ring seal 10 Washer

Figure 2: Dismantling and assembling the buffer piston

4 (5) 6707 434.04-01 EN

 Fuel injection pipe /Buffer piston/Fuel pipe
434.04

5 (5)
Work Cards, classified into sub-assemblies
L48/60B
Figure 3: Kidney-shaped compression of a ring

6707 434.04-01 EN
MAN Diesel & Turbo
2008-10-22
 MAN Diesel & Turbo 434.05

Fuel pipe

Fuel injection pipe /Buffer piston/Fuel pipe

removing and refitting

Summary
Ensure correct execution of work.
Fuel pipe (supply and return pipe) should be detached for certain service
work (e.g. removing the fuel injection pump).
The work/work steps include:
Dismantling components,
fitting components.
Safety requirements
- Operating media systems closed/depressurised
- Operating media systems drained
- Engine secured against starting
- Engine shut down
Tools/aids required
Quantity Designation Number Status
1 Removal and fitting fixture 200.111 Standard
1 Clamping piece 200.111-1 Standard
1 Plate 200.111-2 Standard
1 Combination spanner (set) 009.231 Option
1 Plastic hammer - Inventory
1 Hexagon screwdriver (set) - Inventory
1 Side cutter - Inventory
1 Locking wire - Inventory
1 Pliers for locking wire - Inventory

Work Cards, classified into sub-assemblies

1 Lubricating oil, clean - Inventory

Corresponding Work Cards

Work card Work card Work card
200.03

Technical data
Designation Information
Fuel pipe 6,5 - 8,5 kg
48/60B;51/60DF

Work sequence 1 - Detaching the fuel pipe (supply and return pipe)
2008-07-28

Danger of fire/Danger of explosions!

Do not smoke, do not use any open flames when working on fuel pipes
- danger of fire/danger of explosion!

6704 434.05-03 EN 1 (19)

 434.05 MAN Diesel & Turbo

Work steps 1. Cover fuel injection pumps (1 and 12) in the area of the fuel pipes (5 and
Fuel injection pipe /Buffer piston/Fuel pipe

6) by suitable means (for protection from escaping fuel).

2. Remove locking wire (13) for throttle screws (14 and 15) on adjacent fuel
injection pumps (12) and unscrew throttle screws. See Figs. 1 and 2.
3. Unscrew hexagon socket bolts (8) and remove, together with lockwash-
ers (9). Displace flanges (7 and 17). See Figure 2 and Figure 4/I.
4. Release hexagon socket bolts (3) and screw back by one to two revo-
lutions. Displace pipe clamps (10 and 16). See Fig. 4/I.
5. Fit clamping piece (200.111-1) on fuel pipe (6) and place plate
(200.111-2) on clamping piece. Insert hexagon bolts (22) by means of
clamping piece, screw into plate and tighten by hand. See Figure 4/I and
5.
6. Remove the fuel pipe from the fuel injection pump (1) by careful up and
down movement of the removal and fitting fixture (200.111) and simul-
taneous pulling of the fuel pipe (6) in the direction of the free engine end
(KGS), and displace as far as possible. See Figure 4/II, 6 and 7.

The fuel pipe cannot be displaced

If the fuel pipe cannot be displaced, release it by carefully tapping on the
removal and fitting fixture (200.111) (use wooden or copper support).

7. Detach removal and fitting fixture.

8. Displace second fuel pipe (5) in the same manner. See points 5 to 7 /
see figure 7.
9. Support the fuel pipes (5 and 6) with suitable means.
10. Unscrew hexagon socket bolts (8) and remove, together with lockwash-
ers (9). Displace flanges (7 and 17). See Fig. 8/I.
11. Release hexagon socket bolts (3) and screw back by one to two revo-
lutions. Displace pipe clamps (10 and 16). See Fig. 8/I.
Work Cards, classified into sub-assemblies

12. Fit the removal and fitting fixture to the fuel pipe (6). See Point 5 / see
Figure 5 and 8/l.
13. Displace the fuel pipe by careful up and down movement of the removal
and fitting fixture and simultaneous pulling of the fuel pipe (6) in the
direction of the free engine end (KGS) until the pipe clamps (2 and 18)
can be removed. See Figure 6 and 8/II.

Damage to the throttle screw

You must make sure that the fuel pipe is not pushed too far into the fuel
injection pump since otherwise the throttle screw fitted inside will be
damaged!
48/60B;51/60DF

The fuel pipe cannot be displaced

2008-07-28

If the fuel pipe cannot be displaced, release it by carefully tapping on the

removal and fitting fixture (200.111) (use wooden or copper support).

14. Unscrew hexagon socket bolts (3) and remove, together with lockwash-
ers (4). Remove pipe clamps (2 and 18). See Fig. 9/I.

2 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

15. Detach removal and fitting fixture (200.111), change over to second flat

Fuel injection pipe /Buffer piston/Fuel pipe

(D) and re-fit. See Fig. 9/I.
16. Remove the fuel pipe from the fuel injection pump (1) by careful up and
down movement of the removal and fitting fixture and simultaneous
pulling of the fuel pipe (6) in the direction of the coupling side (KS), and
displace as far as possible. See Figure 6, 9/ll and 10.
17. Detach removal and fitting fixture.
18. Displace second fuel pipe (5) in the same manner. See Points 12, 16 and
17 / see Figure 10.
19. Support the fuel pipes (5 and 6) with suitable means.
20. Remove fuel injection pump (1) (see Work Card 200.03). See Fig. 11.
21. Remove fuel pipes (5 and 6). See Figs. 12 and 13.
22. Remove the O-ring seals (21) and backing rings (20) from the adjacent
fuel injection pumps (12). See Fig. 2.
23. Use suitable means to close off the openings in the adjacent fuel injec-
tion pumps (12) and fuel injection pump drive to prevent the ingress of
dirt.
24. Remove pipe clamps (2, 10, 16 and 18), guide straps (11) and flanges
(7 and 17). See Figure 12/III and 13/III.
25. Clean all individual parts.

Work sequence 2 - Attaching the fuel pipe (supply and return pipe)

Danger of fire/Danger of explosions!

Do not smoke, do not use any open flames when working on fuel pipes
- danger of fire/danger of explosion!

Starting position All individual parts have been cleaned.

Work steps

Work Cards, classified into sub-assemblies

Correct fitting of the fuel pipes
Make sure that the individual fuel pipes are fitted correctly (see Figures):
Fixed bearing side . . . . . . Coupling side,
Floating bearing side . . . . . . Free engine end!

1. Remove plugs for openings on adjacent fuel injection pumps (12) and
fuel injection pump drive (see work sequence 1, Point 23).
2. Check new backing rings (20) and O-ring seal (21) for integrity.
3. Apply clean lubricating oil to backing rings (20) and place them in appro-
priate ring grooves. See Fig. 2.
48/60B;51/60DF
2008-07-28

4. Apply clean lubricating oil to O-ring seals (21), press them into a kidney
shape and place in appropriate grooves, ensuring that they are not twis-
ted. See Fig. 2.
5. Place flanges (7 and 17) on fuel pipes (5 and 6). See Fig. 13/III.

6704 434.05-03 EN 3 (19)

 434.05 MAN Diesel & Turbo

6. Oil the fuel pipes (5 and 6) on the floating bearing side and the new guide
Fuel injection pipe /Buffer piston/Fuel pipe

straps (11) with clean lubricating oil. Fit the guide straps to the fuel
pressure pipes.
7. Place the pipe clamps (10 and 16) over the guide straps (11) and loosely
screw in hexagon socket bolts (3) with new lockwashers (4) in the pipe
clamps. See Fig. 13/III.
8. Fit clamping piece (200.111-1) on fuel pipe (6) and place plate
(200.111-2) on clamping piece. Insert hexagon bolts (22) by means of
clamping piece, screw into plate and tighten by hand. See Fig. 5.
9. Oil the sealing face (C) on the fuel pipe (6) on the fixed bearing side with
clean lubricating oil.
10. Place the fuel pipe (6) with fixed bearing side on the adjacent fuel injec-
tion pump (12) and fit axially by carefully moving the removal and fitting
fixture (200.111) up and down and simultaneously pushing the fuel pipe
(6) in the direction of the coupling side (KS), making sure that the support
and O-ring seal (20 and 21) do not get damaged. See Fig. 13.
11. Detach removal and fitting fixture.
12. Install second fuel pipe (5) in the same manner. See points 8 to 11 / see
figure 13.
13. Support the fuel pipes (5 and 6) with suitable means.
14. Place flanges (7 and 17) on fuel pipes (5 and 6). See Fig. 12/III.
15. Insert pipe clamps (2 and 18) in the relevant grooves (E) on the fuel pipes
(5 and 6), loosely screw the hexagon socket bolts (3) including new
lockwashers (4) in the pipe clamps. See Figure 12/Ail and 14.
16. Oil the fuel pipes (5 and 6) on the floating bearing side and the new guide
straps (11) with clean lubricating oil. Fit the guide straps (11) on the fuel
pipes.
17. Place the pipe clamps (10 and 16) over the guide straps (11) and loosely
screw in hexagon socket bolts (3) with new lockwashers (4) in the pipe
clamps. See Fig. 12/III.
Work Cards, classified into sub-assemblies

18. Place the clamping piece on fuel pipe (6) and place the plate on the
clamping piece. Insert hexagon bolts (22) by means of clamping piece,
screw into plate and tighten by hand. See Fig. 5.
19. Oil the sealing face (C) on the fuel pipe (6) on the floating bearing side
with clean lubricating oil.
20. Place the fuel pipe (6) with floating bearing side on the adjacent fuel
injection pump (12) and fit axially by carefully moving the removal and
fitting fixture up and down and simultaneously pushing the fuel pipe (6)
in the direction of free engine end (KGS), making sure that the support
and O-ring seal (20 and 21) do not get damaged. See Fig. 12.
21. Detach removal and fitting fixture.
48/60B;51/60DF

2008-07-28

22. Install second fuel pipe (5) in the same manner. See points 18 to 20 /
see figure 12.
23. Support the fuel pipes (5 and 6) with suitable means.
24. Fit the fuel injection pump (1) (see Work Card 200.03).

4 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

25. Lightly oil backing rings (20) and O-ring seals (21) in the fuel injection

Fuel injection pipe /Buffer piston/Fuel pipe

pump (1) with clean lubricating oil.
26. Detach the removal and fitting fixture and fit to the second flat (D) on the
fuel pipe (5). See point 18.
27. Oil the sealing face (C) on the fuel pipe (5) on the fixed bearing side with
clean lubricating oil.
28. Place the fuel pipe on the fuel injection pump (1) axially and fix in position
by careful up and down movement of the removal and fitting fixture and
simultaneous pushing on the fuel pipe (5) in the direction of the coupling
side (KS), until the pipe clamp (2) is in contact with the fuel injection
pump, taking care that the support and sealing ring (20 and 21) do not
get damaged. See Fig. 4.
29. Detach removal and fitting fixture.
30. Fit the removal and fitting fixture on the second fuel pipe (6) and fit his
one in the same way. See Points 18, 27 to 29 / see Figure 4.
31. Fit the removal and fitting fixture to the fuel pipe (5) (see Point 18). Oil
the sealing face (C) on the floating bearing side with clean lubricating
oil. Place the fuel pipe on the fuel injection pump (1) axially and fit in
position by careful up and down movement of the removal and fitting
fixture and simultaneous pushing in the direction of the free engine end
(KGS), until the groove (E) is revealed for the pipe clamp (2). When fitting,
make sure that the backing ring and O-ring seal (20 and 21) do not get
damaged. See Fig. 9.
32. Detach the removal and fitting fixture and fit to the fuel pipe (6). See point
18.
33. Oil the sealing face (C) on the fuel pipe (6) on the floating bearing side
with clean lubricating oil.
34. Place the fuel pipe (1) axially and fit by careful up and down movement
of the removal and fitting fixture and simultaneous pushing of the fuel
pipe (6) in the direction of the free engine end (KGS) until the pipe clamps
(2 and 18) can be fitted. See Figure 8/ll and 9/l.

Work Cards, classified into sub-assemblies

Damage to the throttle screw
You must make sure that the fuel pipe is not pushed too far into the fuel
injection pump since otherwise the throttle screw fitted inside will be
damaged!

35. Insert pipe clamps (2 and 18) in the relevant grooves (E) on the fuel pipes
(5 and 6), loosely screw the hexagon socket bolts (3) including new
lockwashers (4) in the pipe clamps. See Fig. 8/II.
36. Detach the removal and fitting fixture and fit to the second flat (D) on the
fuel pipe (6). See point 18.
48/60B;51/60DF

37. Displace the fuel pipe by careful up and down movement of the removal
2008-07-28

and fitting fixture and simultaneous pulling of the fuel pipe (6) in the
direction of the coupling side (KS) until it comes into contact with the
adjacent fuel injection pump (12). See Fig. 8/I.
38. Align the fuel injection pump (1) and tighten the hexagon nuts with the
prescribed torque (see Work Card 200.03).

6704 434.05-03 EN 5 (19)

 434.05 MAN Diesel & Turbo

39. Tighten the hexagon socket bolts (3) for the pipe clamps (2 and 18) on
Fuel injection pipe /Buffer piston/Fuel pipe

the fixed bearing side/coupling side (KS).

40. Displace the flange (17) up to contact with the pipe clamps (2 and 18),
screw in hexagon socket bolts (8) including new lockwashers (9) and
tighten.
41. Displace the pipe clamps (10 and 16) up to contact with the fuel injection
pumps (1 and 12).
42. Tighten the hexagon socket bolts (3) for the pipe clamps (10 and 16) on
the floating bearing side/free engine end (KGS).
43. Displace the flange (7) up to contact with the pipe clamps (10 and 16),
screw in hexagon socket bolts (8) including new lockwashers (9) and
tighten.
44. Screw in throttle screws (14 and 15) including new sealing rings (19) in
adjacent fuel injection pump (12). See Figs. 1 and 2.

Correct installation of the throttle screws

Ensure correct installation of the individual throttle screws! Markings on
throttle screws and on the casing of the adjacent fuel injection pump
must match! Throttle screws and casing are marked as follows:
R - Fuel return flow
Z - Fuel supply!
The fuel return flow is above, the fuel inflow is below! See Fig. 1.

45. Secure throttle screws (14 and 15) by means of locking wire (13). See
Figs. 1 and 2.
46. Remove the covers in the area around the fuel pipes (5 and 6) (see work
sequence 1, Point 1).
47. Check all fuel pipes for leakages before starting the engine.
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2008-07-28

6 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

Fuel injection pipe /Buffer piston/Fuel pipe

1 Fuel injection pump 8 Hexagon socket bolt 15 Throttle screw (fuel return flow)
2 Pipe clamp (fixed bearing) 9 Lockwasher 16 Pipe clamp (floating bearing)
3 Hexagon socket bolt 10 Pipe clamp (floating bearing) 17 Flange
4 Lockwasher 11 Guide strip 18 Pipe clamp (fixed bearing)
5 Fuel pipe (Fuel return) 12 Adjacent fuel injection pump KS Coupling side
6 Fuel pipe (Fuel supply) 13 Locking wire KGS Free engine end
7 Flange 14 Throttle screw (fuel inflow)
Figure 1: Fuel injection pumps and fuel pipes

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2008-07-28

6704 434.05-03 EN 7 (19)

 434.05 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe

1 Fuel injection pump 8 Hexagon socket bolt 17 Flange

2 Pipe clamp (fixed bearing) 9 Lockwasher 18 Pipe clamp (fixed bearing)
3 Hexagon socket bolt 10 Pipe clamp (floating bearing) 19 Sealing ring
4 Lockwasher 11 Guide strip 20 Backing ring
5 Fuel pipe (Fuel return 13 Locking wire 21 O-ring seal
6 Fuel pipe (Fuel supply) 14 Throttle screw (fuel inflow) R Fuel return
7 Flange 15 Throttle screw (fuel return flow) Z Fuel supply
Figure 2: Fuel injection pumps and fuel pipes - Details of Figure 1
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2008-07-28

8 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

Fuel injection pipe /Buffer piston/Fuel pipe

Work Cards, classified into sub-assemblies

1 Fuel injection pump 10 Pipe clamp (floating bearing) 18 Pipe clamp (fixed bearing)
2 Pipe clamp (fixed bearing) 11 Guide strip KS Coupling side
5 Fuel pipe (Fuel return) 12 Adjacent fuel injection pump KGS Free engine end
6 Fuel pipe (Fuel supply) 16 Pipe clamp (floating bearing)
7 Flange 17 Flange
Figure 3: Fuel pipes - floating bearing (detail "T") / Fixed bearing (detail "U")
48/60B;51/60DF
2008-07-28

6704 434.05-03 EN 9 (19)

 434.05 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe
Work Cards, classified into sub-assemblies

1 Fuel injection pump 7 Flange 17 Flange

2 Pipe clamp (fixed bearing) 10 Pipe clamp (floating bearing) 18 Pipe clamp (fixed bearing)
3 Hexagon socket bolt 11 Guide strip KS Coupling side
5 Fuel pipe (Fuel return) 12 Adjacent fuel injection pump KGS Free engine end
6 Fuel pipe (Fuel supply) 16 Pipe clamp (floating bearing) I - II Work steps
Figure 4: Fuel pipes - removing/fitting
48/60B;51/60DF

2008-07-28

10 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

Fuel injection pipe /Buffer piston/Fuel pipe

5 Fuel pipe (Fuel return) 22 Hexagon bolt M10x70
6 Fuel pipe (Fuel supply) I-III Work steps
Figure 5: Fuel pipe - Fitting the removal and fitting fixture to the fuel pipe

Work Cards, classified into sub-assemblies

5 Fuel pipe (Fuel return) 6 Fuel pipe (Fuel supply)

Figure 6: Displacing the fuel pipe - Up/down movement of the removal and
fitting fixture
48/60B;51/60DF
2008-07-28

6704 434.05-03 EN 11 (19)

 434.05 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe

1 Fuel injection pump 6 Fuel pipe (Fuel supply) KS Coupling side

5 Fuel pipe (Fuel return) 12 Adjacent fuel injection pump KGS Free engine end
Figure 7: Fuel pipes - removing/fitting
Work Cards, classified into sub-assemblies
48/60B;51/60DF

2008-07-28

12 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

Fuel injection pipe /Buffer piston/Fuel pipe

Work Cards, classified into sub-assemblies

1 Fuel injection pump 7 Flange 18 Pipe clamp (fixed bearing)

2 Pipe clamp (fixed bearing) 10 Pipe clamp (floating bearing) KS Coupling side
3 Hexagon socket bolt 11 Guide strip KGS Free engine end
4 Lockwasher 12 Adjacent fuel injection pump I - II Work steps
5 Fuel pipe (Fuel return) 16 Pipe clamp (floating bearing)
6 Fuel pipe (Fuel supply) 17 Flange
48/60B;51/60DF

Figure 8: Fuel pipes - removing/fitting

2008-07-28

6704 434.05-03 EN 13 (19)

 434.05 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe
Work Cards, classified into sub-assemblies

1 Fuel injection pump 12 Adjacent fuel injection pump I - II Work steps

5 Fuel pipe (Fuel return) KS Coupling side
6 Fuel pipe (Fuel supply) KGS Free engine end
Figure 9: Fuel pipes - removing/fitting
48/60B;51/60DF

2008-07-28

14 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

Fuel injection pipe /Buffer piston/Fuel pipe

1 Fuel injection pump 6 Fuel pipe (Fuel supply) KS Coupling side
5 Fuel pipe (Fuel return) 12 Adjacent fuel injection pump KGS Free engine end
Figure 10: Fuel pipes - removing/fitting

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2008-07-28

6704 434.05-03 EN 15 (19)

 434.05 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe
Work Cards, classified into sub-assemblies

1 Fuel injection pump 12 Adjacent fuel injection pump I - II Work steps

5 Fuel pipe (Fuel return) KS Coupling side
6 Fuel pipe (Fuel supply) KGS Free engine end
Figure 11: Fuel pipes - removing/fitting
48/60B;51/60DF

2008-07-28

16 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

Fuel injection pipe /Buffer piston/Fuel pipe

Work Cards, classified into sub-assemblies

2 Pipe clamp (fixed bearing) 7 Flange 17 Flange

3 Hexagon socket bolt 10 Pipe clamp (floating bearing) 18 Pipe clamp (fixed bearing)
4 Lockwasher 11 Guide strip KS Coupling side
5 Fuel pipe (Fuel return) 12 Adjacent fuel injection pump KGS Free engine end
6 Fuel pipe (Fuel supply) 16 Pipe clamp (floating bearing) I-III Work steps
Figure 12: Fuel pipes - removing/fitting
48/60B;51/60DF
2008-07-28

6704 434.05-03 EN 17 (19)

 434.05 MAN Diesel & Turbo
Fuel injection pipe /Buffer piston/Fuel pipe
Work Cards, classified into sub-assemblies

3 Hexagon socket bolt 10 Pipe clamp (floating bearing) KS Coupling side

4 Lockwasher 11 Guide strip KGS Free engine end
5 Fuel pipe (Fuel return) 12 Adjacent fuel injection pump I-III Work steps
6 Fuel pipe (Fuel supply) 16 Pipe clamp (floating bearing)
7 Flange 17 Flange
Figure 13: Fuel pipes - removing/fitting
48/60B;51/60DF

2008-07-28

18 (19) 6704 434.05-03 EN

 MAN Diesel & Turbo 434.05

Fuel injection pipe /Buffer piston/Fuel pipe

5 Fuel pipe (Fuel return) D Flat for removal and fitting fixture
(200.111)
6 Fuel pipe (Fuel supply) E Groove for pipe clamp (2 or 18)
A Fixed bearing side KS Coupling side
B Floating bearing side KGS Free engine end
C Sealing face
Figure 14: Fuel pipe

Work Cards, classified into sub-assemblies

48/60B;51/60DF
2008-07-28

6704 434.05-03 EN 19 (19)

MAN Diesel & Turbo

Appendix
1 Introduction
2 Work Cards, Classified by Subjects
3 Work Cards, classified into sub-assemblies
4 Appendix

6704 4-1 EN 1 (1)

MAN Diesel & Turbo 4.1

Insulation
4.1 Insulation
4.2 Lubricating oil pump

6704 4.1-1 EN 1 (1)

 Checklisten-Nr.:

Version 1
Checkliste

Wartungshinweise zur Visuellen Prüfung von

Isolationsbauteilen an Motor, Abgasanlagen, Turbolader etc.

