Technical Documentation

Engine System/Power Station

Working Instructions B2

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . L 32/40 CD

Work No. . . . . . . . . . . . . . . . . . . . . . . . . . Edition only for Information

Plant No. . . . . . . . . . . . . . . . . . . . . . . . . .

6629-- 5
MAN B&W Diesel AG : D-86135 Augsburg : Postfach 10 00 80 : Telefon (0821) 3 22-0 : Telex 5 37 96-0 man d

6629 B2--02 E 04.98 101/ 02

. 2002 MAN B&W Diesel AG

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

6629 B2--03 E 01.02 102/ 02

Table of contents

N 1 Introduction

: : : N 1.1 Preface
1.2 How the working instructions/work cards are organised, and how to use
: : : N them

N 2 Work cards, arranged by subjects/key words

N 3 Work cards, arranged by subassembly groups

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

6629 09.02 L 32/40 101 /01

.
Introduction

1 Introduction

2 Work cards,
arrangend by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 1--02 E 08.97 101/ 01

.
Table of contents

N 1 Introduction

: : : N 1.1 Preface
1.2 How the working instructions/work cards are organised, and how to use
: : : N them

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

6629 09.02 L 32/40 101 /01

.
Preface 1.1

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

Work cards serve the particular prupose of providing essential information

in concise form.

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

One standard paper sheet and one foil-sealed copy of each work card is
available. The foil-sealed copies are insensitive to being soiled and can be
used for information while the job is being done.

6682 1.1--01 E 08.97 General 101/ 01

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

Structure Work cards contain the following information as a rule:

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

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

021. 02

Counting number (card 2)

Subassembly group (crankshaft)

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

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

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

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

▲▲▲ Danger! Imminent danger.

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

▲▲ Caution! Potentially dangerous situation.

Possible consequences: Severe injuries.

▲ Attention! Possibly dangerous situation.

Possible consequences: Slight injuries, possible damage to
property.

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

Tip! For tips regarding use and supplementary information.

6682 1.2--01 E 08.97 General 101/ 02

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

Values for the tightening of bolted connections and the appropriate

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

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

6682 1.2--01 E 08.97 General 102/ 02

Work cards,
arranged by subjects/key words

1 Introduction

2 Work cards,
arranged by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 2--02 E 08.97 101/ 01

.
Table of contents

N 001 Operating media systems/Pipes

000.03 Operating media systems

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

N 002 Operating media/Auxiliary agents

000.04 Lubricating oil

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

N 003 Machine elements

000.11 Galvanized bearings

: : N Assessing
000.11 Bimetal bearings (without a third layer)
: : N Assessing

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

6629 09.02 L 32/40 101 /02

 000.21 Seals made from elastomer
: : N Storage, cleaning, mounting
000.22 Threaded inserts
: : N Use
000.29 Tightening of bolted connections
: : N Tightening torques (illustrated)
000.30 Tightening of bolted connections
: : N Tightening torques (table)
000.31 Tightening of bolted connections
: : N Tightening torques (turning moment)
000.32 Tightening of bolted connections
: : N General remarks
000.34 Surface examination by means of
: : N penetration methods
000.34 Surface examination by means of
: : N magnetic flux leakage methods

N 004 Hydraulic tensioning tools/ High--pressure pump

000.33 Working and safety regulations

: : N Using high--pressure tools/ hydraulic tensioning tools
009.03 Hydraulic hand pump
: : N Use
009.05 High--pressure hoses
: : N Use
009.01 Hydraulic tensioning tool
: : N Use
009.02 Hydraulic tensioning tool
: : N Venting, checking, replacing of sealing rings
009.07 Hydraulic tensioning tool
: : N Use
009.08 Hydraulic tensioning tool
: : N Venting, checking, replacing of sealing rings
009.06 Dial gauge (measuring device)
: : N Checking the bolt elongation

N 005 Operating values/Operating results

000.25 Ignition and compression pressures

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

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

6629 09.02 L 32/40 102 / 02

Operating media systems/Pipes

001 Operating media systems/pipes

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

6682 001--01 E 08.97 101/ 01

.
Operating media systems
Flushing and cleaning 000.03

Purpose of jobs to be done

Keep operating media systems free from contamination and residues,

prevent operating problems/damage.

Brief description

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

1. Lube oil system

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

▲ Attention! Dirt particles penetrating into the engine interior may

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

6682 000.03--01 E 07.02 General 101/ 06

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

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

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

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

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

Important! In case a break-in filter is fitted on the engine, the diffe-

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

6682 000.03--01 E 07.02 General 102/ 06

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

Important! In case a break-in filter is fitted on the engine, the diffe-

rential pressure of this filter has to be monitored continuously and the filter
cleaned, if necessary.
Reconnect the pipelines that were dismantled.
Flushing processes are to be carried out under the supervision of
personnel of MAN B&W Diesel AG.
1.3 Draining and cleaning of system components
In case a special flushing oil was used, the entire lube oil system has to be
thoroughly drained. The remainders in the cooler, the filter and the
separator preheater are to be drained via the outlet pipes. Filter inserts
have to be appropriately cleaned and checked for possible damage.
In case the lubricating oil also used for engine operation was used for
flushing, draining of the system can be dispensed with provided the oil
analysis is satisfactory.
1.4 Break-in filter (if fitted)
If necessary, a break-in filter is mounted directly on the engine. The
inserts in the break-in filter are used for a period commencing when the
test run at the engine manufacturer’s works is carried out and lasting until
the commissioning period at the plant is terminated.
Prior to flushing the system, the break-in filter is to be cleaned in
accordance with the manufacturer’s instructions.
As the filter insert has only a limited service life (200 operating hours), it is
removed after termination of the running-in period. The filter insert is to be
cleaned, preserved and stored at a safe place.
The filter casing remains on the engine.
A filtering effect is then no longer provided, which is indicated by an
appropriate notice on the filter casing.
In case modifications are carried out in the lube oil system requiring
flushing of the system, the break-in filter, too, has again to be equipped
with a filter insert until the flushing process has been completed.

6682 000.03--01 E 07.02 General 103/ 06

2. Fuel delivery system

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

6682 000.03--01 E 07.02 General 104/ 06

3. Cooling water system

Prior to initial operation of the engine and injection valve cooling system it
must be ensured that the surfaces contacted by the cooling water are free
from corrosion and other deposits.
Where spots of corrosion are found, the system has to be cleaned as
000.16.
described in work cards 000.08 and 000.16
The cooling water system is to be flushed with freshwater prior to initial
operation of the engine. A cleanser should be added to the water to
ensure that any traces of the preservation agent used are removed.
Table 1 lists some suitable cleansers in alphabetical order. Cleansers of
other makes may be used provided that they have properties equivalent to
the agents listed. Following the cleansing operation, the system is to be
flushed with plain freshwater.

Supplier Product Concentration Duration of cleaning/temperature

Drew HDE - 777 2 - 5% 4 hrs at 50 - 60 ƒ C
Unitor Seaclean 0.5% 4 hrs at 50 - 60 ƒ C *
Vecom Ultrasonic 4% 12 hrs at 50 - 60 ƒ C
Multi Cleaner
* Can also be used for short-term engine operation.
Table 1. Cleansers for the removal of oil-containing residues
For filtering out the coarse dirt particles, the provisional installation of dirt
traps is indispensable. The mesh width has to be 1 mm for the high-
temperature and low-temperature systems.
The smallest gap in the injection valve is 0.5 mm. To avoid that dirt
particles can deposit there, resulting in a reduced heat dissipation,
provisional installation of a dirt trap having a mesh width of $ 0.4 mm is
required for flushing of the cooling water system for the injection valves.
By installing two shut-off slide valves each, any leakage of water during
cleaning or the removal of the dirt traps is prevented.
Following the flushing operation, the freshwater is to be treated in
accordance with the quality requirements for cooling water (Operating
instructions, sheet 3.3.7).

4. Compressed air system

4.1 Plant-specific system

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

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

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

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

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

6682 000.03--01 E 07.02 General 105/ 06

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

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

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

6682 000.03--01 E 07.02 General 106/ 06

Cooling water system
Cleaning 000.08

Purpose of jobs to be done

Free operating media systems from contamination/residues,

ensure/restore operational reliability.

Brief description

Cooling water systems that show contamination or deposits impede

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

Cleaning

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

specified intervals. If heavily fouled, immediate cleaning is necessary. This
work should preferably be done by a specialist firm which will provide the
cleansers suitable for the particular type of deposits and materials used in
the cooling system. Only in the event that procurement of the services of a
specialist firm is not possible, the cleaning should be performed by the
engine operator.

Oil sludge Oil sludge produced by lube oil entering the cooling system or by an
excessive concentration of anti-corrosion agents can be removed by
flushing with fresh water, with some cleaning agent being added. Table 1
lists appropriate agents in alphabetical order. Products of other
manufacturers may be used provided their properties are comparable. The
manufacturer’s instructions for use are to be strictly observed.