Sämtliche Isolierungsteile sind in regelmäßigen Zeitabständen zumindest visuell auf

Schäden, Funktion oder veränderte Position zu prüften. Ganz besonders jene
Isolationen, die auf stark vibrierenden oder beanspruchten Motorelementen
angebracht sind, sind einer ständigen Kontrolle zu unterziehen.

Diese Anleitung soll dabei eine Hilfestellung sein.

Details for maintenance and visual control of insulation

parts on engine, exhaust gas plants, turbo charger etc.

Every possible insulation part has to be visibly checked for damages, functionality or
misfit on a short period base. Especially these insulation parts which have been
mounted on highly vibrating engine elements have to be checked as a matter of
routine.

This instruction is supposed to be a basic assistance.

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 1von 10
 Checklisten-Nr.:

Version 1
Checkliste

1. Generelle Schäden

Generelle Schäden wie Beulen, Eindrücke

oder Risse könnten durch grobe Arbeiten
an Motor und Rohrleitungen auftreten oder
durch starke Vibration hervorgerufen
werden. Hier soll dringend überprüft
werden, ob eventuell innen liegende
Dämmung beschädigt wurde. Stark
verbogene Verkleidungen müssen
ausgetauscht werden.

Intervall: Sichtung jeweils nach 250

Betriebsstunden
Beschädigtes Gehäuse - sollte getauscht werden.
Damaged Casing – for exchange

General damages

General damages such as buckles, bumps

or cracks could occur during assembling
or maintaining works in the engine or
piping area or because of strong engine
vibrations. It is highly recommended to
check inlaying insulation parts of their
intactness. Heavy damaged casing parts
need to be exchanged.
Gebrochene oder gerissene Verkleidungsteile.
Broken or cracked cladding parts.
Interval: Inspection at any 250 hours of
operation

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 2von 10
 Checklisten-Nr.:

Version 1
Checkliste

2. Schraubverbindungen

Sollten lockere Schrauben festgestellt

werden, so müssen diese umgehend fest
gezogen, bzw. fehlende Schrauben ersetzt
werden.

Intervall: Sichtung jeweils nach 6000

Betriebsstunden

Screwed joints
Lockere Schrauben müssen festgezogen werden.
Loose screws need to get tightened.
If loose screw fittings will be found, an
immediate tightening is necessary. Lost
screws need to get replaced.

Interval: Inspection at any 6000 hours of

operation

Verlorene Schrauben ersetzen!

Replacing lost screws!

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 3von 10
 Checklisten-Nr.:

Version 1
Checkliste

3. Hebel- und Bügelverschlüsse

Durch nicht fachgerechtes Schließen kann

sich der Bügel verziehen oder nicht
gerade aufliegen. Hier bitte korrigieren.
Durch mehrmaliges Öffnen kann sich die
Verbindung lockern. In diesem Fall muss
die Schraube enger gestellt werden.

Intervall: Sichtung jeweils nach 6000

Betriebsstunden

Clip and rocker arm locks

When closing these locks in an incorrect

way the rocker arm could get warped or Prüfen auf korrekten und kraftschlüssigen Sitz.
does not bear on correctly anymore. Checking for correct force-fit.
Please correct it in that case.
Because of constant opening and closing
the connection can get loose. In that case
the rocker arm screw must be tightened.

Interval: Inspection at any 6000 hours of

operation

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 4von 10
 Checklisten-Nr.:

Version 1
Checkliste

4. Hakenverschlüsse

Bei Mattenisolierungen wird diese

Variante zum schlüssigen Verspannen
verwendet. Bei der Wiedermontage
werden die Haken oftmals fehlerhaft
miteinander verbunden.
Achten Sie darauf, dass die Haken sich
korrekt gegenüber liegen und einzeln mit
einem Draht verzurrt sind. Korrigieren Sie
entsprechend.
Fehlerhaftes Verzurren führt zum Verzug
der gesamten Isolation und zur
eventuellen Unwirksamkeit.
Beispiel für perfekten Sitz
Intervall: Sichtung jeweils nach 6000 An example for a perfect fit.
Betriebsstunden

Hook connections

For mat insulations this type is used for

tightened bracing. During reassembling
works the hooks often get connected in an
incorrect way. Please take care of the
hooks lay opposite to each other and
being pairwise connected by a wire.
Please correct if necessary.
An incorrect rigging could cause the whole
insulation to be spoilt and get effectless. Fehlerhaftes Beispiel.
Example for an incorrect bracing.
Interval: Inspection at any 6000 hours of
operation Isolation ist verzogen und undicht.
Insulation is spoilt and leaky.

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 5von 10
 Checklisten-Nr.:

Version 1
Checkliste

5. Beschädigte Isoliermatten

Mattenisolierungen unterliegen nur einer

begrenzten Haltbarkeit und werden je
nach Belastung schnell oder langsam
abgenutzt. Hier muss routinemäßig geprüft
und entsprechend beschädigte Teile
dringend ersetzt werden.
Intakte Isolierung einer Umblaseleitung.
Intact insulation of a by-pass exhaust pipe.
Durch beschädigte Oberflächen kann sich
eine Isoliermatte mit z.B. brennbarer
Flüssigkeit voll saugen.

Intervall: Sichtung jeweils nach 250

Betriebsstunden

Damages on insulation mats

Insulation mats have a limited durability

and getting used up depending upon their
load in a faster or slower way. These parts
have to be checked as a matter of routine.
Affected parts have to be urgently Defekte Isolierung muss ausgetauscht werden.
replaced. Defective insulation need to get exchanged.

Because of a damaged surface an

insulation mat could soak up e.g.
combustible fluids.

Interval: Inspection at any 250 hours of

operation

Defekte Isolierung muss ausgetauscht werden.

Defective insulation need to get exchanged.

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 6von 10
 Checklisten-Nr.:

Version 1
Checkliste

6. Korrekter Sitz der Isolierung

Durch die teilweise starke Vibration der

Motoren kann sich auch die Isolierung
nach einiger Zeit lockern und eventuell
nicht mehr richtig aufliegen.
Betroffene Teile müssen hier erneut
korrekt montiert und eventuell stärker
verzurrt werden.

Intervall: Sichtung jeweils nach 250

Betriebsstunden
Diese Isolierung sitzt perfekt.
This insulation fits correctly.

Correct fit of insulation elements

Because of the strong vibration of the

engine insulation parts can get loose and
do not bear on correctly anymore.
These particular parts have to be
reassembled and eventually clamped in a
stronger way.

Interval: Inspection at any 250 hours of

operation

Diese Isolierung ist verrutscht. Neu-Montage

This insulation has moved. Reassembling.

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 7von 10
 Checklisten-Nr.:

Version 1
Checkliste

7. Russ- / Brandspuren auf der

Isolierung

Sollten Russ-Spuren auf der Isolation zu

sehen sein, ist dies ein Anzeichen dafür,
dass sich unterhalb ein Abgasleckage
befinden könnte. Ein solche Leckage führt
zur Entstehung schwefliger Säure, die zur
Zerstörung der Isolierung führt. In solchen
Fällen muss die Leckage zunächst
umgehend geschlossen und anschließend
die Isolierung ersetzt werden. Betroffene
Isoliermatten dürfen nicht wieder
verwendet werden.

Intervall: Sichtung jeweils nach 250

Betriebsstunden

Beispiel für Russ-Spuren. Dringender Austausch!

Example for soot marks. Urgent exchange!

Soot / Scorch marks

If soot marks appear on the insulations

surface could this be a sign for an exhaust
gas leakage underneath. Leaking exhaust
gas causes the production of sulphuric
acid and destroys the insulation. In such
cases the leakage should get closed first.
All affected insulation parts need to be
replaced. Reusing such parts is not
possible.

Interval: Inspection at any 250 hours of

operation

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 8von 10
 Checklisten-Nr.:

Version 1
Checkliste

8. Sicherheit der Isolation

gegen Eindringen brennbarer
Flüssigkeiten

Achten Sie dringend darauf, dass

Isolierungen, die mit einer Überlappung
versehen sind, nie mit der Öffnung nach
oben montiert werden. Durch die Öffnung
nach oben kann z.B. brennbare
Flüssigkeit eindringen.

Intervall: Sichtung jeweils nach 250

Betriebsstunden

Safety of Insulation against

intrusion of combustible fluids

Please urgently, pay attention that

overlapping insulation parts do not upturn
the open side. This way combustible fluids
could drain in. Vorsicht! Hier können Flüssigkeiten eindringen!
Caution! Here, fluids could enter!
The opening always needs to be
assembled in downward direction.

Interval: Inspection at any 250 hours of

operation

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 9von 10
 Checklisten-Nr.:

Version 1
Checkliste

9. Beständigkeit innen liegender

Isoliermaterialen

Bei einer als Blechsandwich aufgebauten

Isoliervariante mit innen liegendem
Dämmstoff muss regelmäßig geprüft
werden, ob der Dämmstoff noch in seiner
ursprünglichen Form vorhanden oder
eventuell in sich zerfallen oder beschädigt
ist.

Intervall: Sichtung jeweils nach 6000

Betriebsstunden

Prüfen durch Demontage der Verkleidung.

Check after disassembling the cladding parts.
Resistance of lagged / inside
insulation materials

If an insulation has been arranged as a

sheet sandwich with inlaying insulation
material, this material has to be checked
regularly of its natural form or of being
decomposed or even damaged.

Interval: Inspection at any 6000 hours of

operation

Diese Matte ist in einwandfreiem Zustand.

This mat is in perfect shape.

Erstellt: 11.11.05 R. Lasner

Geändert: ---------- ---
Freigegeben: Revision: 000 Seite: 10von 10
MAN Diesel & Turbo 4.2

Lubricating oil pump

4.1 Insulation
4.2 Lubricating oil pump

6704 4.2-1 EN 1 (1)

 02+

8IGLRMGEP(SGYQIRXEXMSR
3TIVEXMSR1EMRXIRERGI1SYRXMRKERH
(MWEWWIQFP]-RWXVYGXMSRWJSVXLI
7IVMIW02+7GVI[4YQT

)CIC6IZC
 02+
'SRXIRXW

 +IRIVEP  4EKI

 %TTPMGEXMSR  4EKI
 -RJSVQEXMSREFSYXXLI4VSHYGX  4EKI
 %HHVIWWMRKSJXLI1ERYEP  4EKI
 1ERYJEGXYVMRK  4EKI
 2EQIW8]TIWERH7M^IW  4EKI
 7IVMEP2YQFIVERH8]TI4PEXI  4EKI
 (EXISJ1ERYEP)\IGYXMSR  4EKI
 'LERKI2SXIWERH1ERYEP2YQFIVW  4EKI
 'ST]6MKLXW  4EKI
 8IGLRMGEP(SGYQIRXEXMSRERH(EXE7LIIX  4EKI
 'YWXSQIV7IVZMGI  4EKI
 5YEPMX]%WWYVERGIERH5YEPMX]XIWXMRK  4EKI
 ;EVVERX]  4EKI

7EJIX]  4EKI

 +IRIVEP6YPIWERH%HZMGI  4EKI
 (ERKIVWSJRSXSFWIVZMRKXLI7EJIX]%HZMGI  4EKI
 7EJIX]GSRWGMSYW;SVOMRK  4EKI
 ;EVRMRKERH%HZMGI7MKRW  4EKI
 7EJIX]%HZMGIJSVXLI3TIVEXSV  4EKI
 7EJIX]%HZMGIJSVXLI7IVZMGI-RWTIGXMSRERH1SYRXMRK  4EKI
 (IRMEPSJ1SHMJMGEXMSRWERH'LERKIW[MXLSYX%TTVSZEP  4EKI
 9REPPS[EFPI6YRRMRK'SRHMXMSRW  4EKI
 3XLIV3TIVEXMSRWERH7EJIX],E^EVHW  4EKI

 8VERWTSVXERH-RXIVQIHMEXI7XSVEKI  4EKI

 7EJIX]1IEWYVIW  4EKI
 8VERWTSVX4VIGEYXMSRW  4EKI
 9RTEGOMRK  4EKI
 -RXIVQIHMEXI7XSVEKI  4EKI
 4VIWIVZEXMSR  4EKI
 %KMRKSJ4VIWIVZEXMSR  4EKI
 6I•4VIWIVZEXMSR  4EKI
 6IQSZEPSJXLI4VIWIVZEXMSR*PYMH  4EKI
 4VSXIGXMSRJVSQXLI)RZMVSRQIRX  4EKI

 (IWGVMTXMSRSJXLI4YQT  4EKI

 +IRIVEP(IWGVMTXMSR  4EKI
 %WWIQFP]ERH3TIVEXMSR  4EKI
 'SRWXVYGXMSRSJXLI4EVXW  4EKI
 4YQTGEWMRK  4EKI
 7TMRHPI7IX  4EKI
 7LEJX7IEP  4EKI
 'EWMRK+EWOIXMRK  4EKI
 &IEVMRK  4EKI
 )RH'SZIV  4EKI
 (VMZI7MHI'SZIV  4EKI
 4VIWWYVI6IPMIJ:EPZI  4EKI
 2S^^PIW  4EKI
 (VMZIERH7LEJXGSYTPMRK  4EKI
 (MQIRWMSRMRKERH+ISQIXV]  4EKI
 7XERHEVH3ZIVEPPERH7MRKPI(MQIRWMSR(VE[MRKW  4EKI
 7XERHEVH%WWIQFP](VE[MRKW  4EKI

)CIC6IZC 4EKIM
 02+
 7XERHEVH7IGXMSREP(VE[MRKW  4EKI
 )\IGYXMSR1SHMJMGEXMSRW  4EKI
 8]TIOI]  4EKI
 7XERHEVH1EXIVMEPSJ'SRWXVYGXMSR  4EKI
 3TIVEXMRK  4EKI
 +IRIVEP3TIVEXMSR*MIPHW  4EKI
 9WISJTYQTWMRTSXIRXMEPP]I\TPSWMZIEVIEW  4EKI
 8IQTIVEXYVI•ERH4VIWWYVI0MQMXEXMSRW  4EKI
 4IVJSVQERGI(EXEERH7TIIHW  4EKI
 4IVJSVQERGI8EFPIW  4EKI
 4S[IV'SRWYQTXMSR(MEKVEQW  4EKI
 -RWXEPPEXMSR  4EKI
 2IGIWWEV]7TEGIJSV3TIVEXMRKERH1EMRXIRERGI  4EKI
 %PPS[EFPI)RZMVSRQIRXEP-RJPYIRGIW  4EKI
 &EWI*SYRHEXMSRERH%RGLSVMRK  4EKI
 7YGXMSRERH(MWGLEVKI4MTMRK  4EKI
 7YTTSVX'SRRIGXMSRW  4EKI

 1SYRXMRKERH-RWXEPPEXMSRW  4EKI

 8SSPW  4EKI
 -RMXMEP-RWXEPPEXMSRSJXLI4YQT  4EKI
 -RMXMEP-RWXEPPEXMSRSJXLI4YQT9RMX  4EKI

 7XEVXYT•7LYXHS[R  4EKI

 8IGLRMGEP(SGYQIRXEXMSR  4EKI
 4MTIW7GLIQEXMGERH1IEWYVMRK4SMRXW  4EKI
 4VITEVEXMSRJSV7XEVXYT  4EKI
 7XEVXYT  4EKI
 7LYXHS[RSJXLI4YQT  4EKI
 6I•WXEVXMRK  4EKI
 7XMPP7XERH  4EKI
 7LYXHS[RJSVYTXS1SRXLW  4EKI
 7LYXHS[RJVSQXS1SRXLW  4EKI
 7LYXHS[RJSVQSVIXLER1SRXLW  4EKI
 3TIVEXMSR7YTIVZMWMSR  4EKI
 &IEVMRKSJXLI(VMZMRK7TMRHPI  4EKI

 1EMRXIRERGI  4EKI

 +IRIVEP  4EKI
 1EMRXIRERGIERH-RWTIGXMSR  4EKI
 (MWEWWIQFP]ERH%WWIQFP]  4EKI
 +IRIVEP4VIGEYXMSR  4EKI
 'YWXSQIV7IVZMGI4IVWSRRIP(ERKIV  4EKI
 (MWEWWIQFP]ERH%WWIQFP]  4EKI
 8SSPW  4EKI
 (MWEWWIQFP]SJXLI4YQT  4EKI
 %WWIQFP]SJXLI4YQT  4EKI
 2SXMGIXSXLIZEPZIEHNYWXMRKTVIWWYVIW  4EKI
 7TEVI4EVXW  4EKI

 8VSYFPI7LSSXMRK  4EKI

 8EFPIXSHIJMRI6IEWSRERHWSPZMRKSJ4VSFPIQW  4EKI
 8SVUYI6IUYMVIQIRXW  4EKI
 %PPS[EFPITMTIJSVGIWERHQSQIRXW  4EKI
 %PPS[EFPITMTIJSVGIWERHQSQIRXW  4EKI

 (VE[MRKW(EXE7LIIXW%TTIRHM\  4EKI

)CIC6IZC 4EKIM
 02+
+IRIVEP 5YEPMX]%WWYVERGIERH5YEPMX]XIWXMRK
%TTPMGEXMSR %GSQTPI\UYEPMX]EWWYVERGIW]WXIQKYEVERXMIWLMKLUYEPMX]WXERHEVH
8LMWWGVI[TYQTMWYWIHJSVTYQTMRKSMPWSVSXLIVPYFVMGEXMRKQIHMEEX PIZIPWJSV0IMWXVMX^WGVI[TYQTW8LIUYEPMX]EWWYVERGIEGGSVHMRKXS
TVIWWYVIWYTXSFEV (-2-73GSZIVWEPPTVSHYGXMSRWXITW[LMGLEVIRIGIWWEV]XSJYP
JMPPEPPXLIUYEPMX]VIUYMVIQIRXWJSVXLMWTVSHYGX
-RJSVQEXMSREFSYXXLI4VSHYGX
5YEPMX]EWWYVERGIQIEWYVIWMIWM^IX]TISJXIWXERHGIVXMJMGEXMSR
%HHVIWWMRKSJXLI1ERYEP
EVIMWWYIHF]XLITYVGLEWIVMR[VMXMRKMRGPYHMRKXLIRIGIWWEV]JSVQW
8LMWQERYEP[EWQEHIJSVXLITYQTWIVMIW02+ ERHHSGYQIRXW4VMSVXSWLMTQIRXEPPTYQTWEVIVMKSVSYWP]XIWXIH
*SVSXLIVI\IGYXMSRWHMJJIVIRXQERYEPWEVIZEPMH8LI]QE]FISVHIVIH 3RP]TYQTW[LMGLJYPJMPPXLIGSRJMVQIHXIWXHEXE[MPPFIWLMTTIH
JVSQXLIQERYJEGXYVIVWITEVEXIP]MJRSXSRLERH 9WISJXLMWQERYEP[MPPLIPTXSEWWYVIEXVSYFPIJVIISTIVEXMSRERHJYPP
1ERYJEGXYVMRK JPS[TIVJSVQERGI8LITVSSJSJXIWXHEXESRXLIFIRGLJSPPS[WXLIKIR
8LIQERYJEGXYVIVSJXLIWGVI[TYQTX]TI02+MW IVEPXIWXVIGSQQIRHEXMSRWJSVVSXEV]TSWMXMZIHMWTPEGIQIRXTYQTWTIV
0)-786-8>4YQTIR+QF, :(1%
VIWMHMRKMRXLI 8LITVSSJSJXIWXERHXLIMVVIWYPXWEVIHSGYQIRXIHMRXIWXGIVXMJMGEXIW
*IHIVEP6ITYFPMGSJ+IVQER] ž1žTIV(-24
2|VRFIVK1EVOKVEJIRWXVEßI•
;EVVERX]
SV 2|VRFIVK4SWXJEGL
(-2•4EVXWEGGIWWSVMIWERHEHHMXMSREPTEVXWEVITYVGLEWIHJVSQ 3YVPMEFMPMX]JSVHIJIGXWSJWLMTTIHKSSHWMWSYXPMRIHMRSYVHIPMZIV]ERH
WYF•WYTTPMIVW TE]QIRXGSRHMXMSRW[LMGLEVITEVXSJSYV7EPIW'SRHMXMSRWERH8IVQW

2EQIW8]TIWERH7M^IW (EQEKIW[LMGLQE]SGGYVEWEVIWYPXSJHMWVIKEVHSJXLIMRWXVYGXMSR
2EQI8LVII•VSXSVWGVI[TYQT QERYEPERHVITPEGIQIRXGSRHMXMSRWEVIRSXGSZIVIHYRHIV[EVVERX]-J
8]TI02+ EXEPEXIVHEXISTIVEXMSRGSRHMXMSRWGLERKIJSVI\EQTPIHMJJIVIRXTVSH
7M^IW YGXZMWGSWMX]XIQTIVEXYVIWTIIHSVMRPIXGSRHMXMSRXLIWIGSRHMXMSRW
ERH LEZIXSFIVIZMI[IHERHEGORS[PIHKIHF]0)-786-8>-JRSSXLIV
*SVEHHMXMSREPMRJSVQEXMSRWIIXLIX]TIOI] EKVIIQIRXWLEZIFIIRQEHI[MXL0)-786-8>XLIHIPMZIVIHTYQTW
GERSRP]FIHMWEWWIQFPIHERHQSHMJMIHF]0)-786-8>SV0)-786-8>•
7IVMEP2YQFIVERH8]TI4PEXI 7IVZMGI6ITVIWIRXEXMZIW3XLIV[MWIXLI[EVVERX]JSVSGGYVVIHHEQ
)EGLYRMXMWIUYMTTIH[MXLEWXERHEVHX]TITPEXI[LMGLWLS[WXLI EKIW[MPPFIZSMHIH
QERYJEGXYVIVWWIVMEPRYQFIVERHX]TIOI])RPEVKIHX]TITPEXIWEVI
EZEMPEFPISRVIUYIWX
(EXISJ1ERYEP)\IGYXMSR
(EXIH3GXSFIV
8IGLRMGEPERHHIWMKRGLERKIWMQTVSZIQIRXWERHEQIRHQIRXWQE]
FIQEHI[MXLSYXRSXMGI
'LERKI2SXIWERH1ERYEP2YQFIVW
%PPI\IGYXIHGLERKIWEVIPMWXIHSRXLIJMREPTEKISJXLMWQERYEP8LI
X]TISJGLERKIHEXII\IGYXSVERHTVSSJVIEHIVEVIRSXIH
1ERYEPRYQFIV)IMRGPYHIWEHHMXMSREPHSGYQIRXEXMSRMRXLI
JSVQSJHVE[MRKW
'ST]6MKLXW
%PPQERYEPWHSGYQIRXWERHHVE[MRKWEVIGST]VMKLXIHEGGSVHMRKXS
(-2
8IGLRMGEP(SGYQIRXEXMSRERH(EXE7LIIX
*SVMRHITXLI\TPEREXMSRWWIIXLIJSPPS[MRKGLETXIVW
7EJIX] 'LETXIV 
8VERWTSVXERH7XSVEKI 'LETXIV 
(IWGVMTXMSRSJXLI4YQT 'LETXIV 
1SYRXMRKERH-RWXEPPEXMSR 'LETXIV 
1SYRXMRKEX7XEVX•YTERH7LYXHS[R 'LETXIV 
1EMRXIRERGI 'LETXIV 
8VSYFPI7LSSXMRK 'LETXIV 
(VE[MRKWERHHSGYQIRXW 'LETXIV 

'YWXSQIV7IVZMGI
-JWIVZMGIMWVIUYMVIHSVUYIWXMSRWRIIHXSFIERW[IVIHTPIEWIGSRXEGX
SYVLIEHUYEVXIVWSVWSQISRIMRSYVWEPIWSVKERM^EXMSR

)CIC6IZC
4EKISJ4EKI
 02+
7EJIX] 7EJIX]%HZMGIJSVXLI7IVZMGI-RWTIGXMSRERH1SYRXMRK
+IRIVEP6YPIWERH%HZMGI
8LMWQERYEPMRGPYHIWKIRIVEPVYPIW[LMGLLEZIXSFISFWIVZIHJSV 8LI IRXMVI WGSTI SJ WIVZMGI MRGPYHMRK MRWTIGXMSR ERH
MRWXEPPEXMSRSTIVEXMSRERHQEMRXIRERGI8LIVIJSVIXLMWQERYEPLEWXS QSYRXMRKLEWXSFIHSRIF]EREYXLSVM^IHWTIGMEPMWX[LS
FIVIEHFIJSVIMRWXEPPEXMSRERHSTIVEXMSRF]XLIMRWXEPPIVEW[IPPEWF] LEWORS[PIHKISJXLMWQERYEP%R][SVOSRXLIQEGLMRI
XLIVIWTSRWMFPIWTIGMEPMWXYWIV-XLEWXSFIQEHIEZEMPEFPIEXXLINSF MWSRP]EPPS[IH[LIRXLIYRMXMWWXERHMRKWXMPP8LIWLYX•
WMXIJSVVIJIVIRGIEXEPEXIVHEXI HS[RSJXLIYRMXHIWGVMFIHMRXLIQERYEPLEWXSFIJSP
(ERKIVWSJRSXSFWIVZMRKXLI7EJIX]%HZMGI PS[IH
-KRSVMRKXLIWEJIX]EHZMGIGERIRHERKIVTISTPIXLIIRZMVSRQIRXERH
XLITYQTYRMX*SVI\EQTPI
(EQEKIXSXLITYQTYRMXWSVGIVXEMRJYRGXMSRWSJXLIWIYRMXWGERIR
HERKIV TIVWSRRIP XLVSYKL IPIGXVMG QIGLERMGEP ERH GLIQMGEP MR
JPYIRGIWIRHERKIVMRKXLIIRZMVSRQIRXF]PIEOEKISJLEVQJYPTVSH -QQIHMEXIP]EXXLIIRHSJER][SVOEPPWEJIX]ERHTVSXIG
YGXWERHSXLIVTSPPYXERXW XMSR HIZMGIW LEZI XS FI MRWXEPPIH GSQTPIXIP] &IJSVI
WXEVX•YTTSMRXWQIRXMSRIHYRHIVLEZIXSFIJSPPS[IH
7EJIX]GSRWGMSYW;SVOMRK
8LIWEJIX]VYPIWPMWXIHMRXLMWQERYEPETTPMGEFPITVIZIRXMZITVEGXMGIW
EW[IPPEWMRXIVREPWEJIX]VYPIWSJXLIYWIVEP[E]WLEZIXSFIJSPPS[IH
(IRMEPSJ1SHMJMGEXMSRWERH'LERKIW[MXLSYX%TTVSZEP
;EVRMRKERH%HZMGI7MKRW
-RXLMWQERYEPWEJIX]W]QFSPWEVIQIRXMSRIH[LMGLGERLIPTXSTVIZIRX 'LERKIWSVQSHMJMGEXMSRWSRXLIYRMX[LMGLLEZIRSXFIIRGSRJMVQIH
EGGMHIRXWXSTIVWSRRIP%KIRIVEPWEJIX]WMKRMHIRXMJMIWLE^EVHW[LMGL F]0IMWXVMX^EVIRSXEPPS[IH
[MPPIRHERKIVXLIYRMXERHMXWJYRGXMSR

9REPPS[EFPI6YRRMRK'SRHMXMSRW

8LISTIVEXMSREPWEJIX]SJXLIHIPMZIVIHYRMXMWSRP]EWWYVIHF]STIVEX
MRKEGGSVHMRKXSXLIGSRJMVQIHHIWMKRERHHEXE9RMXWWLSYPHRSXFI
YWIHYRHIVHMJJIVIRXSTIVEXMRKGSRHMXMSRW[MXLSYXXLIQERYJEGXYVIVW
ETTVSZEP8LIPMQMXEXMSRSJXLITIVJSVQERGIHEXEWLIIXWWLSYPHRIZIV
FII\GIIHIH7EJIX]LE^EVHWQE]VIWYPXMJXLI]EVII\GIIHIH

8LI[SVHž%XXIRXMSRžMWMRWIVXIHMRXLIXI\XXSRSXIXLIWIEHHMXMSREPEH
ZMGIWMKRWERHMWPEFIPIHHMVIGXP]SRXLIYRMX 3XLIV3TIVEXMSRWERH7EJIX],E^EVHW

%PPTEGOMRKQEXIVMEPSJXLITYQTSVXLIYRMXWLEPPSRP]FI
%XXIRXMSR VIQSZIHHMVIGXP]FIJSVIXLIMRWXEPPEXMSRSJXLITYQT
*SVI\EQTPI 2SJSVIMKRTEVXMGPIWEVIEPPS[IHXSIRXIVXLITYQT
(MVIGXMSRSJ6SXEXMSRERH*PS[ 8LIHERKIVSJEREGGMHIRXEXMRWXEPPEXMSRERHQSYRXMRKSJ
)PIGXVMGEP'YVVIRX;EVRMRK XLIYRMXLEWXSFISFWIVZIHEXER]XMQI
1EVOMRKSJXLI2S^^PIWMRPIXSYXPIXEVVS[W &EPERGI WXEFMPMX] EP[E]W LEW XS FI I\MWXMRKEWWIQFP]
1EVOMRK:IRXERH(VEMR3TIRMRK TEVXWLEZIXSFIWIGYVIHEKEMRWXJEPPMRK
ž2SVYF•HV]žWMKRERHSXLIVW 0SSWITEVXWLEZIXSFIWIGYVIHF]TVSTIVQIERW
7EJIX]%HZMGIJSVXLI3TIVEXSV 8LITYQTYRMXMWRSXEPPS[IHXSFIPS[IVIHSVPMJXIHF]XLI
TS[IVWYTTP]PMRIWSVF]XLITMTMRK

•,SXSVI\XVIQIP]GSPHQEGLMRITEVXWEVITSXIRXMEPHERKIVWERHQYWX 'SRRIGXMRKXLITS[IVWYTTP]PMRIXSXLI1SXSVWXEVXIVLEW
FITVSXIGXIHEKEMRWXEGGIWW
XSFIHSRIER)PIGXVMGMERERHJSPPS[MRKXLIIPIGXVMGEPPE]
•'SYTPMRKKYEVHW[LMGLTVSXIGXXLIJPI\MFPIGSYTPMRKERHWLEJXJVSQ
SYXSJXLIQSXSVWYTTPMIV4VSTIVHMQIRWMSRMRKSJXLIPMRIW
EWWIWWWLEPP238FIVIQSZIHHYVMRKVYRRMRKSJXLIIUYMTQIRX
•0IEOEKISJLE^EVHSYWTVSHYGXWEXXLIWIEPF]WYGLEWI\TPSWMZI LEWXSFISFWIVZIH%PPHERKIVWF]IPIGXVMGEPIRIVK]LEZI
XS\MGSVLSXJPYMHWLEZIXSFIGSPPIGXIHERHHVEMRIHXSEWEJITPEGIRSX XSFIIPMQMREXIH2)1%:(%VYPIWERHXLIVYPIWSJXLIPS
XSIRHERKIVSTIVEXMRKTIVWSRRIPERHXLIIRZMVSRQIRX GEP)RIVK]ERH7YTTP]GSQTER]LEZIXSFISFWIVZIHEW
%PPKIRIVEPVYPIWSJPE[ETTPMGEFPIXSXLIWMXILEZIXSFIJSPPS[IH [IPP

)CIC6IZC
4EKISJ4EKI
 02+
8VERWTSVXERH-RXIVQIHMEXI7XSVEKI 8LIPMWXIHTVIWIVZEXMZIEKIRXEVIQIERXXSFIEVIGSQQIRHEXMSR
7EJIX]1IEWYVIW 3XLIVQERYJEGXYVIVWGERFIYWIHEW[IPP4VIWIVZMRKXLIMRXIVREPWSJ
XLITYQTMWEGLMIZIHF]JMPPMRKXLITYQT[MXLXLITVIWIVZEXMSREKIRX
(YVMRKJMPPMRKXLI4EKITS[IVVSXSVLEWXSFIVSXEXIHMRVIZIVWIZIV]
WPS[P]'SRXMRYIJMPPMRKXLITYQTYRXMPXLITVIWIVZEXMSRJPYMHI\MXWXLI
WYGXMSRRS^^PI[MXLER]EMVFYFFPIW

0EVKIVWGVI[TYQTWERHEPPTYQTHVMZIVYRMXWLEZIXSFIXVERWTSVXIH
XSXLIMRWXEPPEXMSRF]QIERWSJPMJXMRKHIZMGIW0MJXMRKERHPS[IVMRKSJXLI
%KMRKSJ4VIWIVZEXMSR
YRMXLEZIXSFIHSRIMREFEPERGIHQERRIV'VERIWERH0MJXMRKHIZMGIW
LEZIXSFIWTIGMJMIHTVSTIVP]-XLEWXSFIEWWYVIHXLEXXLIYRMX[MPP238 %GGSVHMRKXSXLITVIWIVZEXMSRJPYMHQERYJEGXYVIVXLIWLIPJPMJISJ8)'
žXMTSZIVž7LIPZIWERHVEGOWYWIHJSVWXSVEKISJXLIYRMXWLEZIXSFI 8=0MWXS]IEVWEXMRWMHIWXSVEKIERH•QSRXLWEXSYXWMHI
HIWMKRIHXSEGGSQQSHEXIXLI[IMKLXERHWM^I
WXSVEKI8)'8=01MWETTVS\QSRXLWEXMRHSSVWXSVEKISRP]
8VERWTSVX4VIGEYXMSRW &]QM\MRK8)'8=0ERH1GSRWIVZEXMSRTVIWIVZEXMSR
XMQISJ••]IEVWMRHSSVWERHQSRXLWSYXHSSVWGERFII\
TIGXIH