Manufacturer Product Concentration Duration of cleaning procedure /

temperature
Drew HDE - 777 4 - 5% 4 hrs at 50 - 60 •C
Nalfleet Nalfleet 9 - 010 2 - 5% 4 hrs at 60 - 80 •C
Unitor Aquabreak * 0.05 - 0.5% 4 hrs at ambient temperature
Vecom Ultrasonic 4% 12 hrs at 50 - 60 •C
Multi Cleaner
* Can also be used in case of short engine operating periods
Table 1. Cleaning agents for removing oil sludge

Calcareous and rust deposits Calcareous and rust deposits may form if excessively hard water or too
low a concentration of anti-corrosion agent has been used in operation. A
thin layer of scale need not be removed as, according to experience, this
provides protection against corrosion. Calcareous layers of > 0.5 mm in

6682 000.08--01 E 07.97 101/ 03

 thickness, however, will impede the heat transfer to an extent which
results in thermal overloading of the components to be cooled.
Rust in the cooling system adversely affects the stability of the emulsion in
case anti-corrosion oil is being used for cooling water trreatment.
Washed-off rust particles can act like an abrasive (e.g. on the sealing
elements of the water pumps). Together with the water hardness
constituents, they form so-called iron sludge which settles predominantly
in areas of low flow rates.
In general, products used for dissolving calcareous scale deposits are also
suitable for removing rust. Table 2 lists appropriate agents in alphabetical
order. Products of other manufacturers may also be used as long as their
properties are comparable. The manufacturer’s instructions for use are
likewise to be strixctly observed. Prior to cleaning, check whether the
agent concerned is suitable for the materials to be cleaned. The agents
listed in Table 2 are also suitable for stainless steel.

Manufacturer Product Concentration Duration of the cleaning procedure /

temperature
Drew SAF-Acid 5 - 10% 4 hrs at 60 - 70 •C
Descale-IT
Nalfleet Nalfleet 9 - 068 5% 4 hrs at 60 - 75 •C
Unitor Descalex 5 - 10% 4 - 6 hrs at approx. 60 •C
Vecom Descalant F 3 - 10% approx. 4 hrs at 50 - 60 •C

In case of emergency Only in exceptional cases, if none of the special agents the application of
which does not present problems is available, calcareous deposits may be
removed by using aqueous hydrochloric acid or amido sulphur acid as a
means of emergency. The following is to be observed for application:
- Heat exchangers made of stainless steel must never be treated with
aqueous hydrochloric acid.
- Cooling systems containing non-ferrous metals (aluminium, red brass,
brass, etc.) have to be treated with inhibited amido sulphur acid. This
acid should be added to the water at a concentration of 3 - 5%. The
temperature should be 40 - 50ƒ C.
- Aqueous hydrochloric acid may only be used for cleaning steel pipes.
The use of hydrochloric acid for system cleaning always involves the
risk of acid residues remaining in the system even after thorough
neutralisation and flushing. Such residues promote corrosion pitting.
We therefore recommend having the cleaning operation performed by a
firm specialising in this field.
Carbon dioxide bubbles which form in the dissolution process of the
calcareous deposits may obstruct the access of the cleaning agent to the
water scaling. It is, therefore, absolutely necessary to circulate the water
containing the cleaning agent so that the gas bubbles are carried away
and can escape. The duration of the cleaning process depends on the
thickness and composition of the deposits. For guide values, please see
Table 2.

After cleaning Following the cleaning of cooling spaces using cleaning agents, the
system has to be flushed several times. In doing so, make sure to replace
the water. Where acids have been used for cleaning, subsequently
neutralise the cooling system with appropriate chemicals, and then flush it.
When this has been done, the system can be refilled with appropriately
treated water.

▲ Attention! Do not start the cleaning process before the engine

has dooled down. Hot engine components are not allowed to be
charged with cold water. Prior to proceeding to refilling the cooling
water system, make sure that the venting pipes are open. Clogged

6682 000.08--01 E 07.97 102/ 03

 venting pipes obstruct the excape of air and involve the danger of
thermal overloading of the engine.
The relevant regulations have to be observed for the disposal of cleaning
agents or acids.

6682 000.08--01 E 07.97 103/ 03

.
Pipes
Replacement 000.15

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

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

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

Preliminary remarks

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

Instructions

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

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

6682 000.15--01 E 07.97 101/ 02

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

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

6682 000.15--01 E 07.97 102/ 02

Pipes
Cleaning, Acid Bath Treatment and
Preservation 000.16

Purpose of jobs to be done

Keeping operating systems free from contamination and residues,

ensuring/restoring of operational reliability.

Brief description

Pipes, which are replaced or supplemented, must after

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

Preliminary remarks

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

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

Mechanical cleaning

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

6682 000.16--01 E 11.98 General 101/ 03

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

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

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

Acid bath treatment of steel pipes

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

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

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

Important! Copper piping should not be treated in the hydrochloric

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

6682 000.16--01 E 11.98 General 102/ 03

Treating copper pipes

First pickle in sulphuric acid bath, possibly followed by trisodium

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

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

Pressure testing of pipes

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

Preservation of pipes

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

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

6682 000.16--01 E 11.98 General 103/ 03

.
Solderless screwed pipe unions
Mounting 000.17

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

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

Tools/appliances required

Quant Denomination No. Availability

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

Advantages of solderless screwed pipe unions

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

Sequence of operations

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

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

6682 000.17--01 E 07.97 101/ 03

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

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

1 Union nut 3 Pipe 5 Inner cone

2 Stop 4 Cutting and wedge ring 6 Visible collar

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

6682 000.17--01 E 07.97 102/ 03

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

7 Marking

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

Supplementary notes

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

H= Height of the union

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

Figure 4. Minimum distances/bending radii

6682 000.17--01 E 07.97 103/ 03

.
Solderless Screwed Pipe Unions
Additional parts 000.18

Purpose of jobs to be done

Use/replacement of components,
proper processing and installation.

Brief description

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

Preliminary remarks

Reinforcing sleeves , insert nozzles and screwed hose connections are

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

Instructions

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

1 Reinforcing sleeve

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

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

6682 000.18--01 E 07.97 101/ 02

 2 Insert nozzle

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

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

3 Hose
4 Hose clamp

Figure 3. Using screwed hose connections

6682 000.18--01 E 07.97 102/ 02

Operating media/Auxiliary agents

001 Operating media systems/pipes

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

6682 002--01 E 08.97 101/ 01

.
Lubricating oil
Assessing and Treating 000.04

Purpose of jobs to be done

Record and assess the characteristics of the operating media,

keep the state within the permissible range,
avoid/reduce harmful effects.

Brief description

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

regarding its state in regular intervals and maintained continuously.
This includes:
carrying out of a spot test,
having an oil sample analysed,
maintenance of the operating media, and
changing of the operating media.

Assessment of oil

Plotter test/oil analysis The condition of the lubricating oil in the engine should be continually
observed. The intervals at which blotter tests on filter paper are to be
made, or at which oil samples are to be taken for tests in a suitably
equipped laboratory (it is recommended that this be done by the suppliers’
customer service department) are specified in the maintenance schedule .
Oil samples should be drawn with the engine operating, downstream of the
filter. Only then will results be obtained that are representative of the oil
being circulated in the engine.
The progression of changes in the characteristics of the oil can be inferred
from droplet samples taken at regular intervals. Obvious changes in the
appearance of blotter tests as against those taken from earlier oil charges
are an indication of irregularities, such as incomplete combustion, poor
filtration, or increased fuel or water content (see also Work Card D36
000.05-1).
6682/000.05
A reliable conclusion as to whether the used oil is still suitable for further
use can only be drawn from a complete laboratory analysis in which the
values are determined by standardized test procedures.
The limit values given are non-binding empirical values, and no single one
by itself should be taken as the criterion for requiring an oil change. For
this, the various limit values must be evaluated with respect to each other,
and the changes in the oil over an extended period of time should be
known. If in doubt, consult the lube oil suppliers. There may also be
instances where additional analyses (for example spectographic analysis,
particle analysis, or examination on remaining resistance against
oxidation) become necessary.
We recommend using a test kit specifically developed for making routine
on-site tests of fuel and lubricating oils. Together with the firm Mar-Tec,
MAN B&W has developed such a test kit, which contains easy-to-handle
equipment. Using this test kit, the condition of the heavy fuel oil bunkered

6682 000.04--01 E 02.00 General 101/ 03

 and its characteristics that are important for conditioning, as well as the
condition of the used lube oil, can be determined with adequate accuracy.
Information material can be obtained from Mar-Tec, Warnckesweg 6,
22453 Hamburg, Germany.
To subject used oil to routine testing, the following criteria are sufficient as
a rule:

Characteristics Attention limits Method

)
Viscosity at 40ƒ C [mm /s] > 110 ISO 3104
> 220
Flash point (PM) [ƒ C] > 185 ISO 2719
Water content [% by vol.] < 0.2 ISO 3733
(0.5% admissible only for a short period)
TBN [% of fresh oil TBN]  50% ISO 3771
Insolubles [% by mass] < 1.5 DIN 51 592
(see also spot test D365600/E/000--05) In general, depending upon actual dispersant IP 316
properties and increase in viscosity
Metal content [mg/kg] Dependent upon engine type and operating ASTM 5185--91
conditions
Table 1. Examination of lube oils - characteristics/limit values

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

Fuel contained in the Fuel oil in the lube oil can be determined by measuring the flash point and
lube oil viscosity of the used lubricating oil after cleaning, and comparing the
measured values with those of fresh lubricating oil. A change of oil
because of dilution by fuel oil becomes necessary when the oil viscosity
has dropped by one viscosity class, or the flash point has dropped below
185ƒ C. If a laboratory analysis cannot be done, the viscosity can be
roughly determined as follows:
Drip samples of fresh oil with a viscosity one class higher and one class
lower than the oil used in the engine, and a sample of the used oil from the
engine onto an inclined glass or metal plate. It then can be seen from the
flow velocity whether the used oil has a higher or lower viscosity than it
had when it was new.

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

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

6682 000.04--01 E 02.00 General 102/ 03

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

Oil treatment

The fineness of the filter is exactly matched to the requirements of the

engine model. Optimal treatment of the lubrication oil is a basic
prerequisite for trouble-free operation of the engine.
The lube oil is cleaned in the main flow by the filters installed. When
running on heavy fuel oil, this is invariably an automatic filter and an
indicator filter operated by hand and arranged downstream of the
automatic filter.
The triggering and progression of the cleaning process of the filter
cartridges in the automatic filter are controlled automatically. The filter
cartridges have to be cleaned at regular intervals, for which it is advisable
to use a device developed and cleaning fluid supplied by the filter
manufacturer. The same applies to the indicator filter. In the case of
smaller engines running on diesel fuel, the filter cartridges are of the
disposable type and require replacement when the maximum permissible
pressure differential is reached. HFO-operated engines have a separator
in bypass. Engines at the bottom of the range, which are mostly run on
diesel fuel, have engine-mounted free-jet centrifuges as a rule. These are
capable of removing much smaller dirt particles than the filters provided in
the main flow. The separator, which is designed as a ”purifier”, also
removes water. The more effective the cleaning action of the separator is,
the less problems will arise in connection with the filtration of the main
flow. It is essential that the cleaning devices are operated in compliance
with the supplier’s instructions. Pertinent criteria include:
Separator:
- Gravity disc matched to the density of the lube oil,
- correctly adjusted flow rate,
- correct separating temperature,
- cleaning of the drum in time etc.

Free-jet-centrifuge:
- Adequate oil pressure,
- cleaning in time (thickness of dirt layer in the drum max. 10 mm).

Oil change

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

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

6682 000.04--01 E 02.00 General 103/ 03

.
Lube oil/fuel
Carry out drop test 000.05

Purpose of jobs to be done

Record and assess characteristics of operating media,

keep their condition within the admissible range.

Brief description

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

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

Sequence of operations (in lube oil sampling)

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

Evaluation of the lube oil spot test

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

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

6682 000.05--01 E 07.97 101/ 02

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

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

Fuel oil sampling

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

6682 000.05--01 E 07.97 102/ 02

Cooling water
Checking 000.07

Purpose of jobs to be done

Record and assess characteristic values of operating media,

avoid/reduce harmful effects.

Brief description

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

Tools/appliances required

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

Means for checking the When using chemical additives:

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

When using anti-corrosion agents:

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

6682 000.07--01 E 03.01 General 101/ 03

Check the characteristic values of the water

Brief specification

Characteristic value/ Water for charging Water in circulation

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

*) dGH = German hardness

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

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

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

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

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

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

6682 000.07--01 E 03.01 General 102/ 03

Check the concentration of anti-corrosion agents

Brief specification

Anti-corrosion Concentration
agent
Chemical additives in compliance with quality specification in Volume
B1, Section 3, Sheet 3.3.7
Anti-corrosion oil initially, after filling in, 1.5 - 2 % by volume; when
operating conditions have stabilised 0.5 - 1 %
by volume
Anti-freeze not less than 35 % by volume and/or according to
the lowest system temperature occurring
Table 2. Concentration of cooling additives

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

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

Check the concentration of In view of the low probability that anti-freeze will be used, please contact
anti-freeze agents MAN B&W Augsburg works if need arises.

6682 000.07--01 E 03.01 General 103/ 03

.
Engine or components
Preservation treatment 000.14

Purpose of jobs to be done

Counteract corrosion attacks,

carry out/repeat preventive measures.

Brief description

Specific corrosion prevention and preservation measures are to be applied

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

Corrosion inhibition

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

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

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

6682 000.14--01 E 06.02 General 101/ 04

Corrosion inhibitors

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

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

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

Preserving new engines and spare parts

Prior to beeing shipped, engines receive either a standard or a special

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

6682 000.14--01 E 06.02 General 102/ 04

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

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

gine’s running gear any longer.

Preservation of engines for shut-down

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

Steps 1. Drain all the lube oil and fuel oil of the engine, cooler and filter, and
purge the pipes. The oil sump, the lube oil tank and the fuel oil ser-
vice tank should be carefully cleaned. Then top up the oil sump or oil
reservoir with slushing oil of the same viscosity as used for the en-
gine,to a level at which the lube oil pump can draw oil without air
bubbles being entrapped.
Engine-mounted components having their own lube oil circulation
system or a separate oil charge (Woodward governor and possibly
the turbocharger) may be filled with the same slushing oil. This oil
can be left in the engine to be used in place of the engine lube oil
when the engine is taken into operation again, provided it meets the
engine oil specifications, which is normally the case. The slushing oils
that are known to us are compatible with doped (HD) lube oils so that
there is no objection against topping up the engine with lube oil.
The service tank is topped up with a low-viscous slushing oil of SAE
CLASS 10 to 20 instead of fuel oil; this will ensure adequate internal
preservation of the fuel-carrying piping and engine components deliv-
ering fuel.
2. Operate the engine for approximately five minutes with the slushing
oil filled in, to ensure that all the pipes, bearings, and the injection
system are filled with slushing oil. Prior to engine shut-down,

6682 000.14--01 E 06.02 General 103/ 04

 introduce a small amount of the low-viscous slushing oil into the in-
take pipe (of the exhaust gas turbocharger) by spraying.
3. After shutting the engine off, spray a small amount of slushing oil (ap-
prox. 0.5 l) into the main starting air and control air pipes, too.
▲ Attention! Do not start the engine in this condition under any
circumstances. Explosion hazard! Put up a warning sign, and
purge the pipes according to work card 000.03 prior to the next start-
ing procedure.
4. After shut-down of the engine system, all the pressure gauges should
indicate zero. The engine has to be blocked against inadvertent turn-
ing of the running gear. The turning gear should be engaged (if appli-
cable).
5. Preservation of the cooling water spaces is not required if a slushing
oil had been added to the engine cooling water during operation. If a
chemical additive had been used, the cooling water has to be re-
placed and a slushing oil is to be admixed at a concentration of
approximately 3-5%, and engine operation is to be continued for
some more time. If the engine is going to be shut-down for a pro-
longed period of time, or if there is the danger of freezing, it is neces-
sary to drain the cooling water completely from the engine, turbochar-
ger and the coolers of the individual circuits, making sure that the
drain cocks are constantly left open with the engine shut-down. When
draining the cooling water, make sure also to empty the water space
of the cooling water pump. The exhaust valves complete with cage
and the injection valves are to be removed and emptied separately.
6. A corrosion inhibitor has to be applied to all the bare, external engine
components by brushing or spraying.
Important! Engines that have already been operating and for which
a temporary operation for preserving purposes is impossible may be sub-
jected to the preservation treatment described under ”Preservation of new
engines and spare parts”. It should be made sure that prior to preservation
the fuel oil, the lube oil and cooling water are drained. Again, the engine
requires careful cleaning of all its components.

6682 000.14--01 E 06.02 General 104/ 04

Loctite Products
Use 000.19

Purpose of jobs to be done

Use of auxiliary materials,

proper processing and mounting.

Brief description

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

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

Preliminary remarks

The filling compound LOCTITE is a liquid synthetic which automatically

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

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

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

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

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

Operating Sequence 1 -- Assembly

Steps 1. Carefully clean the jointing surfaces using LOCTITE 706 quick
cleaner (evaporation time approximately 3 minutes) or any other
appropriate cleaning agent to remove dirt and grease.
2. If necessary, apply accelator T by means of a spray bottle and allow
it to dry for about 3 minutes. The filling compound will cure more
quickly if the accelerator is used (see the Table).