%HHMXMSREPTEGOMRK[MPPI\XIRHXLITVIWIVZEXMSRXMQIEGGSVHMRKP]8LI
MRKVIHMIRXW MR XLIWI TVIWIVZMRK EKIRX [MPP EPPS[ TVSTIV GSVVSWMSR
(EQEKIHYVMRKXVERWTSVXSJXLIYRMXWLSYPH238SGGYV0MJXMRKYWMRK TVSXIGXMSRIZIREXLMKLLYQMHMX]MRHITIRHIRXSJER]XIQTIVEXYVI
TEVXWPMOIXLIQSXSVGSRHYMXFS\SVETS[IVWYTTP]GEFPIMWRSXTIV
QMXXIH7YJJMGMIRXGEVIWLSYPHFIXEOIRXLEXXLIYRMXGERRSXWPMHISVJEPP
HYVMRKXLIXVERWTSVX8LITEGOMRKQEXIVMEPSJXLIYRMXWLEPPRSXFIHEQ
6I•4VIWIVZEXMSR
EKIH%PPEHZMWISRXLITEGOMRKGVEXISVFS\LEZIXSFIWXVMGXP]JSPPS[IH
*SVPSRKIVWXSVEKIXLIYWIVSJXLITYQTLEW
9RTEGOMRK
%XXIRXMSR XSGLIGOXLITVIWIVZEXMSRSJXLITYQTVIKY
9TSRVIGIMTXSJXLITYQTMQQIHMEXIP]MRWTIGXXLIYRMXJSVTSXIRXMEP PEVP]%ZSMHHEQEKIW[LMGLSGGYVHYIXSMQ
XVERWTSVXHEQEKI8VERWTSVXHEQEKIWLEZIXSFIVITSVXIHMQQIHM TVSTIVTVIWIVZEXMSR
EXIP]XSXLI-RWYVERGI'SQTER]
&IJSVIMRWXEPPMRKXLIYRMXEPPTEGOMRKQEXIVMEPLEWXSFIVIQSZIHGSQ
TPIXIP]%PPYRGSZIVIHSTIRMRKWSJXLIYRMXJSVI\EQTPIXLIEGGIWW
6IQSZEPSJXLI4VIWIVZEXMSR*PYMH
LSPISRXLIFIPPLSYWMRKMWXSFIMRWTIGXIHJSVPSSWIQEXIVMEPWYGLEW
[SSHIRWTPMRXIVWREMPWFSPXWQIXEPWGPEQTWERHSXLIVW7YGLMXIQW &IJSVIWXEVX•YTSJXLITYQTXLITVIWIVZEXMSREKIRXRIIHWXSFIVI
RIIHXSFIVIQSZIH)RHGSZIVWFPMRHTPYKWIXGLEZIXSFIVIQSZIH
QSZIH8LIJPYMH[LMGL[EWYWIHSRXLIMRWMHISJXLITYQTRSVQEPP]
EW[IPP
GERFIVIQSZIHF]JPYWLMRKXLITYQT[MXLTVSHYGXTVSZMHIHXLITVSH
-RXIVQIHMEXI7XSVEKI YGXMWEPPS[IHXSKIXGSRXEQMREXIHF]XLMW-REHHMXMSRTVSTIVWSPZIRXW
GERFIYWIHXSVIQSZIXLIMRRIVERHSYXIVTVIWIVZEXMZIW4VSTIVWSP
8LIHIPMZIVIHWGVI[TYQTWEVIEPVIEH]TVIWIVZIHJSVWLSVXIVWXSVEKI ZIRXWGSYPHFI/IVSWIRI(MIWIPSVHI•QMRIVEPM^IHWTMVMXWMRHYWXVMEP
XMQI*SVPSRKIVWLYX•HS[RXMQIXLITYQTWLEZIXSFIJYVXLIVTVS WSPZIRXWGPIERIVWERHSXLIVTEVEJJMRWSPZIRXW,SXWXIEQGPIERIVW
XIGXIHJVSQGSVVSWMSR%RSYXWMHIMRWMHITVIWIVZEXMSRRIIHWXSFI [MXLEGGSVHMRKEXXEGLQIRXWGERFIYWIHEW[IPP
HSRIEWSYXPMRIHYRHIV
8LI TYQT EP[E]W RIIHW XS FI JMPPIH [MXL
4VIWIVZEXMSR %XXIRXMSR TVSHYGXXSEZSMHWIM^MRKXLITYQTVSXSVWEX
WXEVX•YT-JEXXLIMRWXEPPEXMSRWMXIXLITMTMRK
8LIXMQIPMQMXEXMSRSJXLITVIWIVZMRKQEXIVMEPMWHITIRHIRXSRXLIGSQ XEROWERHSXLIVTEVXWMRZEVMSYWGMVGYPEXMSRW]WXIQWEVIGSZIVIH[MXL
TSWMXMSRSJXLIQEXIVMEP8LIVIJSVITVIWIVZMRKQEXIVMEPWWLSYPHFIYWIH TEVEJJMRGSRXEMRMRKTVIWIVZEXMSRQEXIVMEPXLI[LSPIW]WXIQRIIHWXS
[LMGL[MPPFIWXEFPIJSVEXPIEWXQSRXLW8LIJSPPS[MRKQEXIVMEPWGER FIJPYWLIH8LMWMWRIGIWWEV]FIGEYWITEVEJJMRPS[IVWXLIHIKEWWMRK
FIYWIHJSVERMRWMHIERHSYXWMHITVIWIVZEXMSR GETEFMPMX]SJXLITVSHYGXW8LMWQMKLXGEYWIEVSYKLVYRRMRKTYQTMR
GSRRIGXMSR[MXLPSYHRSMWIHIZIPSTQIRXEIVEXMSR 
4VIWIVZEXMSR4SMRXW 4VIWIVZEXMSREKIRXW
%PPQEGLMRIHERHYRTEMRXIH 8)'8=0
WYVJEGIWPMOIWLEJXIRHERH SVGSQTSYRH
JPERKIGSZIVW 8)'8=0ERH 4VSXIGXMSRJVSQXLI)RZMVSRQIRX
8)'8=0•1
;LIRWXSVMRKXLIWGVI[TYQTXLIHMWGLEVKIERHWYGXMSRJPERKIEP
4YQTGEWMRKMRXIVREPWVSXSV GSQTSYRH
WIXERHIRHGSZIVW 8)'8=0ERH [E]WRIIHXSFIGSZIVIHF]FPMRHJPERKIWFPMRHTPYKWSVWMQMPEVQEXI
8)'8=0•1 VMEP8LIWXSVEKIWLEPPXEOITPEGIMREHYWXJVIIERHHV]VSSQ(YVMRK
WXSVEKIMXMWVIGSQQIRHIHXSXYVRXLIMRRIVTEVXWSJXLITYQTQERY
•• 1ERYJEGXYVMRK:%0:30-2)3)0+QF,
'S••
EPP]IZIV][IIOW8LIVSXSVWIXERHFIEVMRKGLERKIXLIMVTSWMXMSRHYV
8LITVIWIVZEXMZIEKIRXWLEPPFIWTVIEHF]QIERWSJFVYWLMRKSV MRKXLMWTVSGIWW-JXLIWXSVEKIERHTEGOMRKMWHSRITVSTIVP]XLIYRMX
WTVE]MRK GERFITVIWIVZIHJSVEZIV]PSRKXMQI

)CIC6IZC
4EKISJ4EKI
 02+
(IWGVMTXMSRSJXLI4YQT 7LEJX7IEP
+IRIVEP(IWGVMTXMSR 7IEPMRKXLIWXYFWLEJXSJXLIHVMZMRKWTMRHPIEKEMRWXXLITVSHYGXEWMQ
8LI 0IMWXVMX^ 7GVI[ 4YQTW SJ XLI 02+ 7IVMIW EVI PS[ TVIWWYVI TPIRSR•FEPERGIHQEMRXIRERGIJVIIQIGLERMGEPWIEPTSWMXMSR
TYQTWYTXSFEVW8LI]EVIWIPJTVMQMRKTSWMXMZIHMWTPEGIQIRX QSYRXIHHMVIGXP]MRXLIHVMZMRKWMHIGSZIVTSWMXMSR 
TYQTWERHEVIYWIHXSQSZISMPWSVSXLIVPYFVMGEXMRKTVSHYGXW 1EXIVMEPWERHQIERWSJGSRWXVYGXMSRQERYJEGXYVIVSJXLIQIGLERMGEP
WIEP [MPPFIEHNYWXIHXSXLIEGGSVHMRKSTIVEXMRKGSRHMXMSRWERHGLEV
%WWIQFP]ERH3TIVEXMSR EGXIVMWXMGWSJXLITVSHYGXFIMRKTYQTIH
(YIXSXLIWTIGMEPTVSJMPISJXLIXLVIIXYVRMRKWTMRHPIWWIEPIHGEZMXMIW
EVITVSHYGIH8LIHSYFPI•PIEHHVMZMRKWTMRHPITSWMXMSR VSXEXIW 'EWMRK+EWOIXMRK
WIEPMRK[MXLXLIHSYFPI•PIEHMHPIVWTMRHPITSWMXMSR MRXLIWTMRHPI 8LITYQTMWWIEPIHSJJYWMRKJPEXKEWOIXTSWMXMSR ERHWIEPWVMRKW
FSVISJXLITYQTGEWMRKTSWMXMSR [LMGLIRGPSWIWXLIWTMRHPIWIX TSWMXMSR HITIRHMRKSRXLISTIVEXMRKGSRHMXMSRWERHXLITYQTIH
[MXLXMKLXXSPIVERGIW TVSHYGXW
8LIQSXMSRSJXLIX[SMHPIVWTMRHPIMWGEYWIHF]XLIGEPGYPEXIHL]HVEY
PMGJSVGIWPIEZMRKSRP]XLIVIWYPXMRKQSQIRXGEYWIHF]XLIJPYMHJVMGXMSR &IEVMRK
XSFIXVERWQMXXIHSZIVXLIJPEROWSJXLIWTMRHPITVSJMPI8LIVIJSVIXLI 8LISYXFSEVHKVIEWIHWLMIPHIHERHQEMRXIRERGIJVIIFIEVMRKTSWM
WTMRHPIWIXMWEPQSWX[MXLSYXER]PSEHERH[MPPRSX[IEV;MXLXLMWTVMRGM XMSR EGGSVHMRKXS(-2QSYRXWXLITS[IVVSXSVTSWMXMSR
TEPXLITYQTWGSRXMRYEPP]QSZIJPYMH[MXLSYXWLIIVERHXYVFYPIRGI MRXSXLIHVMZIWMHIGSZIVTSWMXMSR 
JVSQXLIWYGXMSRXSXLIHMWGLEVKIWMHI8LMWGSRWXVYGXMZIHIWMKRMR
[SVOMRKTVMRGMTPIEWWYVIWEPS[RSMWIPIZIPERHEREPQSWXTYPWEXMSR
)RH'SZIV
JVIIHMWGLEVKI
8LIGSQTPIXIWTMRHPIKISQIXV]MWGLEWIMRMRE[E]XLEXRSE\MEPXLVYWX 8LIIRHWMHIGSZIVTSWMXMSR SVXLITIHIWXEPTSWMXMSR WLYXW
MWIJJIGXIHSRXLIKVSSZIHFEPPFIEVMRKTSWMXMSRRYQFIV 8LI XLITYQTGEWMRKTSWMXMSR EXWYGXMSRWMHI
KVSSZIHFEPPFIEVMRKTSWMXMSR JM\IWXLIHVMZMRKWTMRHPITSWMXMSR
 MRE\MEPHMVIGXMSR (VMZI7MHI'SZIV
8LIFIEVMRKETTPMGEXMSRSJXLIMHPIVWTMRHPIWTSWMXMSR MWIJJIGXIHMR 8LIHVMZIWMHIGSZIVTSWMXMSR WIVZIWJSVMRXIKVEXMSRSJXLIQI
XLITYQTGEWMRKTSWMXMSR  GLERMGEPWIEPERHJSVJM\MRKSJXLIGSQTPIXITYQT8LIQSYRXMRKJEGIMW
(ITIRHMRKSRXLISTIVEXMRKTVIWWYVIERETTVSTVMEXIGLSOIKETMW EGGSVHMRK XS (-2  TSWMXMSR  WIGXMSR  WUYEVIH QSYRXMRK
FYMPXFIX[IIRXLIFEPERGMRKTMWXSRSJXLIHVMZMRKWTMRHPITSWMXMSR JPERKIW;MXLXLMWJSYVLSPIQSYRXMRKJPERKIXLIGSQTPIXITYQTGERFI
ERHXLIMHPIVWTMRHPIWTSWMXMSR [LMGLKYEVERXIIWXLIL]HVSH] VSXEXIHMRMRGVIQIRXW
REQMGFIEVMRKSJXLIMHPIVWTMRHPIW %XXLIHMWGLEVKIGSRRIGXMSREGEWXMRIVVSVHIWGVMFIWXLI
8LIWYFWIUYIRXXMKLXIRMRKEVIEMWGSRRIGXIH[MXLXLIWYGXMSRWMHI JPS[HMVIGXMSRSJXLITVSHYGX &IJSVI WXEVXYTXLEXJPS[
TYQT VSSQ F] QIERW SJ E FSVMRK ERH WXERHW XLYW EP[E]WYRHIV HMVIGXMSRLEWXSFIGLIGOIH1SYRXMRKXLIGSQTPIXITYQT
WYGXMSRTVIWWYVI&]XLMWKISQIXVMGHIWMKRSJXLIWTMRHPITEGOEKIXLI XSXLIHVMZIVWGVI[WEGGXS(-2SV(-2LEZIXSFI
E\MEPXLVYWXFEPERGMRKMWKYEVERXIIH YWIHXSKIXLIV[MXLLI\LIEHFSPXWERHRYXW

'SRWXVYGXMSRSJXLI4EVXW 4VIWWYVI6IPMIJ:EPZI
4YQTGEWMRK %WHIWGVMFIHSRXLITYQTGERFII\IGYXIH[MXLERMRXIKVEPTVIW
(ITIRHMRKSRXLIQSYRXMRKGSRJMKYVEXMSRXLII\IGYXMSRSJXLITYQT WYVIVIPMIJZEPZI)\EKKIVEXMRKXLIEHNYWXIHZEPYIWXLITSTTIXTSWM
GEWMRK[MPPFIQEHITSWMXMSR 8LIGSQTPIXITYQTGEWMRKGERFI XMSR PMJXWJVSQXLIWIEXERHXLITVSHYGXGMVGYPEXIWMRXSXLIWYGXMSR
QSYRXIHXYVRIHF]IEGLXMQI\XSXLIQEMRWLEJXSJXLIHVMZMRK EVIESJXLITYQTGEWMRK8LISTIRMRKTVIWWYVIMWEHNYWXIHF]GSQ
EKKVIKEXI8LIWYGXMSREVIE[MPPFIGPSWIHSJJ[MXLXLIRSR•HVMZIWMHI TVIWWMRKXLIZEPZIWTVMRKTSWMXMSR [MXLXLIEHNYWXMRKWGVI[TSWM
GSZIVTSWMXMSR 8LIHVMZIWMHIGSZIVTSWMXMSR MWQSYRXIHSR XMSR EXXLIJEGXSV]SVEXXLIYWIVHITIRHMRKSRXLIVIUYMVIQIRX
XLIHMWGLEVKIWMHI%WERSTXMSRXLITYQTGEWMRKGERFII\IGYXIH[MXL 2SXMGIXSXLIZEPZIEHNYWXMRKTVIWWYVIWWIIGLETXIV
ERMRXIKVEXIHVIPMIJZEPZI 9WMRK XLI TYQT[MXLETVIWWYVIPMQMXEXMSRZEPZI GEVI
8LIVIPMIJZEPZITVSXIGXWXLITYQTSRP]EKEMRWXSZIVPSEH WLSYPHFIXEOIRXLEXXLITSTTIX[MPPEP[E]WWXE]QSZEFPI
ERH MWRSXQIERXXSFIYWIHEWETVIWWYVIVIKYPEXMRK MRMXWE\MW%GSQTPIXIGPSWMRKSJXLIZEPZIFSVIF]QIERW
ZEPZI3TIVEXMSRERHQERYEPSJXLITVIWWYVIVIKYPEXMRK SJPSGOMRKXLIEHNYWXQIRXWGVI[ERHXLIGSRRIGXIHZEPZIW
ZEPZIW WII WIGXMSR  8LI TYQT GEWMRK GER FI WTVMRKF]GSQTPIXIGSQTVIWWMSRWLEPPRSXFIEPPS[IH
HVEMRIHMRER]QSYRXMRKGSRJMKYVEXMSR8LIVIJSVIGLIGOFIJSVIWXEVX WMRGIXLMWGSYPHGEYWIHEQEKIXSXLITYQT-JETVIWWYVI
YTSRIZIRXYEPP]RSXTPYKKIHSTIRMRKW VIKYPEXMSRMWRIGIWWEV]XLMWWLEPPFIHSRI[MXLWITEVEXI
3RXLIWYGXMSRGSRRIGXMSRXLIGEWXMRKMWI\IGYXIH[MXLE VIKYPEXMRKHIZMGIWI\IGYXIHERHMRWXEPPIHF]XLIYWIV
GEWXMRJPS[HMVIGXMSREVVS[&IJSVIWXEVXYTXLIJPS[HMVIG
XMSRRIIHWXSFIGLIGOIH 2S^^PIW
7YGXMSRERHHMWGLEVKIGSRRIGXMSREVII\IGYXIHEWE(-2SV%27-•
JPERKIHGSRRIGXMSRQEVOIH[MXLJPS[HMVIGXMSREVVS[WGEWXMRXSXLI
7TMRHPI7IX TEXXIVR;IPHRIGOGSYRXIVJPERKIWEGGSVHMRK(-2SV%27-GERFIWYT
8LIHVMZMRKWTMRHPITSWMXMSR MWHSYFPI•PIEHLEVHIRIHERHE\MEPP] TPMIH[MXLETVMGIEHHIV
TSWMXMSRIH [MXL E KVSSZIH FEPP FIEVMRK TSWMXMSR   8LI MHPIV 1E\MQYQEPPS[EFPIJSVGIWERHQSQIRXWEVIHITIRHMRK
WTMRHPIWTSWMXMSR HSYFPI•PIEHEW[IPPLEVHIRIHSVYRLEVHIRIH SRXLITYQTWM^IERHEVIPMWXIHSRXLIHMQIRWMSRTVMRXSJ
EVITEMVIHXSXLIHVMZMRKWTMRHPI(YVMRKSTIVEXMSRFSXLMHPIVWTMRHPIW XLITYQTSVSRXLIEWWIQFP]HVE[MRKW8LIWIZEPYIW
EVITYWLIHMRE\MEPHMVIGXMSREKEMRWXXLIHVMZMRKWMHIFEPERGMRKTMWXSR WLEPPRIZIVFII\GIIHIH'SRRIGXMSRWJSVHVEMRZIRXSV
SJXLIHVMZMRKWTMRHPITSWMXMSR  LIEXMRKMJRSXRIIHIHRIIHXSFITPYKKIHFIJSVIWXEVXYT

)CIC6IZC 4EKISJ4EKI
 02+
(VMZIERH7LEJXGSYTPMRK )\IGYXMSR1SHMJMGEXMSRW
8LITYQT[MPPFIHMVIGXP]GSYTPIHXSERIPIGXVMGQSXSVSVSXLIVHVMZIZME 8]TIOI]
EFIPPLSYWMRK[MXLJSSXERKPISVEFIPPLSYWMRK[MXLEQSYRXMRKTPEXIMRE 8LIX]TIOI]PMWXIHEXXLIIRHSJXLMWQERYEPHSIWMRGPYHIEPPGSQFMRE
ZIVXMGEPQSYRXEVVERKIQIRX XMSRWSJTYQTQSHMJMGEXMSRWZMERYQFIVERHPIXXIVGSHI)ZIV]WXER
%P[E]WSFWIVZIXLIGSVVIGXHMVIGXMSRSJXLIVSXEXMSRERH HEVHTYQTGERFIHIWGVMFIHF]XLEX
TVSTIVHVMZIWTIIH8LITYQTWGERFIQSYRXIHMRER]
QSYRXMRKTSWMXMSR&IGEYWISJWEJIX]VIEWSRWQSYRXMRK 7XERHEVH1EXIVMEPSJ'SRWXVYGXMSR
XLIQSXSVFIPS[XLITYQTMWRSXEPPS[IH8LIWLEJXGSY
4YQTGEWMRK  SV 
TPMRKXVERWQMXWXLIXYVRMRKQSQIRXJSVQGPSWI[MXLEXLVII
(VMZIWMHIGSZIV 
TMIGIIPEWXMGJSVQGSRRIGXMRKGSYTPMRK[LMGLFEPERGIW
)RHGSZIV 
E\MEPVEHMEPERHERKYPEVQMWEPMKRQIRXSJXLIGSRRIGXMRK
(VMZMRKWTMRHPI LEVHIRIH
WLEJXW (MJJIVIRXI\IGYXMSRQERYJEGXYVIVERHQEXIVMEP
-HPIVWTMRHPI LEVHIRIHSV
GSQFMREXMSRW EVIEZEMPEFPI[MXLTVMGIEHHIV
+EWOIX ')28)00)2;7

(MQIRWMSRMRKERH+ISQIXV] 3TIVEXMRK
7XERHEVH3ZIVEPPERH7MRKPI(MQIRWMSR(VE[MRKW +IRIVEP3TIVEXMSR*MIPHW
7XERHEVHSZIVEPPHMQIRWMSRWJSVXLIWM^IXLVSYKLEVIEGGSVH +IRIVEPMRHYWXV]XIGLRSPSK]SMPFYVRMRKIRIVK]WLMTFYMPHMRKERHSJJ
MRKXSHVE[MRK)[MXL(-2JPERKIGSRRIGXMSRW WLSVIXIGLRSPSK]QEGLMRIERHLIEZ]QEGLMRIV]QERYJEGXYVMRKXERO
JEVQWGLIQMGEPERHTIXVSGLIQMGEPERH3)1-RHYWXVMIWJSSHTVSGIW
7XERHEVHWMRKPIHMQIRWMSRHVE[MRKWJSVXLIWM^I WMRKERHSXLIVW
[MXL(-2JPERKIGSRRIGXMSRW
 HVE[MRK) 9WISJTYQTWMRTSXIRXMEPP]I\TPSWMZIEVIEW
 HVE[MRK) 8LIWITYQTWERHTYQTYRMXWEVIWYMXEFPIJSVYWIMR
 HVE[MRK) TSXIRXMEPP]I\TPSWMZIEVIEWEGGSVHMRKXS)'(MVIGXMZI)'%8)< 
 HVE[MRK) 8LIGSRHMXMSRMW
 HVE[MRK) XLEXXLITYQTYRMXWEVIHIWMKRIHEGGSVHMRKXSXLIWTIGMJMGEXMSRWERH
 HVE[MRK) XLEXXLMWHIWMKRMWGSRJMVQIHMRXLITVSNIGX•VIPEXIHTYQTHEXEWLIIXW
 HVE[MRK) 4VSTIVSTIVEXMSRERHXLITIVQMWWMFPIETTPMGEXMSRPMQMXWQYWXFIGSQ
  HVE[MRK) TPMIH[MXLEWWTIGMJMIHMRXLIGSVVIWTSRHMRKGLETXIVWSJXLIHEXEWLIIXW
 HVE[MRK) ERHSJXLISTIVEXMRKQERYEP%PWSWII'LETXIVSJXLMWSTIVEXMRKQER
YEP'SQQMWWMSRMRK 
 HVE[MRK)
8LIGSRJMVQEXMSRJSVXLITIVQMWWMFPIEVIESJYWIMW
 HVE[MRK)
HSGYQIRXIHMRXLI)'(IGPEVEXMSRSJ'SRJSVQMX]JSVXLIGSVVIWTSRHMRK
 HVE[MRK) TVSNIGX(IXEMPIHHSGYQIRXWEVIMRGPYHIHMRXLITVSNIGXHSGYQIRXE
 HVE[MRK) XMSRMRTEVXMGYPEV%8)<GIVXMJMGEXIWSRHIZMGIWSVEXXEGLIHTEVXWVIUYMV
MRKZIVMJMGEXMSR
JYVXLIVTVSNIGXVIPEXIHHVE[MRKW[MPPFIEXXEGLIH
8IQTIVEXYVI•ERH4VIWWYVI0MQMXEXMSRW

-JWITEVEXIWMRKPIHMQIRWMSRWLIIXWLEZIFIIRI\IGYXIHJSVXLIYWIV
XLI]LEZIXSFIVIUYIWXIH

7XERHEVH%WWIQFP](VE[MRKW
8LIRSQMREPTVIWWYVIZMWGSWMX]ERHXIQTIVEXYVIHIXEMPWQYWXFI
%WWIQFP]HVE[MRKJSVXLIWM^IXLVSYKL[MXL(-2JPERKI RIIHIHWIIHEXEWLIIX -JRSHIXEMPWEVIKMZIRXSXLIGSRXVEV]XLI
GSRRIGXMSRWERHZEVMSYWQSXSVWM^I EVIEZEMPEFPI ZEPYIWKMZIRGERFIGSRWMHIVIHEWVIPMIJZEPYIWERHQE]RSXFI
*SVJSSXTYQTW ( I\GIIHIH-JTVSXIGXMZIQIEWYVIWEVIVIUYMVIHEWEVIWYPXSJXLI
*SVWYFQIVKIHTYQTW ( STIVEXMRKXIQTIVEXYVIWSVXIQTIVEXYVIPMQMXWXSTVIZIRXHMWXYVFERGI
*SVXEROXSTQSYRXIHTYQTW ( SJXLIWYVJEGIXLIWIEVIXSFIETTPMIHF]XLIGYWXSQIVERHQE]RSX
%WWIQFP]HVE[MRKJSVXLIWM^IXLVSYKL[MXL(-2JPERKI FIVIQSZIHMRSTIVEXMSR
GSRRIGXMSRWERHZEVMSYWQSXSVWM^I EVIEZEMPEFPI
*SVTIHIWXEPTYQTW ( 4IVJSVQERGI(EXEERH7TIIHW
*SVJPERKITYQTW (
JYVXLIVTVSNIGXVIPEXIHHVE[MRKW[MPPFIEXXEGLIH 4IVJSVQERGI8EFPIW
4IVJSVQERGIXEFPIWEGGSVHMRKXSTYQTWM^IERHPIEHERKPIJSVZEVMSYW
WTIIHWERHZMWGSWMX]WWII)TEKI•
-JWITEVEXIQSYRXMRKHVE[MRKWLEHFIIRQEHIJSVXLIYWIVXLI]LEZI
XSFIVIUYIWXIH
4S[IV'SRWYQTXMSR(MEKVEQW
4S[IVGSRWYQTXMSRWHMEKVEQWJSVTYQTWM^IERHPIEHERKPIJSVZEVM
7XERHEVH7IGXMSREP(VE[MRKW
SYWWTIIHWERHZMWGSWMX]WXLI]LEZIXSFIVIUYIWXIH
7XERHEVHGVSWWWIGXMSREPHVE[MRKWJSVEPPWM^IWERHTSWWMFPII\IGY
XMSRWEGGSVHMRKXSHVE[MRK)SV' -RWXEPPEXMSR

-JWTIGMEPGVSWWWIGXMSREPHVE[MRKWJSVXLIYWIVLEZIFIIRQEHIXLI] 2IGIWWEV]7TEGIJSV3TIVEXMRKERH1EMRXIRERGI
LEZIXSFIVIUYIWXIH 'LSSWIXLIQSYRXMRKWTEGIXLEX[E]XLEXERYRHMWXYVFIHSTIVEXMSR
%PPEFSZIHVE[MRKWEVIEZEMPEFPIMRHMJJIVIRXPERKYEKIWSRVIUYIWX ERHYRGSQTPMGEXIHQEMRXIRERGI SJ XLI YRMX MW TSWWMFPI *SPPS[ EPP
WEJIX]VIKYPEXMSRWEW[IPP

)CIC6IZC 4EKISJ4EKI
 02+
%PPS[EFPI)RZMVSRQIRXEP-RJPYIRGIW ;IVIGSQQIRHXLIMRWXEPPEXMSRSJWYGXMSRWXVEMRIVW[MXLXLIJSPPS[MRK
)\MWXMRK IRZMVSRQIRXEP MRJPYIRGIW [LMGL [SYPH LEZI QIWLWM^IW
RIKEXMZIMRJPYIRGISRXLISTIVEXMSRSJYRMXMILMKLLIEX
VEHMERGIJVSQRIMKLFSVMRKQEGLMRITEVXWWTPEWL[EXIV 1IWLWM^I ZMWGSWMX]
ERHWSJSVXLLEZIXSFIEZSMHIHEWQYGLEWTSWWMFPI%PP •QQ "QQW
IRZMVSRQIRXEP MRJPYIRGIW ERH QSYRXMRK GSRJMKYVEXMSRW LEZI XS FI •QQ •QQW
WXEXIHYTSRSVHIVMRK%HHMXMSREPP]STIVEXMSRQIEWYVIWMIMRWYPEXMRK •QQ QQW
ZMFVEXMSRHEQTIVWLEZIXSFIWXEXIHEXSVHIV
(YVMRKXLIGSRRIGXMSRSJXLITMTMRKXSXLITYQTXLIJPS[HMVIGXMSR
&EWI*SYRHEXMSRERH%RGLSVMRK XLVSYKLXLITYQTLEWXSFISFWIVZIHEVVS[WSRXLITYQT 8LIGSR
8LIERGLSVMRKMWHITIRHMRKSRXLIX]TIERHXLIWM^ISJXLIYRMX-JXLI RIGXMSRSJETVIWWYVIKEYKISRXLITYQTFSH]WLSYPHFITPERRIH
YRMXMWQSYRXIHZME0•FVEGOIXXLIQSYRXMRKLSPIWVIWTIGXMZIIPSR
KEXIHLSPIWSJXLIJSSXFVEGOIXLEZIXSFIYWIH 8LIGPIERMRKSJXLITMTI[SVOWLSYPHRSXFII\IGYXIH[MXL[EXIV
8LIQSYRXMRKWLSYPHFIGLSWIRXLEXRSQSZIQIRXSJXLI SV[MXLJPYMHW[MXLQMRMQYQZMWGSWMX]FIPS[XLIQMRMQYQMRHMGE
YRMXMWTSWWMFPI%PPWYFFEWIWERHJSYRHEXMSRWQYWXFI XIHZMWGSWMX]WLS[RMRXLITYQTHEXEWLIIX(YVMRKL]HVSWXEXMG
WXEXMGEPP]WSYRH8LIYRMXWLSYPHRSXFII\TSWIHXSXLI XIWXSJXLI[LSPITMTI[SVOW]WXIQXLITYQTQYWXFIMWSPEXIH
ZMFVEXMSRW SJ SXLIV QEGLMRIW -J ZMFVEXMSRW GERRSX FI 8LIL]HVSXIWXSJXLITYQTH]REQMGSVWXEXMG [MPPGEYWIHEQEKI
EZSMHIHZMFVEXMSRMWSPEXSVWLEZIXSFIMRWXEPPIH XSXLITYQTIWTIGMEPP]XSXLIWLEJXWIEPMRKW]WXIQ -JXLMWTVSGI
-JXLIYRMXMWQSYRXIH[MXLEPMHTPEXISRXSEXEROIRWYVI HYVIMWRSXQEMRXEMRIHXLIKYEVERXIIMWRSXZSMH
XLEXXLIXEROGERWYTTSVXXLI[IMKLXSJXLITYQT-XMWVIG 7YTTSVX'SRRIGXMSRW
SQQIRHIHXSYWIZMFVEXMSRMWSPEXSVW8LMW[MPPVIHYGIXLI %PPSXLIVWYTTSVXGSRRIGXMSRWLEZIXSFIHMQIRWMSRIHTVSTIVP]ERH
RSMWI EXXLIXERO [EPPW HVEWXMGEPP]0IMWXVMX^GERRSXFI FVSYKLXXS[EVHWXLIYRMX8LIYWIVMWWSPIP]VIWTSRWMFPIJSVXLIWM^MRK
QEHIPMEFPIJSVHEQEKIWSJXLIYRMXHYIXSYRWXEFPIERGLSVMRK ERHQEXIVMEPWIPIGXMSR-RTVMRGMTEPRSQIGLERMGEPJSVGIWEVIEPPS[IHXS
7YGXMSRERH(MWGLEVKI4MTMRK XEOITPEGI(EQEKIHWYTTSVXTMTIWLEZIXSFIVITEMVIHSVI\GLERKIH
8LITYQTYRMXMWRSXTIVQMXXIHXSEGXEWEQSYRXMRKTSMRX MQQIHMEXIP]
JSVTMTMRK8LIQE\MQYQEPPS[EFPIJSVGIWERHQSQIRXW
SRXLIJPERKIWQIRXMSRIHMRXLIHMQIRWMSRWLIIXWERH
EWWIQFP]HVE[MRKWQE]RSXXSFII\GIIHIH8LMWMWXVYI
JSVTSWWMFPIXIQTIVEXYVIJSVGIWEW[IPPWIIWIGXMSR8LITMTIWM^IW
SRXLIWYGXMSRERHHMWGLEVKIWMHIWLSYPHFIEXPIEWXXLIWM^ISJXLI
TYQTGSRRIGXMSRW8LIWIPIGXMSRSJXLITMTILEWXSFIHSRIYWMRKXLI
I\MWXMRKJPS[ZIPSGMX]8LIJPS[ZIPSGMX]MRXLIWYGXMSRPMRIWLSYPHRSX
I\GIIHQIXIVTIVWIGSRHERHMRXLIHMWGLEVKIPMRIQIXIVWTIVWI
GSRH;LIRTMTMRKYTWYGXMSRERHHMWGLEVKIPMRIWGEVIWLSYPHFI
XEOIRXLEXXLIJPS[SJXLIQIHMYQMWRSXHMWXYVFIHF]QSYRXMRKWLSVX
VEHMYWIPFS[WVMKLXERKPIZEPZIWSVGLIGOSVFEGOTVIWWYVIZEPZIWMR
XLIWYGXMSRPMRI9REZSMHEFPIHMEQIXIVGLERKIWMRXLIJPS[PMRIWLEZI
XSFII\IGYXIH[MXLWQSSXLVIHYGIVW%R]WYHHIRHMVIGXMSRGLERKIW
WLSYPHFIEZSMHIH8LIWYGXMSRERHHMWGLEVKIPMRIWLEZIXSFIWIEPIH
XMKLXP]ERHTMTIHMRWYGLEQERRIVXLEXRSEMVFYFFPIWGERFYMPHYT
8LIVIJSVIXLITMTMRKQYWXEP[E]WFIPE]IHMREVMWMRKQERRIV8LI
WTMRHPIWSJKEXIZEPZIWWLSYPHFITSWMXMSRIHLSVM^SRXEPP]SVZIVXMGEPP]
HS[R[EVHXSEPPS[ZIRXMRKSJXLIPMRIWEXXLILMKLIWXTSMRX*PERKIKEW
OIXWGERRSXFITIVQMXXIHXSTVSXVYHIMRXSXLI-(SJXLITMTIERHMRWXEP
PEXMSRSJMWSPEXMSRZEPZIWFIJSVIERHEJXIVXLITYQTEW[IPPEWEGLIGO
ZEPZIEXXLIHMWGLEVKIWMHIMWVIGSQQIRHIH8LIMWSPEXMSRZEPZIWEVI
SRP]YWIHXSGPSWIXLIPMRIWJSVTYPPMRKXLIYRMXSYXSJWIVZMGI8LI]LEZI
XSFIGSQTPIXIP]STIRHYVMRKRSVQEPSTIVEXMSR%PPTMTIWERHZEPZIW
LEZIXSFIGPIERIHXLSVSYKLP]FIJSVIXLITYQTMWQSYRXIHMRSVHIVXS
JPYWLSYX[IPHWPEK[IPHFIEHWERHTSWWMFPIQSYRXMRKHIFVMWPMOI
FSPXWRYXWERHWSJSVXL2SPMEFMPMX]GERFIGPEMQIHJSVHEQEKIWXSXLI
TYQT[LMGLLEZIFIIRGEYWIHF]WSPMHTEVXMGPIWMRXLITVSHYGX1SYRX
XLITYQTSRXSXLIXEROMRWYGLQEXXIVXLEXEMVFYFFPIWERHJSEQTEV
XMGPIW[LMGLQMKLXLEZIFIIRTVSHYGIHMRXLIJPYMHEVIOITXSYXSJXLI
TYQTMRPIX

8LIXEROLEWXSFIHMQIRWMSRIHERHQSYRXIHMRWYGL
JEWLMSRXLEXXLIYWISJQE\MQYQEPPS[EFPIJPS[ERHQIHME
XIQTIVEXYVIWEVIRSXI\GIIHIHTVSTIVMRWXEPPEXMSRWQIE
WYVIWEGLMIZIXLMWKSEP
8LIPMJIXMQISJEWGVI[TYQTMWHIXIVQMRIHF]XLIGPIERPMRIWWSJXLI
TVSHYGXERHMXWVIPEXMSRWLMTXSXLIXMKLXXSPIVERGIWFIX[IIRXLIVSXSVW
ERHXLIVSXSVWPIIZI

)CIC6IZC 4EKISJ4EKI
 02+
1SYRXMRKERH-RWXEPPEXMSRW 'EVIJYPERHEGGYVEXIEHNYWXQIRXSJXLIWLEJXIRHW[MPP
8SSPW PIRKXLIRXLIPMJIXMQISJXLIGSYTPMRK8LIGSYTPMRKLEPJSR
XLITYQTWMHIMWRSXEPPS[IHXSFIMRWXEPPIH[MXLELEQQIV
*SVXLIXSXEPQSYRXMRKSVHMWEWWIQFP]WXERHEVHXSSPWEVIRIGIWWEV]
•%PPIRLIEH[VIRGLIWEGGSVHMRKXS(-2 &IPPLSYWMRKSVSXLIVWYTTSVXQIEWYVIWSJXLITYQTLEZIXSFIXLSV
•3TIRIRH[VIRGLIWEGGSVHMRKXS(-2-73 SYKLP]GLIGOIHJSVTSWWMFPIHIJIGXMZIQERYJEGXYVMRK8LIVIJIVIRGIH
•3TIRIRH[VIRGLIWEGGSVHMRKXS(-2 QMRMQYQEPPS[EFPIZEPYIWJSVVEHMEPE\MEPERHERKYPEVSJJWIXSJXLI
•1EGLMRMWXLEQQIVEGGSVHMRKXS(-2 WLEJXWEGGSVHMRKXS(-2XEFPI2ERHXEFPI2 LEZIXSFI
•6YFFIVQEPPIX EGLMIZIHQERYJEGXYVMRKXLIFIPPLSYWMRK1SYRXMRKEHZMWIWSJXLIGSY
•7GVI[HVMZIVEGGSVHMRKXS(-2% TPMRKQERYJEGXYVIVLEZIXSFISFWIVZIH
•7GVI[HVMZIVMRWYPEXIHIPIGXVMGEP
•+IEVTYPPIVSVEVQIH %PPVSXEXMRKTEVXWLEZIXSFITVSXIGXIHEKEMRWXYRMRXIR
•4PMIVWJSVWRETVMRKWEGGSVHMRKXS(-2 XMSREPXSYGL(EQEKIWGEYWIHF]MQTVSTIVQSYRXMRKSV
•7RETVMRKTPMIVWEGGSVHMRKXS(-2 EHNYWXQIRXSJXLITYQTERHQSXSVEVIRSXGSZIVIHYRHIV
•1SYRXMRKWPIIZIWJSVFEPPFIEVMRKW [EVVERX]

-RMXMEP-RWXEPPEXMSRSJXLI4YQT
8LIWLEJXIRHSJXLITYQTERHHVMZIVLEZIXSFIEPMKRIH
GEVIJYPP]WMRGIIGGIRXVMGMX]RSR•TEVEPPIPMWQWERHTPEMR
EVVS[W[MPPJEWXHIWXVS]XLIIPEWXMGIPIQIRXSJXLIGSYTPMRK
ERHJYVXLIVQSVIGERGEYWIHEQEKIXSXLITYQT1SYRX
MRKXLITYQTXSEHVMZIVGEVIWLSYPHFIXEOIRXLEXXLIWMHISJJWIXSJXLI
WLEJXWHMWXERGIFIX[IIRWLEJXW XLIQE\MQYQIGGIRXVMGMX]GIRXIVSJJ
-RMXMEP-RWXEPPEXMSRSJXLI4YQT9RMX
WIXFIX[IIRXLIWLEJXW ERHXLIQE\MQYQERKYPEVMX]SJXLIX[SWLEJXW
HSRSXI\GIIHXLIVIGSQQIRHIHHEXESJXLIGSYTPMRKQERYJEGXYVIVW 8LITYQTYRMXLEWXSFIMRWTIGXIHEXXLINSFWMXIJSVHEQEKIW-JXLIYRMX
;LIRYWMRKWTIGMEPGSYTPMRKWXLIVIGSQQIRHEXMSRWSJXLIQERYJEG MWEWWIQFPIHEXXLINSFWMXIJSPPS[%JXIVTVSTIVEPMKRQIRXXLI
XYVIVGERRSXFII\GIIHIH%\MEPJSVGIWEVIRSXEPPS[IHXSFIXVERW GSQTPIXIYRMXLEWXSFIERGLSVIHEGGSVHMRKP]&EWIERHJSYRHEXMSRW
QMXXIHXLVSYKLXLIGSYTPMRKMRXSXLITYQT WII

1SYRXMRKXLIMRHMGEXSVSRXLIHVMZI 1SYRXMRKMRHMGEXSVSRSRIWLEJXERH
WLEJXERHVSXEXMSRSJFSXLWLEJXW XYVRMRKSJFSXLWLEJXW
GLIGOMRKSRGSRGIRXVMGMX]ERHGSVVIGXMSR GLIGOMRKSJTEVEPPIPMWQERHGSVVIGXMSRMJ
MJRIGIWWEV] RIGIWWEV]