6682 000.19--01 E 11.97 101/ 04

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

Sequence 2 -- Disassembly

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

Sequence 3 -- Reassembly

1. Mechanically remove the old LOCTITE layer on both parts

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

6682 000.19--01 E 11.97 102/ 04

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

Thread sealing Surface sealing

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

6682 000.19--01 E 11.97 103/ 04

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

2) Tensile shear strength N/mm2

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

6682 000.19--01 E 11.97 104/ 04

Machine elements

001 Operating media systems/pipes

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

6682 003--01 E 08.97 101/ 01

.
Galvanized bearings
Assessing 000.11

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

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

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

Related work cards

Work card Work card Work card

000.10

General

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

Figure 1. Galvanized bearings -- structure

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

5600 000.11--01 E 06.99 General 101/ 09

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

Wear Limits

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

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

Figure 2. Degree of running surface wear

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

5600 000.11--01 E 06.99 General 102/ 09

Appearance of the bearing surface

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

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

Figure 3. Normal wear pattern

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

Figure 4. Partly worn through running layer

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

Figure 5. Shiny reflections

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

5600 000.11--01 E 06.99 General 103/ 09

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

Figure 6. Edge-carrying wear

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

Figure 7. Carrying wear on one edge

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

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

5600 000.11--01 E 06.99 General 104/ 09

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

Figure 9. Striation and foreign particles in the running surface

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

Figure 10. Cracks

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

5600 000.11--01 E 06.99 General 105/ 09

 9. “Bark Beetle” effect

Figure 11. Barks beetles

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

Figure 12. Separation or detachment of the running layer

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

Figure 13. Smearing of the running layer

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

5600 000.11--01 E 06.99 General 106/ 09

 12. Roughening of bearing-metal layer

Figure 14. Roughening of the running layer

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

Figure 15. Crumbling

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

Figure 16. Overheating of the bearing-metal layer

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

5600 000.11--01 E 06.99 General 107/ 09

 15. Electro-erosion

Figure 17. Electro-erosion

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

Figure 18. Corrosion

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

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

5600 000.11--01 E 06.99 General 108/ 09

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

Figure 20. Cold shots on the rear of the bearing

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

Bearing spread

D Bearing diameter
S Spread

Figure 21. Bearing spread

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

5600 000.11--01 E 06.99 General 109/ 09

.
Bimetal bearings (without a third layer)
Assessing 000.11

Purpose of jobs to be done

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

Brief description

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

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

Related work cards

Work card Work card Work card

000.10

General

1 Bearing metal
2 Aluminium bonding
layer
3 Steel shell

Figure 1. Composition of bearing

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

6682 000.11--03 E 07.97 101/ 03

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

Appraisal of the running behaviour and criteria for replacement

Figure 2. Measuring the wall thickness

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

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

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

1. Bearing wear pattern uniform over the entire bearing width

A B

Figure 3. Normal bearing wear pattern

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

6682 000.11--03 E 07.97 102/ 03

2. Bearing wear pattern showing traces of seizure

C D

Figure 4. Bearing wear pattern showing seizure

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

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

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

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

6682 000.11--03 E 07.97 103/ 03

.
Seals made from elastomer
Storage, cleaning, mounting 000.21

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

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

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

Explanatory remarks

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

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

Storing elastomer seals

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

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

6682 000.21--01 E 07.97 101/ 03

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

Cleaning

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

Assembly

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

6682 000.21--01 E 07.97 102/ 03

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

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

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

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

6682 000.21--01 E 07.97 103/ 03

.
Threaded inserts
Use 000.22

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

Threaded inserts serve for making firmly locking threads in components

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

Tools/appliances required

Commercially available twist drills, with diameters as required for the

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

Explanatory remarks

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

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

6682 000.22--01 E 07.97 101/ 03

Operating sequence 1- installation

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

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

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

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

E Core hole diameter

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

Figure 2. Twist drill/bore hole

G Diameter of the special

tap, suitable for A

Figure 3. Special tap

C Tang
H Fitting tool

Figure 4. Fitting tool

6682 000.22--01 E 07.97 102/ 03

 L Tang breaker/punch
M Unfitting tool

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

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

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

Operating sequence 2 - removal

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

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

6682 000.22--01 E 07.97 103/ 03

.
Tightening of bolted connections
Tightening torques (illustrated) 000.29

Purpose of jobs to be done

Indicating tightening torques for essential bolted connections.

Guaranteeing operating safety.

Brief description

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

using a hydraulic tensioning tool are to be tightened or released by the
specified values.
Work cards 000.29 and 000.30 contain the necessary information.

Explanations

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

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

6629 000.29--07 E 01.02 L 32/40 101/ 04

Figure 1. Cross-section/side view of engine

6629 000.29--07 E 01.02 L 32/40 102/ 04

Figure 2. Crankshaft with flywheel and pumps attached/camshaft

6629 000.29--07 E 01.02 L 32/40 103/ 04

Figure 3. Turbocharger and charge-air cooler mounted

6629 000.29--07 E 01.02 L 32/40 104/ 04

Tightening of bolted connections
Tightening torques (table) 000.30

Purpose of jobs to be done

Indicating tightening torques for essential bolted connections.

Guaranteeing operating safety.

Brief description

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

using a hydraulic tensioning tool are to be tightened or released by the
specified values.
Work cards 000.29 and 000.30 contain the necessary information.

6629 000.30--07 E 03.02 L 32/40 101/ 11

6629 000.30--07 E 03.02 L 32/40 102/ 11
6629 000.30--07 E 03.02 L 32/40 103/ 11
6629 000.30--07 E 03.02 L 32/40 104/ 11
6629 000.30--07 E 03.02 L 32/40 105/ 11
6629 000.30--07 E 03.02 L 32/40 106/ 11
6629 000.30--07 E 03.02 L 32/40 107/ 11
6629 000.30--07 E 03.02 L 32/40 108/ 11
6629 000.30--07 E 03.02 L 32/40 109/ 11
6629 000.30--07 E 03.02 L 32/40 110 / 11
6629 000.30--07 E 03.02 L 32/40 111 / 11
.
Tightening of bolted connections
Tightening torques (turning moment) 000.31

Purpose of jobs to be done

Indicating tightening torques for essential bolted connections.

Guaranteeing operating safety.

Brief description

Screwed connections should be tightened by means of torque spanners as

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

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

Strength class 5.6 6.8 10.9 12.9

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

6682 000.31--01 E 08.97 101/ 02

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

6682 000.31--01 E 08.97 102/ 02

Tightening of bolted connections
General remarks 000.32

Purpose of jobs to be done

Impart the necessary knowledge,

ensure the operational reliability of bolted connections.

Brief description

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

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

Related work cards

Work card Work card Work card

000.29 000.30 000.31

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

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

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

Tightening acc. to bolt elongation The method of tightening bolted connections primarly or exclusively by
elongation of the bolt/compression of the parts to be connected has lost in
significance compared with others. The elongation/compression is

6682 000.32--01 E 08.97 101/ 02

 nowadays only used as a control measure supplementing the hydraulic
tensioning procedure.

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

6682 000.32--01 E 08.97 102/ 02

Surface examination by means of
penetration methods 000.34

Purpose of jobs to be done

Examination of components for cracks/surface defects.

Evaluation regarding usability/remachining possibilities/tightness.

Brief description

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

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

Tools/appliances required

Qty Designation No. Availability

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

Application ranges

Surface examinations by the penetration method are based on the

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

6682 000.34--01 E 05.01 General 101/ 06

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

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

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

Precleaning

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

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

Operating sequence 2 -- Application of the penetrant

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

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

Penetration process

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

Figure 2. Possibilities for applying the penetrant

6682 000.34--01 E 05.01 General 102/ 06

Operating sequence 3 -- Intermediate cleaning of the component surface

The excessive penetrant which adheres to the component surface has to

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

Intermediate cleaning

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

Figure 3. Possibilities for intermediate cleaning

Operating sequence 4 -- Drying of the cleaned component surface

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

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

Drying process

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

Figure 4. Possibilities for component drying

Operating sequence 5 -- Developing process

Apply the developer to the component surface to be examined as

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

6682 000.34--01 E 05.01 General 103/ 06

 Developing process

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

Figure 5. Possibilities for applying the developer

Operating sequence 6 -- Evaluation of the results

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

Evaluation of results

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

Figure 6. Possibilities for recording the examination results

1 Cold cracks 6 Accumulation of pores

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

Figure 7. Fault indications

6682 000.34--01 E 05.01 General 104/ 06

 Figure 8. Valve cone with stress cracks at the fillet

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

6682 000.34--01 E 05.01 General 105/ 06

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

Manufacturing firm Special cleaner Penetrant Developer

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

Figure 10. Test chemicals of various manufacturers

(special cleaner/penetrant/developer respectively)

6682 000.34--01 E 05.01 General 106/ 06

Surface examination by means of
Magnetic flux leakage methods 000.34

Purpose of jobs to be done

Examination of components for cracks/surface defects.

Evaluation regarding usability/remachining possibilities/tightness.

Brief description

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

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

Tools/appliances required

Qty Denomination No. Availability

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

Application ranges

Surface examinations by Magnaflux test cause magnetic discontinuities

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

6682 000.34--02 E 03.99 General 101/ 05

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

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

Figure 2. Permanent magnet with special varnish and magnetic particles

in spray cans (source Messrs Helling)

6682 000.34--02 E 03.99 General 102/ 05

Yoke magnetising

Figure 3. Course of flux lines during yoke magnetising

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

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

B Component with defect

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

C Component with defect

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

6682 000.34--02 E 03.99 General 103/ 05

Applying the magnetic particles

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

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

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

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

Execution of the Magnaflux testing

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

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

6682 000.34--02 E 03.99 General 104/ 05

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

Magnetic particle indications

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

Figure 6. Valve cone with stress cracks at the fillet

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

Demagnetising

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

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

6682 000.34--02 E 03.99 General 105/ 05

.
Hydraulic tensioning tools/
High-- pressure pump

001 Operating media systems/pipes

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

6682 004--01 E 08.97 101/ 01

.
Safety regulations

1. Study work cards carefully and observe safety regulations.

2. Clean dirt away from contact surfaces of engine components or tools,
check the threads and clean them if necessary.
3. Only use absolutely serviceable tools. Overhaul or replace
defective/dubious parts.
4. Apply the specified tensioning pressures and lubricants.
5. Use a low-viscous slushing oil as the hydraulic fluid (no lube oil, no
fuel oil).
6. The securing ring (knurled, threaded ring) must be screwed up to the
stop after the hose coupling has engaged.
7. Hose couplings to which no hose is connected have to be locked with
dummy plugs.
8. Wear safety goggles.
9. Keep persons away from the extended line of the bolt or hydraulic
tool axles.
10. Keep a save distance away from hydraulic tools and high-pressure
hoses whenever possible.
11. Raise the pressure slowly on the pressure regulation valve, do not
exceed the specified pressure.
12. No heavy blows on loaded bolts, nuts and presses.
13. Do not excessively bend high-pressure hoses; the minimum bending
diameter is 400 mm.
14. After each tensioning process, check if the hydraulic piston has been
properly reset. The procedure is described in the work cards for the
hydraulic tensioning tools.
15. For loosening hydraulically tightened bolts, do not exceed the
specified tensioning pressure by more than 5 %. See under item 16.
16. When checking hydraulically tightened bolts, the releasing pressure
must not be more than 7 % below and 5 % above the specified value
000.30).
(see work card 000.30
If the releasing pressure is too low (max. 7 % below the specified
pressure), the cause is to be traced (neglected tightening, wear,
pronounced settling of the screwed connection). If the releasing
pressure is 10 % or more below the specified pressure, consult MAN
B&W Diesel AG, Augsburg for checking measures. If the releasing
pressure is too high (tensioning pressure plus 5 % inadequate for
releasing the connection) the cause should be eliminated as far as
possible (screwed connection damaged/corroded/blocked by paint,
tensioning tool damaged/wrongly mounted). If despite such improving
measures the connection cannot be undone, the tensioning pressure
may only be increased far enough to allow the connection to be
released if MAN B&W Diesel AG, Augsburg has definitely given its
approval (danger of bolt overstretching/component deformation). As
an alternative solution, the nut is to be cut open, and replaced
together with the bolt.

6682 000.33--01 E 07.97 102/ 03

Storage and care of the tools

1. Store tools at temperatures between 15 EC and 25 EC, if possible, in

order to avoid premature aging of plastic materials, and keep the
hydraulic fluid at an appropriately low viscosity. Plastic sealings
should be protected against the action of light.
2. Keep tools away from dust, dirt, chemicals and liquids so as to avoid
sealing faces to be affected.
3. Depressurize presses and high-pressure hoses prior to being stored.
4. Do not bend high-pressure hoses. Fit couplings into one another.
5. For overhaul work, make sure to use original spare parts because
proper performance depends, e.g., on the correct hardness of
O-rings.
6. Verify at regular intervals that the pump pressure gauge readings are
correct.

6682 000.33--01 E 07.97 103/ 03

.
Hydraulic hand pump
Use 009.03

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

The hydraulic hand pump produces the pressure required for tensioning
and untensioning large screwed connections by means of hydraulic
tensioning tools. It is of a two--stage design and produces pressures of up
to 1500 bar at low delivery rates.
Information is imparted concerning:
technical data,
putting into operation,
putting out of operation,
maintenance, and
behaviour in case of disturbances.

Tools/appliances required

Qty Denomination No. Availability

1 Hydraulic hand pump 009.320 Standard
1 Tools, basic scope 000.002 Standard
1 Anti--corrosion oil (Esso Rust--Ban PH 6297) -- Inventory

Technical details

Term Information
Oil filling 1.9 kg
Quality Anti--corrosion oil
Pressure range 0 -- 1500 bar
Dimensions 696x287x120 mm
Weight 8.5 kg

6682 009.03--02 E 11.97 32/40 101/ 04

Technical/functional description

The following is required for tensioning and untensioning large-sized

screwed connections:
- the hydraulic hand pump,
- special, pressure-resistant hoselines, and
- hydraulic tensioning tools, with resetting devices if necessary.
The hydraulic hand pump delivers a relatively low volume of fluid (under
pressures of up to 1,500 bar if required) through push-and-lock hoselines
to one or several tensioning tools.
After the piston of the tensioning tool has been screwed onto the bolt
thread, the hydraulic fluid will lift the piston in the casing, whereby the bolt
is elongated; the tensioning tool as such is supported on the environment
of the bolt.

1 Hand lever
2 Oil pressure gauge
(0-1600 bar)
3 Oil admission socket
with strainer
5 Pressure relief valve
7 Pipe coupling
connection

Figure 1. Hydraulic hand pump, type 30, GERUS make

The hydraulic hand pump is operated by means of the hand lever (1). As
a result, the hydraulic pressure for the tensioning tools is produced via a
two-stage pump element and led to the four pipe coupling connections. In
addition, the hydraulic hand pump is equipped with an overpressure valve
(4) and a pressure relief valve (5).

Putting into operation

▲ Attention! Observe the safety instructions given in work

000.33!
card 000.33

Steps 1. Check the oil level in the pump by opening the oil admission socket
(3); top up anti-corrosion oil if necessary.
Important! When topping up oil make sure that this is exclusively
done through the strainer because foreign particles may cause failures.
2. Connect the hydraulic hand pump to the pressure cylinder of the
tensioning tool via the connection hoses.
3. Open the relief valve (5) (counter-clockwise) to relief the oil side of
the hydraulic hand pump.
4. Verify that all the hoses have been correctly connected (block the
sliding sleeve of the coupling by means of arresting ring).
5. Close the relief valve (5) (clockwise).

6682 009.03--02 E 11.97 32/40 102/ 04

 Important! When connecting hoses and tensioning tools, these
must be vented and completely filled with oil, too.
6. Move the hand lever (1) of the hydraulic hand pump up and down
until the desired pressure is indicated on the pressure gauge (2) --
this will take some time, depending on the size and number of the
tensioning tools connected to the hydraulic hand pump.
Tip! Actuate the pump until the desired oil pressure is reached,
leakages have to be compensated by subsequent delivery.

1 Hand lever
2 Oil pressure gauge
(0-1600 bar)
3 Oil admission socket
with strainer
4 Overpressure valve
opens at 1500 bar
5 Pressure relief valve
6 Two-stage pump
7 Pipe coupling
connection
8 Oil tank for
anti-corrosion oil

Figure 2. Hydraulic hand pump -- functional diagram

Putting out of operation

Steps 1. Open the pressure relief valve (5). By this, the oil side of the pump
becomes pressureless (pressure gauge returns to zero). Pressure
reduction in the hoses takes more time. Therefore, after releasing
the pressure, leave the high-pressure hoses connected to the pump
for approx. 3 minutes with the relief valve opened. Otherwise, an
internal pressure might remain resulting in blocking of the hose
coupling. For trouble rectification, refer to work card 009.05.
009.05
▲ Attention! On no account, loosen the quick-lock couplings while
they are under pressure - risk of accident! Pressure gauge (2) must
indicate zero.
2. Leaf the connection hose on the pipe coupling connection (7) and
displace the anti-corrosion oil from the pressure cylinder of the
tensioning tool with the pressure relief valve opened (anti-corrosion
oil flows back into the oil tank of the hydraulic hand pump). For a
description of this process, refer to the work cards concerning the
tensioning tools.
Tip! This process might take a few minutes, as the diameter of the
return bore is small and the flow rates are low.
3. Disconnect the quick-lock couplings of the connection hoses.