)CIC6IZC
4EKISJ4EKI
 02+
7XEVXYT•7LYXHS[R 8LIHMWGLEVKIPMRILEWXSFIZIRXIHYRXMPTVSHYGXI\MXWXLIZIRXZEPZISV
ZIRXWGVI[8LIZIRXMRKHIZMGIWLEZIXSFIGPSWIHEJXIVXLMWTVSGI
8IGLRMGEP(SGYQIRXEXMSR HYVI
%JXIVWXEVXYTSJXLITYQTXSXEPTYQTTVIWWYVIJPS[VEXIZMWGSWMX]
XIQTIVEXYVIWTIIHERHLSVWITS[IVLEZIXSFIGSQTEVIHXSXLISVHIV
&IJSVIWXEVXYTGLIGOEPPXIGLRMGEPHIQERHW
%XXIRXMSR ERHHSGYQIRXEXMSRW)WTIGMEPP]GLIGOXLI ERHSTIVEXMSRHEXE'LIGOIWTIGMEPP]XLEX[MXLLMKLIVWTIGMJMGKVEZMX]
SVLMKLIVZMWGSWMX]SJXLITVSHYGXEWSVMKMREPEWWYQIHXLIHVMZIV[MPP
TYQTYRMXSR
RSXFISZIVPSEHIHERH247,VIUYMVIHSJXLITYQTMWRSXI\GIIHIH
•WIVMEPRS 3XLIV[MWIGEZMXEXMSR[MPPXEOITPEGI'LIGOXLIPMUYMHPIZIPMRXLIXERO
•X]TIERHWM^I IWTIGMEPP]EXXEROQSYRXIHYRMXWXLEXXLIWYGXMSRSTIRMRKEP[E]W
•JPS[HMVIGXMSRERHSTIVEXMSRX]TI WXE]WJPSSHIH

4MTIW7GLIQEXMGERH1IEWYVMRK4SMRXW
8SXLIWEZIERHXVSYFPIJVIISTIVEXMSRXLIZEPZIEHNYWXMRKTVIW
WYVIMWXSFII\EQMRIH•WIIGLETXIV
8LIXSXEPTMTMRKEVVERKIQIRXTVSTIVGSRRIGXMSRERHHMQIRWMSRSJ
QIEWYVMRKERHKSZIVRMRKHIZMGIWLEZIXSFISFWIVZIH 7LYXHS[RSJXLI4YQT
-JXLITYQTMWYWIHMRTSXIRXMEPP]I\TPSWMZIEVIEWXLIQIEWYVMRKERH
GSRXVSPXIGLRSPSK]QYWXFIGLIGOIH[MXLVIKEVHXSXLIETTVSZEPSJXLI *SVXLIWLYXHS[RSJXLIHVMZIVRSTVITEVEXMSRWEVIRIIHIH-JXLITYQT
HIZMGIW8LIHIGPEVEXMSRWSJGSRJSVQMX]EVIMRGPYHIHMRXLITVSNIGX MWWLYXHS[REKEMRWXJYPPTVIWWYVIMX[MPPWXERHWXMPPMQQIHMEXIP]YR
HSGYQIRXEXMSR TVSFPIQEXMGJSVTYQTERHIPIGXVMGQSXSV -XMWVIGSQQIRHIHXSMRWXEPPE
GLIGOZEPZIFIX[IIRXLIMWSPEXMSRZEPZIERHHMWGLEVKIPMRI%XPSRKIV
8LIGPIERMRKSJXLITMTI[SVOWLSYPHRSXFII\IGYXIH[MXL[EXIV
SV[MXLJPYMHW[MXLQMRMQYQZMWGSWMX]FIPS[XLIQMRMQYQMRHMGE WLYXHS[RXLIMWSPEXMSRZEPZIWWLSYPHFIGPSWIH-JEGLERKISJXLIJPYMH
XIHZMWGSWMX]WLS[RMRXLITYQTHEXEWLIIX(YVMRKL]HVSWXEXMG GSRGIRXVEXMSR GV]WXEPPM^EXMSR WSPMHMJMGEXMSR ERH SXLIVW LEZI XS FI
XIWXSJXLI[LSPITMTI[SVOW]WXIQXLITYQTQYWXFIMWSPEXIH XEOIRMRXSGSRWMHIVEXMSRXLITYQTLEWXSFIHVEMRIHERHJPYWLIH[MXL
8LIL]HVSXIWXSJXLITYQTH]REQMGSVWXEXMG [MPPGEYWIHEQEKI ETVSTIVJPYMH
XSXLITYQTIWTIGMEPP]XSXLIWLEJXWIEPMRKW]WXIQ -JXLMWTVSGI
HYVIMWRSXQEMRXEMRIHXLIKYEVERXIIMWRSXZSMH 6I•WXEVXMRK
(EQEKIW[LMGLSGGYVHYIXSMQTVSTIVTSWMXMSRMRKSVHM
QIRWMSRMRKSJQIEWYVMRKERHKSZIVRMRKHIZMGIWEVIRSX %JXIVEWLSVXWLYXHS[RXLITYQTGERFIVI•WXEVXIH[MXLSYXER]TVITE
GSZIVIHYRHIV[EVVERX] VEXMSRW%JXIVPSRKIVWXMPPWXERHMRKXMQISVVI•MRWXEPPEXMSRSJXLITYQT
XLITVSGIHYVIEGGSVHMRKXSWIGXMSRTVITEVEXMSRJSVWXEVXYTLEWXS
FIJSPPS[IH
4VITEVEXMSRJSV7XEVXYT
7XMPP7XERH
&IJSVIMRMXMEPWXEVXYTXLIJSPPS[MRKWGSTIWLEZIXSFI
GSQTPIXIH 7LYXHS[RJSVYTXS1SRXLW
•'PIERMRKSJXLITMTMRKWIGXMSR
•'LIGOMRKSJXLIERGLSVMRKWIGXMSR -JXLIWXEVXYTSJXLITYQTMW[MXLMRQSRXLWSJMRWXEPPEXMSRSVXLIWLYX
HS[RSJXLITYQTMWPIWWXLERQSRXLWRSWTIGMEPTVIWIVZEXMSRMWVI
•'LIGOMRKSRTS[IVWYTTP]XSXLIQSXSV
•'LIGOXLIHMVIGXMSRSJVSXEXMSRSJXLIHVMZMRKQSXSV UYMVIH
XLIHMVIGXMSRSJVSXEXMSRQYWXGSVVIWTSRHXSXLIHMVIG
7LYXHS[RJVSQXS1SRXLW
XMSRSJVSXEXMSREVVS[SRXLITYQT&]ERMRGSVVIGX
HMVIGXMSRSJVSXEXMSRXLITYQT[MPPTVSHYGIRSWYGXMSR
&IJSVIXLIMRMXMEPWXEVXYTXLIWYGXMSRERHHMWGLEVKITSVX
XLMW[MPPGEYWIXLITYQTXSFIHEQEKIH
LEZIXSFIGSZIVIH[MXLEFPERO%XWLYXHS[RWYGXMSR
•6IQSZIFPMRHTPYKWSRWYGXMSRERHHMWGLEVKIPMRIWWIGXMSR
ERHHMWGLEVKIMRWYPEXMSRZEPZIWLEZIXSFIGPSWIH;MXL
•'LIGOTMTMRKEGGSVHMRKXSJPS[HMVIGXMSRWIGXMSRERH
XLEXQIEWYVIXLITYQTVIQEMRWJMPPIH[MXLTVSHYGX-JXLI
•:MWYEPGLIGOMRKSJXLITYQTYRMXWIGXMSR
TVSHYGXMRGPYHIWEKKVIWWMZITEVXMGPIW[LMGLQMKLXEXXEGOXLIQEXIVMEPW
•3TIRMRKSJXLIWITEVEXMSRZEPZIW
SJGSRWXVYGXMSRSJXLITYQTJSPPS[EGGSVHMRKWIGXMSR
•*MPPTYQT[MXLTYQTMRKPMUYMHERHFIWYVIXSTVSXIGXEKEMRWXVYRRMRK
HV]*SVJMPPMRKMRJSVQEXMSRERHVIGSQQIRHEXMSRWWII(SGYQIRX)
7LYXHS[RJSVQSVIXLER1SRXLW
WII%TTIRHM\ 
•%PPKSZIVRMRKERHGSRXVSPIUYMTQIRXLEZIXSFIGLIGOIHSRJYRG
8LITYQTLEWXSFIGPSWIHSJJERHWIEPIHSJJEGGSVHMRKXS
XMSREJXIVMRWXEPPEXMSRMIIQIVKIRG]W[MXGLSJJRIIHPITVIWWYVI
ERHLEWXSFIJMPPIH[MXLTVIWIVZEXMSRQEXIVMEP8S
KEYKIERHSXLIVW
TVSXIGXXLIVYRRMRKWYVJEGIWSJXLIFIEVMRKWEKEMRWXGSQ
•8STVSXIGXTISTPIEPPIUYMTQIRXLEWXSFIEGGSVHMRKXSVYPIWERH
TVIWWMSR QEVOW GEYWIH F] ZMFVEXMSRW SV WLSGOW XLI
VIKYPEXMSRW
TS[IVVSXSVMWXSFIXYVRIHMREGGSVHMRKXMQIMRXIVZEPW-IEPP[IIOW
VSXEXIHQERYEPWSXLEXTEVXWPMOIXLIVSXSVWIXERHXLIFIEVMRKWLSYPH
7XEVXYT IRHMREHMJJIVIRXTSWMXMSRIEGLXMQI 

&IJSVIWXEVXYTXLIVSXEXMSRHMVIGXMSRERHWTIIHLEWXSFI 3TIVEXMSR7YTIVZMWMSR
GLIGOIH7YGXMSRERHTVIWWYVIKEYKIWLEZIXSFISF
WIVZIHERHGSQTEVIHXSSVHIVERHSTIVEXMSRHEXE8IQ 8LIRIGIWWEV]WYTIVZMWMSRSJE0IMWXVMX^WGVI[TYQTMW
TIVEXYVIERHZMWGSWMX]SJXLITVSHYGXWLSYPHFIGLIGOIH ZIV]QMRSV-RTVSTIVXMQIMRXIVZEPWHMWGLEVKITVIWWYVI
3RXLIHVMZIWMHIGSZIVMRXLIFEPPFIEVMRKEVIEXLIXIQ JPS[VEXII\GIWWTS[IVGSRWYQTXMSRSJXLIIPIGXVMGEPQS
TIVEXYVIGERFI•'FIPS[XLITVSHYGXXIQTIVE XSVEPMKRQIRXSJXLITYQTGSYTPMRK WIEPJMPXIVGSRXEQM
XYVIFYXLEWXSFIFIPS[' REXMSRERHYRYWYEPRSMWIWWLSYPHFISFWIVZIH8LIGPIERPMRIWWSJXLI
TVSHYGXMWXLIQEMRJEGXSVMRXLIPMJIXMQISJXLITYQT%ZMWYEPGLIGOSJ

)CIC6IZC
4EKISJ4EKI
 02+
XLITYQTWLSYPHFIHSRIEXPIEWXSRGIEQSRXL8LITYQTWLSYPHEP KVIEWI•JMPPMRK•UYERXMXMIW
[E]WVYRUYMIXERHZMFVEXMSRJVII8LITYQTMWRSXTIVQMXXIHXSVYRHV]
7LEJXWIEPWLSYPHFIGLIGOIHIWTIGMEPP]HYVMRKWXEVXYTXMQIPIEOEKI X]TISJTYQT KVIEWIJMPPMRKUYERXMX]
QMKLXSGGYV
8LIPIEOEKISJSRIHVSTSJTVSHYGXTIVLSYVMWEREZIVEKI 02+ K
JSV ER YRHEQEKIH QIGLERMGEP WIEP -J XLI TYQTW EVI 02+ K
QSYRXIHEWWTEVIWXLI]WLSYPHFIWXEVXIHYTJVSQXMQIXS 02+ K
XMQIJSVEWLSVXTIVMSHSJXMQIXSEWWYVIXLI]EVIVIEH] 02+ K
[LIRRIIHIH*YVXLIVQSVIXLIWLEJXWLSYPHFIVSXEXIHEGGSVHMRKXS 02+ K
WIGXMSR 02+ K
02+ K
&IEVMRKSJXLI(VMZMRK7TMRHPI
02+ K
8LIFIEVMRKSRXLITS[IVVSXSVMWEQEMRXIRERGIJVII 02+ K
KVIEWITEGOIHWIEPIHFEPPFIEVMRK8LIFIEVMRKMWHI 02+ K
WMKRIHJSVLSYVWVYRRMRKYRHIVXLIGSRHMXMSRWHI 02+ K
WGVMFIHYRHIVWIGXMSR-REVSYKLWIVZMGILMKLXIQ 02+ K
TIVEXYVIWSVSXLIVWXLIHIWMKRPMJIGERFIWLSVXIRIHHVEWXMGEPP] 02+ K
02+ K
-JXLIVIMWEVIKVIEWMRK•TSWWMFMPMX]EXXLITYQTXLIKVSSZIFEPPFIEVMRK 02+ K
LEWXSFIVIKVIEWIHVIKYPEVP]8LIVIKVIEWMRKMRXIVZEPWHITIRHSRXLI 02+ K
KVIEWIWIVZMGIPMJISJXLIYWIHKVIEWI•QIHMEERHSRXLISTIVEXMSREP 02+ K
GLEVKIW%QSRXLP]MRWTIGXMSRVIWTIGXMZIP]ERMRWTIGXMSREJXIVST
IVEXMRKLSYVW[SYPHFIVIGSQQIRHIHF]XLIQERYJEGXYVIV
8LIMRHMGEXIHPYFVMGERXWI\GPYWMZIP]ETTP]XS
*SVXLIPYFVMGEXMSREPPLMKL•UYEPMX]ERHXIQTIVEXYVI•VIWMWXERXFEPPFIE
VMRK•KVIEWIWEWTVSTSWIHEWJSPPS[WGERFIYWIH
%XXIRXMSR XLITYQT4PIEWI]SYGSRWMHIVXLIMVVIKYPE
XMSRW[MXLJYVXLIVGSQTSRIRXWJSVPYFVMGEXMSR

QERYJEGXYVIV YTXS ' YTXS '

%VEP %VEPYF,04
&4 &4•)RIVVIEWI07•)4
'EWXVSP 7TLIIVSP%T
()% +PMWWERHS)4 (MWOSV4PYW
)WWS &IEGSR)T 9RMVI\7
*YGLW 6IRSPMX*)4 6IRSTPI\)4
1SFMP 1SFMPY\)4 1SFMPXIQT7,'
3TXMQSP 3PMX)4SHIV 3TXMXIQT,8
0SRKXMQI4(
7LIPP %PZERME+VIEWI)4 (EVMRE+VIEWI

SVGSQTEVEFPIKVIEWI•TVSHYGXW

)CIC6IZC
4EKISJ4EKI
 02+
 1EMRXIRERGI *SVTYQTWLERHPMRKHERKIVSYWWYFWXERGIW
%XXIRXMSR ERHSV IRZMVSRQIRXEPP] LE^EVHSYW QIHME
XLIS[RIVQYWXMRJSVQMXWS[REWWIQFP]TIV
 +IRIVEP
WSRRIPSRWMXISJXLMWJEGXSVSYVJEGXSV]TIVWSRRIPMRGEWI
8LIQEMRXIRERGI[SVOMRGPYHIWEPQSWXI\GPYWMZIP]GLIGOMRKSJTYQT SJVIXYVR-RXLMWGEWI[IQYWXFITVIWIRXIH[MXLTVSSJSJ
TEVXWJSV[IEVERHHEQEKI0IMWXVMX^7GVI[4YQTWSJXLI7IVMIW02+ XLITYQTMRKQIHMYQIKMRXLIJSVQSJE(-27EJIX](EXE
7LIIXXSKIXLIV[MXLXLIVIUYIWXJSVGYWXSQIVWIVZMGI
RIIHQMRMQYQQEMRXIRERGIEWPSRKEWXLIGSRJMVQIHSTIVEXMRKHEXE
EVIOITXERHXLIJPYMHMWEWJVIIEWTSWWMFPIJVSQEFVEWMZITEVXMGPIW8LI (ERKIVSYWWYFWXERGIWEVI
GPIERPMRIWWERHXLIGETEFMPMX]XSPYFVMGEXIXLITVSHYGXEVIHSQMRERXMR
8S\MGGEVGMRSKIRMGIQFV]SXS\MGWYFWXERGIWKIRI•
XLII\TIGXERG]PMJISJETYQT-JELMKLSTIVEXMSRWEJIX]MWRIGIWWEV]
EPXIVMRKWYFWXERGIWSVWYFWXERGIW[LMGLEVISXLIV
[IVIGSQQIRHXLIJSPPS[MRKQEMRXIRERGIMRXIVZEPWEGGSVHMRKXSWIG
[MWILEVQJYPXSXLILIEPXLSJERHHERKIVSYWXSLYQER
XMSR FIMRKW
'EYWXMGWYFWXERGIW
-VVMXERXWI\TPSWMZIJMVITVSQSXMRKLMKLP]JPEQQEFPI
 1EMRXIRERGIERH-RWTIGXMSR
ERHJPEQQEFPIQEXIVMEPW
•%JXIVLSYVWSJSTIVEXMSRXLITYQTWLSYPHFII\ 'SVVSWMZIQEXIVMEPW
EQMRIH XLI TYQT WLSYPH FI GLIGOIH JSV YRYWYEP
RSMWIWERHMXWLEPPFIGLIGOIH[MXLEXIQTIVEXYVIWIR 8LIYWIVMWWSPIP]VIWTSRWMFPIJSVQSYRXMRKSRWMXI[EVR
WSV8LIXIQTIVEXYVIHMJJIVIRGIFIX[IIRXLIJPYMHERH MRKWMKRW[LMGLREXYVEPP]WLEPPFISFWIVZIHEXEPPXMQIW
XLIHVMZIWMHIGSZIVWLSYPHRSXI\GIIH•'8LI (YVMRKEPPEGXMZMXMIWSRWMXIXLIS[RIVWS[RTIVWSRRIP
PIEOEKISJXLIQIGLERMGEPWIEPWLSYPHRSXI\GIIHEJI[ ERH 0)-786-8> IQTPS]IIW QYWX FI MRJSVQIH SJ EPP
HERKIVW[LMGLGERSGGYVHYVMRKHMWQERXPMRKERHSVVITEMV
HVSTWTIVLSYV
[SVO
•%JXIV]IEVWXLITYQTWLSYPHFIHMWEWWIQFPIHERHEPPMRRIVTEVXW
*SVQSYRXMRKERHVITEMV0)-786-8>TIVWSRRIPGERFIQEHIEZEMPEFPI
WLSYPHFII\EQMRIHJSVHEQEKIERH[IEVIWTIGMEPP]XLIQIGLERMGEP
XSXLIYWIVYTSRVIUYIWX
WIEPLEWXSFIGLIGOIHMRXLIWPMHMRKWYVJEGIW8LIMHPIVVSXSVLIEH
 (MWEWWIQFP]ERH%WWIQFP]
WYVJEGIWLEZIXSFIGLIGOIHJSV[IEVEW[IPP
8LIQSWXMQTSVXERXHMWEWWIQFPMRKERHQSYRXMRKWXITW
•;SVRTEVXWRIIHXSFIVITPEGIH'LIGOXLIGEWMRKERHXLIJPS[TSGO
EVIHIWGVMFIHMRXLIJSPPS[MRK
IXWMRXLIVIPMIJZEPZIJSVHMVXGSRXEQMREXMSR-JHMVXHITSWMXWEVIRSXIHMX
2S[EVVERX]GPEMQWGERFIEGGITXIHMJEPPRIGIWWEV]EW
RIIHWXSFIGPIERIHSYX WIQFP]WXITWLEZIRSXFIIROITXMRSVHIVSVHEQEKIW
HYIXSMQTVSTIVHMWEWWIQFP]SVEWWIQFP]SGGYVVIH