6682 009.03--02 E 11.97 32/40 103/ 04

Servicing

The components and connections of the hydraulic hand pump should be

checked for tightness from thime to time, and overhauled if necessary.
Prior to use, check the oil level and top up if necessary. The pump must
never run completely dry because air would then be aspirated. The oil
charge should be drained at intervals of approx. one year, and fresh oil
should be filled in.

Cases of failure

Pump does not deliver or delivers too little

Reason 1: Air in the suction pipe
Remedy: Vent the hydraulic system.
Reason 2: Suction filter clogged
Remedy: Clean the suction filter
Oil pressure drops severely
Reason 1: Pipe coupling connections defective
Remedy: Check, clean and/or replace the pipe coupling connections.
Reason 2: Non-return valve on the pump element (6) and/or overpressure
valve (4) defective
Remecy: Check and, if necessary, replace the non-return valve on the
pump element (6) and/or the overpressure valve (4).

6682 009.03--02 E 11.97 32/40 104/ 04

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

Purpose of jobs to be done

Impart the necessary knowledge,

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

Brief description

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

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

Preliminary remarks

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

Hazards

The most essential items are dealt with in the work cards and in the
passages following below.
The high pressure and forces occurring in hydraulic tools require that
serious attention is given to the following points:
1. Fracture of highly loaded parts during pressure build-up in the tool
(preloading, releasing and routine testing). Broken parts will be flung
in the direction of the force applied, i.e. the extension of the bolt axles
or the axles of the hydraulic tensioning tool. Such a hazard exists
during pressure build-up or when the hydraulic tool is under full
tension and additional stress is induced by heavy blows.
2. Ejection of needle-like or razor-sharp hydraulic fluid jets due to leaky
sealing elements, bursting hoses or fracture of fittings. Hazard of
injury of the skin or the eyes at distances up to one metre.
3. Rupture of running gear bolts causing serious engine damage may
occur if the tightening proceses have not been carried out according
to the instructions. Possible causes of failure: Wrong pressure
built-up during preloading, connection of a hose has been omitted,
the hose coupling has not proper engaged, the tensioning process
has not been properly controlled (length not mesaured, the number of
holes for nut tightening has been neglected).

6682 000.33--01 E 07.97 101/ 03

High-- pressure hoses
Use 009.05

Purpose of jobs to be done

Impart the necessary knowledge,

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

Brief description

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

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

Tools/appliances required

Quant Denomination No. Availability

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

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

Design

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

high--pressure pump with hydraulic tensioning tools. These hoses consist
of a steel--wire--clad synthetic hose on the inside and a protective external
hose which collects the fluid issuing in case of leakage.

6682 009.05--01 E 07.97 32/40, 40/45, 40/54, 48/60, 58/64 101/ 02

 Admissible service pressure
J under constant load 1500 bar,
J under pulsating load 900 bar.
Minimum burst pressure 3300 bar.

Using

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

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

▲ Attention! Observe the safety instructions in work card 000.33

000.33!

Force the check valve open After having been used, i.e. after the high--pressure pump has been
switched off and the unloading valve has been opened, the hoses should
be left connected for a further 3 minutes approx. Otherwise, residual
internal pressure may block the hose coupling when attempting to pull it
off. As a result, it may happen that the high--pressure hose can no longer
be inserted in the coupling. In this case, the check valve has to be opened
using the appropriate device (opener 009.026). See Figure 2. Other tools
must not be used to avoid damage.
The high--pressure hoses are equipped with check valves on both ends.
Therefore they cannot run empty during storage.

1 Hydraulic end fitting on

the high--pressure
hose
2 Knurled screw for
fixing in place
3 Knurled screw for
forcing the valve open

Figure 2. Using the opener

6682 009.05--01 E 07.97 32/40, 40/45, 40/54, 48/60, 58/64 102/ 02

Hydraulic tensioning tool
Use 009.01

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

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

Tools/appliances required

Quant Denomination No. Availability

1 Hydraulic tensioning tool 009.096 Standard
1 Hydraulic tensioning tool 009.097 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
1 High--pressure hose 009.304 Standard
1 High--pressure hose 009.305 Standard
1 High--pressure hose 009.306 Standard
1 High--pressure hose 009.330 Standard
1 Resetting device 009.092 Standard
1 Open--jaw wrench 24x27 000.606 Standard
1 Tommy bar 10 000.263 Standard
1 Tommy bar 6 000.261 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.02
009.03 009.05

6629 009.01--02 E 11.97 32/40 101/ 05

Technical details

Term Information
Test pressure 1,300 bar
Tool number 009.096 / 009.097
Effective piston area 72.72 cm2
Delivery stroke 11 mm
Nominal pressure 1,200 bar

Preliminary remarks

Using the piston and casing of the tensioning tool, completed by thrust
pads and adapter pieces, bolts are elongated relative to the components
to be connected. This is achieved by forcing hydraulic fluid against the
piston by means of the high--pressure pump/hydraulic hand pump. If the
pressure is sufficiently high, the nut of the bolt can either be unscrewed or
tightened to specification.
Hydraulic tensioning tools as well as high--pressure hoses must be
completely filled with hydraulic oil prior to use. Air has to be bled if
necessary.
The tightness is to be checked from time to time; please refer to work card
009.02.
009.02
High-- pressure hoses have check valves on both ends. Therefore they
cannot run empty.
A prerequisite for the correct tensioning of the screwed connection is a
correctly indicating pressure gauge. In case of doubt, check the pressure
gauge by comparing it with a reference gauge.
For notes on the resetting of the tensioning tool, please refer to operating
sequence 3.

Tensioning tools Single--type tensioning tools are used either individually or in combination
with others.
Tandem tensioning tools are used as one unit as a matter of principle.

6629 009.01--02 E 11.97 32/40 102/ 05

 1 Piston
2 Casing
3 Thrust pad
4 Nut
5 Bolt
6 Tommy bar
7 Hose connection

A Gap width for

untensioning the
screwed connection

Figure 1. Single--type tensioning tool, not auto--resetting. Ready for tensioning at the left, and for releasing at the right

Tensioning Before tensioning the screwed connection, the nut has to be tightened by
hand. The piston of the tensioning tool is to be screwed on in such a way
that the casing and the thrust pad are blocked.

Untensioning To undo the tensioned screwed connection, the piston of the tensioning
tool has to be turned back from the hand--tightened position by a specified
angular amount. Otherwise, it may happen that the nut comes loose while
the bolt and tensioning tool are still under tension so that the tool cannot
be removed.

Operating sequence 1 -- Untensioning

Steps 1. Clean the thread of bolt (5).

2. Put the thrust pad (3) over the nut (4).
3. Screw on the tensioning tool, making sure that the thrust pad is
seated concentrically.
▲ Attention! Prior to mounting a tensioning tool, make sure that
the piston is completely pressed in. If the piston is too far out, there
is the danger that hydraulic oil escapes abruptly.
4. Once the tensioning tool is properly seated, turn the piston back by
the angular amount that applies to the screwed connection concerned
000.30). The resultant gap width A can be measured
(see work card 000.30
on or underneath the thrust pad.
5. Connect the high--pressure hose to the tensioning tool and high--
pressure pump/hydraulic hand pump.
6. Operate the high--pressure pump/hydraulic hand pump (see work
card 009.03).
009.03
7. Close gap A.
8. Increase the pressure in the tensioning tool by pumping until nut (4)
can be loosened.
▲ Attention! The pressure applied must not be more than 7%
below and 5% above the tensioning pressure (refer to work cards
000.33).
000.30 and 000.33
9. Insert the tommy bar through the recess in the thrust pad and turn
the nut back (for the angular amount of turning back, refer to work
000.30).
card 000.30

6629 009.01--02 E 11.97 32/40 103/ 05

 10. Depressurise the tool, disconnect the high--pressure hose from the
tensioning tool and high--pressure pump/hydraulic hand pump.
11. Screw off the tensioning tool and remove the thrust pad.

Operating sequence 2 -- Tensioning

1. Tighten nut (4) by hand, using the tommy bar (6).

2. Put the thrust pad (3) over the nut.
3. Screw on the tensioning tool, making sure that the thrust pad is
positioned concentrically.
4. Connect the high--pressure hose to the tensioning tool and
high--pressure pump/hydraulic hand pump.
5. Operate the high--pressure pump/hydraulic hand pump (see work
009.03).
card 009.03
6. Tension the stud bolt (5) at the specified pressure (refer to work card
000.30).
000.30
7. Insert the tommy bar through the recess in the thrust pad and fasten
the nut to contact, hand--tight.
8. Depressurise the unit, disconnect the high--pressure hose from the
tensioning tool and high--pressure pump/hydraulic hand pump.
9. Screw off the tensioning tool and remove the thrust pad.

Operating sequence 3 -- Resetting the piston

1 Casing
2 Piston
3 Thrust spindle
4 Thrust pad
5 Hose nipple with check
valve

Figure 2. Usage of the resetting device

Whenever the tensioning tool has been used, make sure to push the
piston back to its home position, thereby avoiding that the effective stroke
is exceeded. Danger of hydraulic fluid escaping abruptly, or of leakage!
Danger of tilting!

It is adviseable to reset the piston with the tensioning tool connected/

operative as a matter of principle. The first step then is to open the relief
valve of the high--pressure pump/hydraulic hand pump (whereby it
becomes possible to displace the hydraulic fluid). Resetting of the piston is
facilitated if the corresponding hose is temporarily connected to return
(only in case of high-pressure pumps).

For the resetting of a tensioning tool without the hose and high--pressure
pump/hydraulic hand pump being connected, first open the check valve of
the hose nipple, using the tool provided for this purpose (opener).

6629 009.01--02 E 11.97 32/40 104/ 05

Steps 1. Turn the two--armed resetting device 009.092 far enough back, then
insert it in the blind holes of the casing.
2. Turn the thrust spindle (3) forwards until the matching projection of
the thrust pad (4) engages in the bore of the piston.
3. Continue turning until contact is reached, and then reset the piston as
far as possible.
4. Remove the resetting device.

6629 009.01--02 E 11.97 32/40 105/ 05

.
Hydraulic tensioning tool
Venting, checking, replacing of
sealing rings 009.02

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

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

Tools/appliances required

Quant Denomination No. Availability

1 Hydraulic tensioning tool 009.097 Standard
1 Piston 009.097--1 Standard
1 Casing 009.097--12 Standard
1 Hydraulic tensioning tool 009.096 Standard
1 Piston 009.096--1 Standard
1 Casing 009.096--12 Standard
1 Hydraulic nipple 009.096--20 Standard
1 Threaded piece 009.096--21 Standard
1 Sealing ring 009.096--22 Standard
1 O--ring seal 009.096--26 Standard
1 Backing ring 009.096--27 Standard
1 O--ring seal 009.096--30 Standard
1 Backing ring 009.096--31 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
1 High--pressure hose 009.306 Standard
1 Opener 009.026 Standard
1 Resetting device 009.092 Standard
1 Resetting device 009.092--1 Standard

6629 009.02--02 E 11.97 32/40 101/ 04

Related work cards

Work card Work card Work card

009.01

Preliminary remarks

Hydraulic tensioning tools as well as high--pressure hoses have to be

completely filled with hydraulic fluid prior to being used. Air must be vented
if necessary. They should be checked for tightness from time to time.
High--pressure hoses have check valves on both ends; therefore they
cannot run empty.

1,2 Piston
12,13 Casing
20 Hydraulic nipple
21 Threaded piece *)
22 Sealing ring
26 O--ring seal
27 Backing ring
30 O--ring seal
31 Backing ring
* Threaded piece is glued to hydraulic nipple by means of Loctide 586
Figure 1. Single--type tensioning tool, not auto--resetting
The hydraulic tensioning tool has to be disassembled if sealing rings
require replacement and when it has suffered damage. If disassembly
becomes necessary, it is advisable to replace all the sealing rings.
Because of the high working pressures and the critical clearances and
surfaces, major interventions/repairs are advised against. We recommend
instead to have the tool overhauled by MAN B&W Diesel AG or one of its
authorised service locations, if required.

Operating sequence 1 -- Vent the tensioning tool/check for tightness

Venting 1. Place the tensioning tool with the hydraulic nipple (20) pointing up.
2. Connect the high--pressure pump (009.338) or the hydraulic hand
pump (009.320) and high--pressure hose.
3. Force the tensioning tool approx. 10 mm (not more!) apart.
4. Reduce the pressure to ”0” and disconnect the high--pressure hose.
009.01). Force the
5. Apply the resetting device 009.092 (see work card 009.01
check valve in the hydraulic nipple (20) open, using the opener (for
application, see work card 009.05).
009.05
6. Hold the tensioning tool so that the high--pressure nipple points
upwards; using the resetting device, press the piston inward until
bubble--free hydraulic fluid emerges.
7. Dismount the opener and the resetting device.
Check for tightness 8. From time to time, check the tensioning tool for tightness. For this
purpose, mount it on an easily accessible bolt. Connect the
high--pressure hose.
9. Operate the high--pressure pump/hydraulic hand pump and build up
the tensioning pressure that is specified for these bolts. No leakage
should occur during 5 minutes after.
10. Depressurise the tool, disconnect the high--pressure pump/hydraulic
hand pump and high--pressure hose. Dismount the tensioning tool.

6629 009.02--02 E 11.97 32/40 102/ 04

Operating sequence 2 -- Disassemble and reassemble the tensioning tool/replace the sealing elements

1 Piston
12 Casing

Figure 2. Disassembling the tensioning tool (forcing out the piston)

Disassemble 1. Place the tensioning tool on a clean surface, or mount it in a vice with
the wrench flats of the piston (1, 2).
2. Fasten the opener 009.026 to the hose nipple and force the check
009.05).
valve open (for application, refer to work card 009.05
3. Put the spacer (10) onto the piston.
4. Turn the resetting device 009.092 back far enough, then insert it in
the blind holes of the casing.
5. Turn the thrust spindle forward until the projection of the thrust pad
engages in the spacer.
6. Continue turning until the piston comes clear. During the last phase,
avoid tilting as far as possible and secure against falling out.
7. Carefully remove the sealing rings and backing rings.
8. Clean all the parts and check them for damage, and replace them if
necessary.
9. Apply a thin film of Belzona anti--seize lubricant on all the fitting
surfaces of the piston and casing, excluding the sealing elements and
grooves.
Replace sealing rings 10. Fit new backing rings and sealing rings, making sure that they are in
the correct position. The O--ring seal should always be on the
pressurised side, the backing ring with the depression facing the
O--ring seal.
Reassemble 11. For reassembly, follow the reverse order of disassembly. The
resetting device is in this case to be applied from the opposite side.
Take care not to tilt the piston when introducing it. If appropriate,
change the position of the resetting device by 180E. Be careful not to
damage the sealing rings. Use the opener for reassembly, too.
12. After reassembly, vent the tensioning tool as described under working
sequence 1, and check it for tightness.

6629 009.02--02 E 11.97 32/40 103/ 04

 Figure 3. Reassembling the tensioning tool

6629 009.02--02 E 11.97 32/40 104/ 04

Hydraulic tensioning tool
Use 009.07

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

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

Tools/appliances required

Qty Designation No. Availability

1 Hydraulic tensioning tool 009.346 Standard
1 Hydraulic tensioning tool 009.347 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
1 High--pressure hose 009.304 Standard
1 High--pressure hose 009.305 Standard
1 High--pressure hose 009.306 Standard
1 High--pressure hose 009.330 Standard
1 Open--jaw wrench 55 000.570 Standard
1 Tommy bar, 10 mm 000.263 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.08

6629 009.07--02 E 05.01 32/40 101/ 03

Technical details

Term Information
Effective piston area 2 x 20.23 = 40.46 cm2
Delivery stroke 3.5 mm
Nominal pressure 1,000 bar
Test pressure 1,100 bar
Tool number 009.346 / 009.347

Preliminary remarks

Using the piston and the casing of the tensioning tool, supplemented by
thrust pads and adapters, the bolts are elongated relative to the
components to be connected by hydraulic fluid being pressed against the
piston underside by means of the high-pressure pump or hydraulic hand
pump. If a sufficiently high pressure is applied, the nut of the bolt comes
clear and can either be loosened or fastened to specification.

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

A Gap width for

untensioning the
screwed connection

B Bore for tommy bar

X Untensioning
Y Tensioning

Figure 1. Tandem tensioning tool, auto-resetting

Hydraulic tensioning tools as well as high-pressure hoses must be
completely filled with hydraulic oil prior to use. They have to be vented if
required. The unit should be checked for tightness from time to time.
009.08.
Please refer to work card 009.08
High-pressure hoses have non-return valves on both ends, therefore they
cannot run empty.
A prerequisite for the correct tensioning of screwed connections is a
correctly indicating pressure gauge. In case of doubt, compare the
pressure gauge with a reference gauge.

6629 009.07--02 E 05.01 32/40 102/ 03

 The hydraulic tensioning tool is automatically reset to zero by a set of disk
springs (2). This requires that the high-pressure pump/hydraulic hand
pump is connected and its relief valve is opened.

Operating sequence 1 - Untensioning

Steps 1. Clean the thread of bolt (7).