 8SSPW
 (MWEWWIQFP]ERH%WWIQFP] 2IGIWWEV]%WWIQFP]8SSPWWII7IGXMSR

 +IRIVEP4VIGEYXMSR  (MWEWWIQFP]SJXLI4YQT

•8LITS[IVPMRIWLEZIXSFIHMWGSRRIGXIHF]ER)PIG
;MXLTVSTIVWYTIVZMWMSRSJXLITYQTSTIVEXMSRMRXIVVYTXMSRW[LMGL XVMGMER1SXSVSVHVMZIVLEZIXSFIQEHIYRJYRGXMSREP
QMKLXQEOIEHMWEWWIQFP]RIGIWWEV]EVIZIV]VEVI-JERMRXIVVYTXMSR •'LIGOMRKSJXLIMRWYPEXMSRZEPZIWMRWYGXMSRERHHMW
SGGYVWXLITSWWMFPIGEYWIWLSYPHFIHIXIVQMRIHFIJSVIHMWEWWIQFP] GLEVKIPMRIXLI]LEZIXSFIGPSWIH
MJEXEPPTSWWMFPI8LIXVSYFPIWLSSXMRKXEFPIMRWIGXMSRKMZIWLMRXW •0IXTYQTGSSPHS[RXSWYVVSYRHMRKIRZMVSRQIRXXIQ
EFSYXTSWWMFPIGEYWIW%XEPPHMWEWWIQFP]ERHEWWIQFP]EPPTEVXW TIVEXYVI
LEZIXSFILERHPIH[MXLGEVI7LSGOWERHMQTEGXWLEZIXSFIEP[E]W •(MWGSRRIGXWYGXMSRERHHMWGLEVKIJPERKIW
EZSMHIH%PPTEVXWLEZIXSFIGEVIJYPP]GPIERIHTSWWMFP]VI•GSRHM •&]YRFSPXMRKXLIQSYRXMRKJPERKIXLITYQTGERFI
XMSRIH SV I\GLERKIH JSV WTEVI TEVXW %JXIV EWWIQFP] XLI (VMZMRK PMJXIHJVSQXLIQSYRXMRKYRMX
•'SYTPMRKWLEPJSRTYQTWLEJXLEWXSFITYPPIHZME
WTMRHPILEWXSVSXEXIJVIIP]SXLIV[MWIXLIFIEVMRKERHQIGLERMGEPWIEP
KIEVTYPPIVVIQSZIOI]TSWMXMSR JVSQTYQT
GSYPHFIHEQEKIH%XEPP[SVOXLITVSTIVGVSWWWIGXMSREPHVE[MRKLEW
WLEJX
XSFIYWIHEW[SVOFEWI
•:EPZIWWTVMRKTSWMXMSR RIIHWXSFIVIPIEWIHZME
EHNYWXMRKWGVI[XLIWIEPRYXTSWMXMSR RIIHW
XSFIPSSWIRIHJSVXLMWTYVTSWISRP][MXLMRXIKVEP
TVIWWYVIVIPMIJZEPZI 
 %JXIV7EPIW7IVZMGI8IGLRMGMERW(ERKIVW
•8SVIQSZIIRHWMHIGSZIVSVXLITIHIWXEPTSWMXMSRSV XEOI
SYXFSPXWTSWMXMSRSV ERHVIQSZIKEWOIXWTSWMXMSR 
0)-786-8>•7IVZMGI 8IGLRMGMERW JSV QSYRXMRK ERH VITEMVW GER FI
•6IQSZIZEPZITEVXWTSWMXMSRERH SRP][MXLMRXIKVEP
QEHIEZEMPEFPIXSXLIYWIVYTSRVIUYIWX
VIPMIJZEPZI 
-JVITEMV[SVOMWXSFIGEVVMIHSYXF]XLIS[RIVSVF]0)-7 •0SSWIRWGVI[WTSWMXMSR SRHVMZIWMHIGSZIVTSWMXMSR ERH
86-8>WIVZMGITIVWSRRIPXLITYQTQYWXEP[E]WFIHI VIQSZIHVMZIWMHIGSZIVERHKEWOIXTSWMXMSR JVSQTYQTGEW
TVIWWYVMWIHGSQTPIXIP]HVEMRIHERHGPIERIH8LMWMWIW MRKTSWMXMSR (SMRKXLEX[EXGLJSVWTMRHPIWIXQIGLERMGEP
TIGMEPP]ETTPMGEFPIJSVTYQTWXLEXEVIVIXYVRIHXSSYVJEG WIEPERHKVSSZIHFEPPFIEVMRK7IIZEPMHWIGXMSREPHVE[MRK
XSV]JSVVITEMV-RSVHIVXSTVSXIGXSYVIQTPS]IIWERHJSV •7ITEVEXIMHPIVWTMRHPIWTSWMXMSR JVSQHVMZMRKWTMRHPITSWMXMSR
IRZMVSRQIRXEPTVSXIGXMSRVIEWSRWTYQTWJMPPIH[MXLTYQTMRKQIHMYQ  
[MPPRSXFIEGGITXIHJSVVITEMV3XLIV[MWIXLIS[RIV[MPPFIGLEVKIHJSV •6IQSZIGMVGPMTTSWMXMSRERH ERHWYTTSVXMRKHMWOTSWMXMSR
XLIGSWXWJSVERIRZMVSRQIRXEPP]ETTVSTVMEXIHMWTSWEP  

)CIC6IZC
4EKISJ4EKI
 02+
•4YPPHVMZMRKWTMRHPITSWMXMSR XLVSYKLXLI-(SJXLIKVSSZIH [MXLXLIWYTTSVXMRKHMWOTSWMXMSR MRTPEGIXLVSYKLXLIHVMZI
FEPPFIEVMRKTSWMXMSR XS[EVHWWYGXMSRWMHIXLVSYKLXLIHVMZI WMHIGSZIVERHXLIFEPPFIEVMRK2IZIVHVMZIXLIHVMZMRKWTMRHPI
WMHIGSZIV6IQSZIWYTTSVXMRKHMWOTSWMXMSR  XLVSYKLXLIFEPPFIEVMRK[MXLMQTEGXF]ELEQQIVRSVXLIFEPP
•8LIVSXEV]TEVXSJXLIQIGLERMGEPWIEPLEWXSFIGEVIJYPP]TYPPIH FIEVMRKSZIVXLIWLEJXZMELEQQIV8LIHVMZMRKWTMRHPIWPMKLXP]
JVSQXLIHVMZMRKWTMRHPI(ITIRHMRKSRXLIQERYJEGXYVIVXLIPSGO KVIEWIHRIIHWXSIRKEKI[MXLXLIMRRIVHMEQIXIVSJXLIFEPPFIEV
MRKHIZMGILEWXSFIVIQSZIH MRKEPPXLI[E]SRXSXLIWLSYPHIVSRXLIHVMZMRKWTMRHPI%JXIV
•8LIWXEXMSREV]JEGISJXLIQIGLERMGEPWIEP[MXL3•VMRKSVWIEPVMRK [EVHWQSYRXXLIWYTTSVXMRKHMWOTSWMXMSR ERHGMVGPMTTSWM
GERRS[FITVIWWIHSYXGEVIJYPP]SJXLIHVMZIWMHIGSZIV XMSR 
•6IQSZIKVSSZIHFEPPFIEVMRKTSWMXMSR MRHMVIGXMSRWLEJXIRH •4YX3•VMRKTEVX MRTPEGISRXSHVMZIWMHIGSZIVTSWMXMSR 
[MXLEKIEVTYPPIVSYXSJXLIHVMZIWMHIGSZIVTSWMXMSR  •4SWMXMSRXLIMHPIVWTMRHPIWTSWMXMSR EWETEMVSRXSXLIHVMZMRK
WTMRHPIERHWPMHIWTMRHPIWIXMRXSXLIGEWMRK;EXGLJSVXLITSWM
 %WWIQFP]SJXLI4YQT XMSRSJXLIVYRRMRKWYVJEGIWQEVO XLIGEWMRKFS\WLSYPHFI
WPMKLXP]SMPIHJSVXLMWTYVTSWI&SPXXLITYQTGEWMRK[MXLWGVI[W
%VI•EWWIQFP]GERSRP]FITIVQMXXIHMJJYPPJYRGXMSREPERH
TSWMXMSR SRXSHVMZIWMHIGSZIVRSXIXLEXXLIWGVI[WRIIHXS
YRHIJIGXMZITEVXWEVIYWIH;IVIGSQQIRHEW[IPPE
FITYPPIHWMQYPXERISYWP]ERHXLITVSTIVTSWMXMSRSJXLIGSRRIGXMSR
GPIERMRKSJLIEZMP]WXEMRIHTEVXW
JPERKIWLEWXSFIRSXIH
•%WWIQFP]ZEPZITEVXWTSWMXMSRRYQFIV[MXLMRXLI
•8LIKVSSZIHFEPPFIEVMRKTSWMXMSR RIIHWXSFIGLIGOIHJSV
TVSTIVSVHIVMRXSXLIZEPZIGEZMX]SRP][MXLI\MWXMRKVIPMIJZEPZI 
HEQEKIWHIJIGXMZIWIEPHMWOWXLIRMXWLSYPHFITVIWWIHMRXSXLI
•4PEGIKEWOIXTSWMXMSR SRXSXLIIRHWMHIGSZIVSJXLITYQT
HVMZIWMHIGSZIVTSWMXMSR 0MOIWQSSXLVYRKVIEWIJMPPMRK
GEWMRKTSWMXMSR 
2IZIVJSVGIXLIFIEVMRKMRTPEGIF]QIERWSJELEQQIVXLMW
•8YVRWIXWGVI[TSWMXMSR XLEXJEVMRXSXLIIRHWMHIGSZIV
[SYPHGEYWIHEQEKISJXLIVYRRMRKWYVJEGIWERHXLIFIEVMRK
TSWMXMSR XLEXXLIXMTSJXLIEHNYWXQIRXWGVI[XSYGLIWXLI
FEPPW7IGYVIMRTPEGIF]QIERWSJXLIGMVGPMTTSWMXMSR 
WTVMRKTPEXITSWMXMSR [MXLSYXXIRWMSRMRKXLIZEPZIWTVMRK
•1SYRXMRKSJXLIQIGLERMGEPWIEPRIIHWEFWSPYXIGPIERPMRIWW
TSWMXMSR %JXIV[EVHWTYPPXLIIRHWMHIGSZIVXMKLXF]QIERW
)WTIGMEPP]EHEQEKISJXLIWPMHMRKWYVJEGIWERHIPEWXSQIVWLEZI
SJYWMRKWGVI[WTSWMXMSR WIEPRYXTSWMXMSR SRXSEHNYWX
XSFIEZSMHIH
QIRXWGVI[ERHEJXIVEHNYWXMRKXLIVIPMIJZEPZIXSTVSTIVSTIVEXMRK
•8LIWXEXMSREV]IPIQIRXSJXLIQIGLERMGEPWIEP
TVIWWYVIWWIEPXMKLXSRP]MJEVIPMIJZEPZII\MWXW 
TSWMXMSR GERFITVIWWIHMRXSXLIHVMZIWMHIGSZIV[MXLXLI
•,IEXTYQTWMHIGSYTPMRKLEPJXSETT'ERHWPMHI
3•VMRKMRTPEGI;EXGLJSVIUYEPTVIWWYVIHMWXVMFYXMSRSZIVXLI
SRXSWLEJXIRHSJXLIHVMZMRKWTMRHPI[MXLXLIOI]
[LSPIVMRK;EXGLEW[IPPJSVXLITSWMXMSRSJXLIIHKIHEHNYWXMRK
 MRTPEGI8LIGSYTPMRKLEPJWLEPPRSXFIMRWXEPPIH
TMRTSWMXMSR MRHVMZIWMHIGSZIVTSWMXMSR -JRIGIWWEV]
[MXLMQTEGXF]ELEQQIV
WTEGIVVMRKTSWMXMSR SRXSHVMZMRKWTMRHPITSWMXMSR 
;EXGLJSVEFWSPYXIP]YRHEQEKIHHVMZMRKWTMRHPIWYVJEGIMRXLI %JXIVGSQTPIXIVI•EWWIQFP]XLITYQTLEWXSFIMRWXEPPIHMRXSXLIHVMZ
QIGLERMGEPWIEPEVIE MRKYRMXERHFIQSYRXIHEGGSVHMRKXSWIGXMSR8LIVIEJXIVXLIHMW
•8SVIHYGIXLIJVMGXMSRJSVGIWEXEWWIQFP]SJXLIQIGLERMGEPWIEP GLEVKIWYGXMSRERHWYTTP]PMRIWLEZIXSFIGSRRIGXIHTVSTIVP]%XXLI
SMPHVMZMRKWTMRHPITSWMXMSR MRXLIEVIESJXLIVSXEXMRKIPIQIRX VIWXEVX•YTWIGXMSRLEZIXSFIJSPPS[IHERHXLITVIWWYVIPMQMXEXMSR
[MXLSMPSVWMPMGSRIKVIEWIJMPP-XMWRSXTIVQMXXIHXLEX8IJPSRSMPVMRK ZEPZIWEJIX]ZEPZIMJI\MWXMRKLEWXSFIEHNYWXIH
KIXWMRGSRXEGX[MXLQMRIVEPSMPSVKVIEWI7MPMGSRIKVIEWIMWVIG •8LIHS[RZEPZIWTVMRKTSWMXMSR LEVHZMEEHNYWXQIRXWGVI[
SQQIRHIHHITIRHMRKSRWIEPI\IGYXMSRXLIVSXEV]TEVXRIIHWXS TSWMXMSR 
FIPSGOIHSRXSXLIWLEJX •7XEVXTYQT[MXLXLIXLVSXXPIZEPZI%STIR
%FSZI MWRSXETTPMGEFPIJSVVYFFIVFIPPS[W •8LVSXXPMRKZEPZI%WSXLEXXLITVIWWYVIKEYKIWLS[WXLIVIUYMVIH
%XXIRXMSR WIEPWXLI]LEZIXSFIQSYRXIH[MXLETVSTIV
WSPZIRX[EXIVSVEPGSLSP
ZEPZISTIRMRKTVIWWYVIERHXLIJPS[QIXIV&WLEPPWLS[WXIEH]
JPS[
•6IPIEWIZEPZIWTVMRKZMEEHNYWXQIRXWGVI[TSWMXMSR YRXMPXLI
•2IZIVKVIEWIXLIWPMHMRKWYVJEGIWEP[E]WQSYRXGSQTPIXIP]HV] JPS[VEXISRXLIJPS[QIXIVRYQFIV&PS[IVW8LMWQIERWXLIVIPMIJ
ERHHYWXJVII ZEPZISTIRMRKTVIWWYVIMWVIEGLIH
•%JXIVQSYRXMRKSJXLIVSXEV]IPIQIRXTSWMXMSR SRXSXLIHVMZ •'PSWIXLVSXXPIZEPZI%2S[XLITVIWWYVIKEYKI[MPPWLS[XLI
MRKWTMRHPITSWMXMSR XLIHVMZMRKWTMRHPIRIIHWXSFIQSYRXIH TVIWWYVI[LIVIXLIXSXEPJPS[MWG]GPIHSZIVXLIZEPZI



 

)CIC6IZC
4EKISJ4EKI
 02+
• (IWMKRZEVMERX[MXLWIEPMRKRYXERHEHNYWXMRKWGVI[
•0SGOWIEPRYX XMKLXP]

• (IWMKRZEVMERXGETRYXWIEPMRKSJEHNYWXMRKWGVI[
*SVJM\MRKSJXLIEHNYWXMRKWGVI[TSWMXMSR XLMWSRILEWXSFI
GSYRXIVIH[MXLXLILI\EKSREPRYXTSWMXMSR ERHXLIWIEPMRKVMRK
TSWMXMSR %JXIV[EVHWXLIGETRYXTSWMXMSR LEWXSFIXMKLX
IRIH[MXLIXLIWIGSRHWIEPMRKVMRKTSWMXMSR 

*YVXLIVWXITWWIIWIGXMSR

 2SXMGIXSXLIZEPZIEHNYWXMRKTVIWWYVIW
0MOIEPPTSWMXMZI•HMWTPEGIQIRXTYQTWXLMWWGVI[TYQTVIUYMVIWE
TVIWWYVIVIPMIJZEPZIXSTVSXIGXEKEMRWXSZIVPSEHMRK8LMWZEPZIGERFI
MRWXEPPIHI\XIVREPP]EWERI\XIVREPZEPZIMRXLITMTMRKW]WXIQSVHM
VIGXP]EWEREXXEGLIHTEVXSRXLITYQT8LIVIWTIGXMZIQSHIPMWWTIGM
JMIHMRXLIHEXEWLIIXSVXLIZEPMHHVE[MRKW
-JRSSXLIVEKVIIQIRXLEWFIIRQEHIXLIZEPZIEGXYEXMSRTVIWWYVIMW
TVI•WIXEXXLIJEGXSV]SRXLIXIWXFIRGL8LISTIRMRKTVIWWYVIMWET
TVS\XS EFSZIXLISTIVEXMRKTVIWWYVI,S[IZIVXLIZEPYIWSR
XLIW]WXIQQYWXFIGLIGOIHTVMSVXSGSQQMWWMSRMRK
8LIJSPPS[MRKHMWXMRGXMSRMWQEHIJSVZEPZIW
• :EPZIEGXYEXMRKTVIWWYVIXLMWMWXLITVIWWYVIEX[LMGLXLIZEPZI
FIKMRWXSSTIR
• :EPZIWLSVX•GMVGYMXTVIWWYVIXLMWMWXLITVIWWYVIEX[LMGLXLIIR
XMVITYQTJIIHUYERXMX]JPS[WSJJZMEXLIZEPZI
• :EPZIGPSWMRKTVIWWYVIXLMWMWXLITVIWWYVIEX[LMGLXLIZEPZILEW
GPSWIHEKEMRJSPPS[MRKVIPMIJ
-XQYWXFIRSXIHXLEXEXPS[STIVEXMSRTVIWWYVIWXLIEHNYWXQIRXZEPYIW
EVIWIPIGXIHWSXLEXXLIZEPZIGPSWMRKTVIWWYVIMWEP[E]WEFSZIXLI
STIVEXMRKTVIWWYVIERHXLIZEPZIWLSVX•GMVGYMXTVIWWYVIHSIWRSX
PIEHXSSZIVPSEHMRKSJXLITYQTERHHVMZI
-JXLMWMWRSXSFWIVZIHHEQEKIXSXLITYQTERHHVMZIQE]VIWYPX;I
WLEPPEWWYQIRSPMEFMPMX][LEXWSIZIVJSVHEQEKIVIWYPXMRKJVSQEJEMPYVI
XSSFWIVZIXLMWJEGX

 7TEVI4EVXW
-RKIRIVEP[IVIGSQQIRHXLEXXLIYWIVWLSYPHOIITEGSQTPIXIWIXSJ
WTEVITEVXWJSVXLITYQTYRMXSRWXSVIW-XMWEPWSTSWWMFPIXSWIPIGXEWIX
SJETTVSTVMEXIWTEVIWEGGXSSYVWTEVITEVXWPMWXJSVXLIMRHMZMHYEPYWIV
-RSVHIVXSHSXLMWXLIJSPPS[MRKMRJSVQEXMSRWLEPPFIWYTTPMIH[LIRSV
HIVMRK
•4YQT8]TI
•4YQT7M^I
•0IMWXVMX^7IVMEP2YQFIV
•'VSWW7IGXMSREP(VE[MRK2YQFIV
•4YVGLEWIV9WIV
•2EQI
•%HHVIWWERH8IPITLSRI2YQFIV
%RMRXIVGLERKIEFMPMX]GERSRP]FIKYEVERXMIH
%XXIRXMSR MJEGGYVEXIMRJSVQEXMSRMWKMZIR

'SRWIVZMRKERHMRXIVQIHMEXIWXSVEKISJWTEVITEVXWSVWTEVITYQTW
WIIWIGXMSRERH

)CIC6IZC
4EKISJ4EKI
 02+
8VSYFPI7LSSXMRK 7SPZMRKEPPSJXLITEVXMGYPEVHMWXYVFERGIWXLITYQTRIIHW
8EFPIXSHIJMRI6IEWSRERHWSPZMRKSJ4VSFPIQW XSFI[MXLSYXW]WXIQTVIWWYVIERHRIIHWXSFIHVEMRIH

8LIXEFPIFIPS[MWYWIHXSHIJMRIIZIRXYEPP]LETTIRMRKHMWXYVFERGIWEX
XLITYQTYRMX-JTVSFPIQWSGGYVHYVMRKSTIVEXMSRSJXLIYRMX[LMGLEVI
RSXPMWXIHMRXLIXVSYFPIWLSSXMRKPMWX[IVIGSQQIRHEGLIGOFEGO[MXL
XLIJEGXSV]SVXLIWEPIWJSVGIW

4VSFPIQWEXXLITYQTYRMX

6IEWSRWERH6IWSPYXMSR

'SQTEVIVSXEXMSRHMVIGXMSREVVS[SJXLITYQT[MXLXLIQSXSVHMVIGXMSR
SJVSXEXMSRMJRIGIWWEV]GLERKIQSXSVHMVIGXMSR
'LIGOWYGXMSRWERHEVQEXYVIWJSVXMKLXRIWWGSRXVSPPIHTVIWWYVIVIPMIJZEPZI
247,EZEMPEFPIXSPS[WLSVXIRWYGXMSRPMRI
QSYRXTYQTPS[IVMRW]WXIQMQTVSZIJPS[PE]WYGXMSRPMRIWQSVIWXVEMKLX
HMQIRWMSRWYGXMSRPMRIFMKKIVMRHMEQIXIVIPMQMREXIJPS[XYVFYPIRGI
IPMQMREXIJPS[XYVFYPIRGI PE]WYGXMSRPMRIWQSVIWXVEMKLX
7]WXIQERHTYQT[MXLSYXJPYMHJMPPTYQT[MXLTVSHYGX
(VMZIWTIIHXSSPS[GLIGOHVMZIVSRWTIIHERHGLIGOTS[IVWYTTP]XSQSXSV;MXLIPIGXVMGEPQSXSVW
GLIGOWTIIHEQTIVEKIERHJVIUYIRG]XSX]TIOI]ERHGSQTEVIXSI\MWXMRKTS[IVWYTTP]
(MWGLEVKITVIWWYVIXSSLMKLGLIGOSTIVEXMRKHEXESJXLITYQT
ZMWGSWMX]XSSLMKLGLIGOSTIVEXMRKHEXESJXLITYQTLIEXYTTVSHYGX
:MWGSWMX]XSSPS[GLIGOSTIVEXMRKHEXE MJRIGIWWEV]MRGVIEWIHVMZIWTIIH
YWITYQT[MXLLMKLIVWTMRHPITMXGLSVRI\XWM^ITYQT
MJRIGIWWEV]GLERKIXIQTIVEXYVIXSMRGVIEWIZMWGSWMX]SJXLITVSHYGX
(YVMRKSTIVEXMSRXLIW]WXIQERHTYQT[EWRSXJMPPIH[MXLTVSHYGX
%MVMRWYGXMSRERHHMWGLEVKIW]WXIQHI•EIVEXIXLITYQTEXXLILMKLIWXTSMRX
YWIPEVKIVXERO[MXLFIXXIVHI•KEWWMRKIJJIGXHVSTVIXYVRPMRIFIPS[JPYMHPIZIPMRXERO
1IGLERMGEPWIEPHEQEKIHF]MQTYVMXMIWMRXLITVSHYGX
QIGLERMGEPWIEPJEGIWHEQEKIHERH[SVRSYX
WIEPWYVJEGIWVERHV]SZIVLIEXIHERHHIJIGXMZIVITPEGIQIGLERMGEPWIEP
WTMRHPIWWIM^IHMRXLIGEWMRKFSVMRKSVQEGLMRIHXLIQWIPZIWMR
PETTMRKSJHEQEKIHEVIEMJQMRSVVI•QSYRXMRKGLIGOERHHSRSXI\GIIHSTIVEXMRKHEXE
4YQTMRRIVTEVXWLEZIXSFIHEQEKIHERH[SVRVI•QSYRXWTEVITEVXWJMPXIVXLITVSHYGXSVGLERKI
JMPXIVWGLIGOSTIVEXMSRHSRSXI\GIIHSTIVEXMRKTSMRXW
4YQTERHGSYTPMRKRSXTVSTIVEPMKRIHERHQSYRXIH
RI[EPMKRQIRXGLIGOHEXESJGSYTPMRKQERYJEGXYVIVERHSFWIVZI
'SRRIGXMSRWXSRS^^PIWEVIRSXQSYRXIH[MXLSYXER]XIRWMSR
EPMKRTMTMRKQSYRXXIRWMSRJVIIMJRIGIWWEV]QSYRXGSQTIRWEXMSRTMIGIWMRTMTIW
WYTTSVXTMTMRKEGGSVHMRKP]
*SYRHEXMSRFSPXWEVIYRHIVHMJJIVIRXXIRWMSR
PSSWIR XIRWMSR MHIRXMGEP
&EPPFIEVMRKHIJIGXHMWEWWIQFPIERHVITPEGI
'SYTPMRKIPEWXSQIVHIJIGXHMWEWWIQFPIHTYQTQSXSVYRMXERHVITPEGIIPEWXSQIV

)CIC6IZC 4EKISJ4EKI
 02+
8SVUYI6IUYMVIQIRXW %PPS[EFPITMTIJSVGIWERHQSQIRXW
2IGIWWEV]XSVUYIVIUYMVIQIRXWEGGSVHMRK&(-WLIIXQI *SVGIWERHQSQIRXWWLS[RSREWWIQFP]ERHHMQIRWMSREPHVE[MRKW
HMYQJVMGXMSR JEGXSVJSVWLEJXWWGVI[WERHQIXVMGWXERHEVHXLVIEH WLEPPRSXFII\GIIHIH
EGGSVHMRKXS(-2TEVXERHLIEHHMQIRWMSRSJLI\LIEHWGVI[W
EGGSVHMRKXS(-2SV%PPIRLIEHWGVI[WEGGSVHMRKXS(-2 :MSPEXMRKERHI\GIIHMRKXLIWIZEPYIWGERHEQEKIXLI
TYQTGEYWMRKSTIVEXMRKTVSFPIQW)ZIRXYEPP]SGGYVVMRK
XLVIEHWM^I TVSTIVX]GPEWW WXEVXMRKXSVUYIMR2Q
XLIVQSXIRWMSRWLEZIXSFIGSVVIGXIHF]HIWMKRQSHMJMGE
1   XMSRJPI\MFPITMTMRK 
1  
1  
1  
1  
1  

%PPS[EFPITMTIJSVGIWERHQSQIRXW

6IZ•2S 'LETXIV 4EKI 1SHMJMGEXMSR (EXI 2EQI 'LIGOIH

   PYFVMGEXMSRMRJSVQEXMSREHHIH  *VFK
 EPP WM^IW•EHHXS  *VFK
  • 6IQEVOWXSžXIQTIVEXYVI•ERHTVIWWYVIPMQMXEXMSRWžEHHXS  *VFK
•
   'PIERMRKTVIWWYVIXIWXERHJMPPMRKSJXLITMTI[SVO  ,& *VFK

   PYFVMGEXMSRMRJSVQEXMSREHHIH02+YTXS02+  *VFK
   -RJSVQEXMSRž)<•ETTPžERHžZEPZIEHNYWXMRKTVIWWYVIWžEHHIH  *VFK

   PYFVMGEXMSRMRJSVQEXMSREHHIH  *VFK

*MVWXIHMXMSR 4VITEVIH 'LIGOIH %TTVSZEP  

(EXI 3GX   
(ITEVXQIRX /74  

(VE[MRKW(EXE7LIIXW%TTIRHM\



)CIC6IZC 4EKISJ4EKI
 %HHMXMSREPJSV7LEJX7IEP
4YQTIR+QF,
ž3MP6IGIMZIV1IGLERMGEP7IEPž 02+
STXMSREP

3MP6IGIMZIV8ERO 3MP6IGIMZIV8ERO
TYQTTSWMXMSR TYQTTSWMXMSR
LSVM^SRXEPPMRI ZIVXMGEPPMRI

6IKVIEWMRK
HIZMGI

*YRGXMSRSJXLISMPVIGIMZIV 3RWIEPMRKPIEOEKIERHLMKLIVEXQSWTLIVMGTVIWWYVIEXXLIWYGXMSRMR

8LIGSRXEGXFIX[IIRXLILSXGSRZI]MRKQIHMYQERHXLIGSSPEQFMIRXEMV XEOI SJXLITYQTXLIPIZIPVEMWIW
LEWXSFIEZSMHIHJSVGSRZI]MRKPYFVMGERXWEXXIQTIVEXYVIWJVSQ' -RWTIGXMSRERHJMPPMRKMRXIVZEPW
JSVI\EQTPILIEZ]SMPW;LIRPIEOEKIIWGETIW[LMGLMWXSEPIWWHIKVII 8LIMRWTIGXMSRERHXLIVIJMPPMRKSJXLIVIGIMZIVWMWHITIRHIRXSRXLIVI
MRIZMXEFPIJSVQIGLERMGEPWIEPWXLIIWGETMRKPMUYMHMWGVEGOMRKERHGEY WTIGXMZISTIVEXMRKHEXESJXLIW]WXIQ8LIPIZIPERHXLIGSRWYQTXMSR
WIWQEPJYRGXMSRWSJXLIQIGLERMGEPWIEP WLSYPHFIGLIGOIHMRWLSVXMRXIVZEPWHYVMRKXLIFVIEO•MRTIVMSH;IWYK
KIWXXSGLIGOXLIPIZIPSRSTIVEXMRKWXEVXHEMP]ERHEJXIVETIVMSHSJSTIVE
-RWXEPPEXMSRSJXLISMPVIGIMZIV
XMSR[IIOP]3RGSRXEQMREXMSRSJXLISMPJMPPMRKZMWMFPISRXLIGLERKISJXLI
8LIMRWXEPPEXMSRMWHIWGVMFIHMRXLIMPPYWXVEXMSRWEFSZI8LISMPVIGIMZIVMW
SMPGSPSVXLISMPWLSYPHFII\GLERKIHEJXIVGPIERWMRK
TPEGIHYT[EVHW[LIRTYQTLEWELSVM^SRXEPEVVERKIQIRXERHMRHMVIG
XMSRSJXLIHVMZMRK[LIRXLITYQTLEWEZIVXMGEPEVVERKIQIRX 6IKVIEWMRKMRWXEPPEXMSRFEPPFIEVMRK
(IWMKRSJXLISMPVIGIMZIV 8LIFEPPFIEVMRKWEVII\GPYWMZP]JMXSYX[MXLEVIKVIEWMRKMRWXEPPEXMSR
8LISMPVIGIMZIVEPPS[WEHYWX•TVSSJJMPPMRKSJYRTVIWWYVM^IHVIGMTMIRXQI
;IVIGSQQIRHEQSRXLP]VIKVIEWMRKSVEVIKVIEWMRKEJXIVQE\VYR
HMYQW8LIXVERWTEVIRXG]PMRHIVNEGOIXWGSRWMWXSTXMSREPSJTPI\MSVREXY
RMRKLSYVW-RJSVQEXMSRWEFSYXXLIKVIEWIPIZIPWERHXLIWYKKIWXIHPY
VEPKPEWXLIWIEPWGSRWMWXSJ2&6SVZMXSR8LIQEXIVMEPW[MPPFIHIWMKRIH
FVMGERXWGSYPHFIJSYRHMRXLISTIVEXMRKMRWXVYGXMSRW)
XSQIIXXLIVIUYMVIQIRXW
6IGMTMIRXQIHMYQ
*SVJMPPMRKXSGSRZI]XLILIEZ]SMPLIEXXVERWJIVSMPWLSYPHFIYWIHI\GPY
WMZIP]8LIVIGIMZIVWEVIIQTX]SRHIPMZIV]8LIJMPPMRKLEWXSFITVSGII
HIHTVISTIVEXMSREP8LIVIGMTMIRXQIHMYQWLSYPHFIGLSWIRMRXLI[E]
XLEXXLIZMWGSWMX]EQSYRXWJVSQETTVS\XSQQCWSRXIQTIVEXYVI
HYVMRKSTIVEXMSR8LIVIWIVZSMVWLSYPHFIJMPPIHXSETTVS\ MRSVHIVXS
PIXWYJJMGMIRXGSQTIRWEXMSRTPEGISRPIEOEKI3RWIEPMRKPIEOEKIERHPS
[IVEXQSWTLIVMGTVIWWYVIEXXLIWYGXMSRSJXLITYQTXLIPIZIPVIHYGIW

%TTIRHM\XS)
 %PPS[EFPIHMWTPEGIQIRXW
ETTIRHM\XSEPPTYQTMRWXVYGXMSRW

HE

6
%

WTIIHR!YTXSQE\VTQ WTIIHR!YTXSQE\VTQ

ÍGSYTPMRK
6 QE\ ?QQA % QE\ ?QQA 6 QE\ ?QQA % QE\ ?QQA
YTXSHE!?QQA
    
    
    
    
    
    
    
    
    
    
    
    
    

'LETXIV1SYRXMRKERH-RWXEPPEXMSR SJXLITYQTST 4YQTYRMXWSVETYQTERHPERXIVRYRMXEVIHIWMKRIHXS

IVEXMRKMRWXVYGXMSRWWTIGMJMIWXLEXXLIWLEJXIRHWSJXLI GSQTP][MXLXLIWIVIUYMVIQIRXWMRXLISVMKMREPWXEXI
TYQTERHHVMZMRKQSXSVQYWXFIGEVIJYPP]EPMKRIH-R WYTTPMIHF]0IMWXVMX^ -JEXXEGLIHTEVXWEVITYVGLEWIH
XLIEFSZIXEFPIXLIUYEPMX]SJXLMWEPMKRQIRXGERFIHI
WITEVEXIP] RSX MRGPYHIH MR 0IMWXVMX^ HIPMZIV] WGSTI 
XIVQMRIH[MXLVIJIVIRGIXSXLIGSYTPMRKWM^I?HEA
XLIVIUYMVIQIRXWJSVXLIKISQIXV]SJXLIWITEVXWQYWX
-XWLSYPHFIRSXIHXLEXEREPMKRQIRXSJXLIX]TIWLS[R
EPWSFIGSQTPMIH[MXL
GERSRP]FIGEVVMIHSYXMRLSVM^SRXEPP]MRWXEPPIHTYQT
YRMXW -RWTIGMEPGEWIWEREPMKRQIRXSJXLITYQTVIPEXMZIXS
*SVYRMXW[MXLEžPERXIVREVVERKIQIRXžMXQYWXFIIR XLI PERXIVR MW TIVQMWWMFPI LS[IZIV XLMW EHNYWXQIRX
WYVIHXLEXXLITSWMXMSRSJXLITYQTWLEJXMWHIXIVQMRIH WLSYPHFIWIGYVIH[MXLEWYMXEFPIPSGEXMRKHIZMGI
F]XLIKISQIXV]SJXLIPERXIVRVIPEXMZIXSXLIQSYRXMRK -JWTIGMEPGSYTPMRKWEVIYWIHIK[MXLVIQSZEFPIIP
JPERKISJXLIHVMZMRKQSXSV8LIWLETIERHTSWMXMSRSJ IQIRXWWTIGMEPHSGYQIRXWEVIEHHIHXSXLITVSNIGX
XLIPERXIVRQYWXFIWYGLXLEXXLIEPMKRQIRXZEPYIWSJ HSGYQIRXEXMSR-RGEWISJWTIGMJMGUYIWXMSRWTPIEWI
XLIEFSZIXEFPIEVIEGLMIZIH GSRXEGXSYVEKIRXWSVXLITPERX

)I6IZC.YP]
 23.04.2007 1 / 5
ASSEMBLY PROCEDURE Spindle Set Abt.: KDP
E 185 5434
Rev. 0
L3NG – 160 - 180 - 200

Assembly Procedure AP 185 5434

The following procedure applies for the disassembly and

reassembly of the pump types L3NG 160, 180 or 200
Basis forms the manual the pump type
L3NG – IFOGV – O direct driven / Document No. E185 5177_e

Assembly tools see Manual E185 5177_e Chapter 5.1

Additional the Spindle set clamp device (additional tool, as in chapter 5.1 described)
Part No. 0290775 for Size L3NG 160
Part No. 0290984 for Size L3NG 180
Part No. 0291189 for Size L3NG 200

Spindle set clamp device for each size.

Before starting the disassembly / assembly:

CLEAN ASSEMBLY AREA. Inspect all parts, keep bearing sets together.
Make sure not to mix up parts (rings, bearing parts, etc.).

For the disassembly / assembly the valid in each case sectional drawing is to be
laid out.

KDP, Freiberger Montageanleitung.doc

 23.04.2007 2 / 5
ASSEMBLY PROCEDURE Spindle Set Abt.: KDP
E 185 5434
Rev. 0
L3NG – 160 - 180 - 200

1. Disassembly steps

Step Action / Inspection Check /

Remarks
Note down the serial number of the pump. Serial No.
01
=
Dismantling of the pumps from the plant in accordance with
02 manual chapter 7.4.

Pump vertically at assembly work place present.

03
Remove circlip Pos. 174.
04
Draw the spindle set including the ball bearing with take-off de-
05 vice half-way up.

Fix idler spindles and driving spindle with a spindle set clamp
device (see picture on first page)
06
For the respective sizes the following clamping devices are to be
used:
07 L3NG 160 = Part No. 0290775
08 L3NG 180 = Part No. 0290984
09 L3NG 200 = Part No. 0291189
Remove spindle set completely out of the casing (use lifting de-
vice)

10

KDP, Freiberger Montageanleitung.doc

 23.04.2007 3 / 5
ASSEMBLY PROCEDURE Spindle Set Abt.: KDP
E 185 5434
Rev. 0
L3NG – 160 - 180 - 200

Loosen spindle set clamping device and remove idler spindles

11
from the driving spindle.
Remove circlip and distance ring (attachment of the ball bearing
12
on the driving spindle).
Draw the groove ball bearing with take-off device from the driving
13
spindle.
Attention: The shaft nut at the driving spindle (if available) must
14
not be loosened (manufacturing depending connection)
Inspect the developed parts for outside condition, on possible
15
damages (for further usefulness examine).
Make as required new parts available.

16

Including ball bearings and circlip.

2. Assembly

Attention: A re-assembly can only be permitted if full functional and

undefective parts are used. We recommend as well a cleaning of
stained parts.
The following proceeding is to be kept:

Step Action / Inspection Check /

Remarks
1 Grooved ball bearings examine whether further operability (run
condition) are given. We recommend the installation of new
camps.

KDP, Freiberger Montageanleitung.doc

 23.04.2007 4 / 5
ASSEMBLY PROCEDURE Spindle Set Abt.: KDP
E 185 5434
Rev. 0
L3NG – 160 - 180 - 200

2 Heat the grooved ball bearing to a temperature of approx.

80°C (degrees) and slide or press it onto the driving spindle by
means of a sleeve or a ring bush. Do not apply heavy strokes
in order to fix the groove ball bearing. This would cause dam-
age to the running surface and the balls.
Lock the grooved ball bearing afterwards with a distance ring
(pos. 172) and circlip (pos. 173).

Align the idler spindles in pairs around the driving spindle

Join with the spindle set clamp device assigned in each case.

KDP, Freiberger Montageanleitung.doc

 23.04.2007 5 / 5
ASSEMBLY PROCEDURE Spindle Set Abt.: KDP
E 185 5434
Rev. 0
L3NG – 160 - 180 - 200

Slightly lube the spindle fixing borings in the pump casing

slightly with oil.

Insert the complete spindle set into the pump casing (use lift-
ing device). Ball bearing must be installed (described like al-
ready.

7 Circlip for the attachment of the spindle set in the casing in-
stall.
The further assembly of the pump and the installation of the
8 pump at the gears and/or motor unit are to be made acc. to
manual E185 5177.

KDP, Freiberger Montageanleitung.doc

MAN Diesel & Turbo

Index

Index

6704 B2-1 EN 1 (1)