2. Place the thrust pad (5) over the nut (6).
3. Use the single-ended open-jaw wrench A/F 55 to check whether the
nut (3) is firmly screwed onto the tensioning tool (1) (see work card
009.08).
009.08
4. Screw on the tensioning tool, taking care that the thrust pad is placed
concentrically.
Tip! For screwing on, insert the tommy bar in bore (D).
5. Following attachment, use the nut (3) to turn the piston back by the
angular amount that applies to the corresponding screwed connection
(refer to work card 000.30).
000.30 The corresponding gap width (A) is
obtained in this way.
6. Connect the high-pressure hose to the tensioning tool and
high-pressure pump/hydraulic hand pump.
7. Operate the high-pressure pump/hydraulic hand pump (see work card
009.03).
009.03
8. Close gap (A).
9. Pump pressure to the tensioning tool until it becomes possible to
unscrew nut (6).
▲ Attention! The pressure pumped should not be more than 7%
below and 5% above the tensioning pressure (refer to work cards
000.30 and 000.33).
000.33
10. Turn the nut back applying the tommy bar through the recess in the
thrust pad (for angular amount of turning back, see work card
000.30).
000.30
11. Depressurise the unit, disconnect the high-pressure hose from the
tensioning tool and the high-pressure pump/hydraulic hand pump.
12. Screw off the tensioning tool and remove the thrust pad.

Operating sequence 2 - Tensioning

Steps 1. Tighten nut (6) by hand using tommy bar (4).

2. Place the thrust pad (5) over the nut.
3. Screw on the tensioning tool (1), taking care to place the thrust pad
concentrically.
Tip! For screwing in place, insert the tommy bar in bore (D).
4. Connect the high-pressure hose to tensioning tool and high-pressure
pump/hydraulic hand pump.
5. Operate the high-pressure pump/hydraulic hand pump (see work card
009.03).
009.03
6. Tension the stud (7) to the specified pressure (refer to work card
000.30).
000.30
7. Screw the nut (6) down to contact, hand-tight, with the tommy bar
inserted through the recess in the thrust pad.
8. Depressurise the unit, disconnect the high-pressure hose from the
tensioning tool and high-pressure pump/hydraulic hand pump.
9. Screw off the tensioning tool and remove the thrust pad.

6629 009.07--02 E 05.01 32/40 103/ 03

.
Hydraulic tensioning tool
Venting, checking, replacing of
sealing rings 009.08

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

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

Tools/appliances required

Quant Denomination No. Availability

1 Hydraulic tensioning tool 009.346 Standard
1 Hydraulic tensioning tool 009.347 Standard
1 Hydraulic nipple 009.346--1 Standard
1 Sealing ring 009.346--2 Standard
1 Threaded piece 009.346--3 Standard
1 Sealing ring 009.346--4 Standard
3 Disk spring 009.346--10 Standard
1 Closing cap 009.346--13 Standard
1 Nut 009.346--16 Standard
1 Piston 009.346--17 Standard
1 Piston 009.346--18 Standard
1 Backing ring 009.346--19 Standard
1 O--ring seal 009.346--20 Standard
1 Casing 009.346--21 Standard
1 O--ring seal 009.346--22 Standard
1 Backing ring 009.346--23 Standard
1 Casing 009.346--24 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
1 High--pressure hose 009.306 Standard
1 Opener 009.026 Standard

6629 009.08--02 E 11.97 32/40 101/ 04

 Quant Denomination No. Availability
1 Eye bolt 001.404 Standard
1 Open--jaw spanner 55 000.570 Standard
1 Open--jaw wrench 46 000.568 Standard
1 Hexagon screw driver 12 000.299 Standard
1 Tools, basic scope 000.002 Standard

Related work cards

Work card Work card Work card

009.07

Preliminary remarks

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

Figure 1. Tandem tensioning tool, auto--resetting

Hydraulic tensioning tools as well as high--pressure hoses must be
completely filled with hydraulic fluid prior to use. They have to be vented if
required, and checked for tightness from time to time.
High--pressure hoses have check valves at both ends, therefore they
cannot run empty.
The hydraulic tensioning tool has to be disassembled if sealing rings have
to be replaced, or if it has suffered damage. If disassembled, all the
sealing rings should preferably be replaced. Major interventions/repairs are
advised against, because of the high working pressures and critical
clearances and surfaces. We recommend that you have the tool
overhauled by MAN B&W Diesel AG or one of the authorised service
bases in case of need.

Operating sequence 1 -- Vent the tensioning tool/check for tightness

Vent 1. Put up or mount the tensioning tool with the pulling nut so that the
hydraulic nipple (1) points upwards.

6629 009.08--02 E 11.97 32/40 102/ 04

 2. Connect the high--pressure pump (009.338) or the hydraulic hand
pump (009.320) and high--pressure hose.
3. Force the tensioning tool approx. 3 mm (not more!) apart, or pump (in
the mounted condition).
Important! In the latter case, take care that the loading pressure of
the bolt selected is not exceeded.
4. Depressurise the unit. Resetting of the piston by the disk springs will
displace the air into the high--pressure hose.
5. Disconnect the high--pressure hose and bleed the air by using the
opener (009.026).
Check for tightness 6. For routine checks of the tensioning tool for tightness, mount the tool
on an easily accessible bolt. Connect the high--pressure hose.
7. Pump the tensioning tool to the tightening pressure stipulated for this
bolt. No leaking should occur subsequently within a period of
5 minutes.
8. Depressurise the unit, disconnect the high--pressure pump/hydraulic
hand pump and high--pressure hose. Remove the tensioning tool.

Operating sequence 2 -- Disassemble and reassemble the tensioning tool

Starting condition The screw cap (15) or pulling nut (M30 x 2/M33 x 2) screwed off the
piston (6) (single open--end wrench 000.570 to be used for this purpose).

Steps 1. Remove the disk springs (13).

2. Attach the opener (009.026) to the hydraulic nipple (1) and force
open the check valve in the hydraulic nipple.
3. Pull off the casing (14).
4. Put the piston (6) onto hexagonal screw driver (000.299) fixed
between chucks, and loosen and remove nut (5).
Tip! The screwed connection of the nut and piston is a left--hand
thread!
5. Pull the pistons (6 and 7) out of the casing (10).
6. Clean all the parts and check for damage, replace if required.
For reassembly, proceed in the reverse order of disassembly. Previously,
apply a thin film of Belzona--Antiseize on all metallic fitting faces on the
pistons (6 and 7) and the casing (10). Keep clear of threads, sealing
elements and grooves. When introducing the piston in the casing, take
particular care not to damage sealing elements. Also use the opener
(009.026) for reassembly. Insert a new seal (4) and tighten the nut (5)
down to the stop. Fit the disk springs (13) in the correct order (see
illustration). Using the single open--end wrench (000.570), screw the
pulling nut (M30 x 2 / M33 x 2) down to contact, holding the piston (6) in
position using the hexagonal screw driver (000.299).

Important! To ensure that the pulling nut contacts the piston, the
disk springs (13) must be slightly compressed.

After reassembly, bleed air from the hydraulic tensioning tool and check for
tightness (see operating sequence 1).

Operating sequence 3 -- Replace the sealing elements

Starting condition The tensioning tool has been disassembled, cleaned and checked for
damage.
The sealing rings have been removed.

6629 009.08--02 E 11.97 32/40 103/ 04

Steps 1. Clean the grooves in pistons (6 and 7) and in casings (10 and 14).
2. Place the backing rings (8 and 12) and O--ring seals (9 and 11) in the
corresponding grooves.
Important! Make sure that the sealing elements are correctly
positioned. O--ring seals always on the pressure side, depression in the
backing ring pointing towards the O--ring seal.

6629 009.08--02 E 11.97 32/40 104/ 04

Dial gauge (measuring device)
Checking the bolt elongation 009.06

Purpose of jobs to be done

Tighten and release important bolted connections at the correct values,

ensure correct execution of work.

Brief description

The measuring device serves the purpose of determining the bolt

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

Tools/appliances required

Quant Denomination No. Availability

1 Measuring device 009.121 Standard
1 Magnetic prism with support 009.121--1 Standard
1 Guide piece 009.121--3 Standard
1 Clamping piece 009.121--5 Standard
1 Dial gauge (measuring device) 009.121--8 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.096 Standard
1 Hydraulic tensioning tool 009.097 Standard

Related work cards

Work card Work card Work card

009.01 000.29 000.30

Preliminary remarks

Bolted connections of particular significance require that the bolt

elongation is measured and compared with a reference value. This is to
ensure that the necessary preload resulting from the bolt elongation and
from forcing the corresponding components together is really achieved.

6629 009.06--03 E 02.98 32/40 101/ 02

 This is not the case if the tensioning tool is blocked or if some of the
tensioning pressure is absorbed by friction.

1 Knurled screw
2 Washer
3 Thrust pad
4 Casing
5 Piston

Figure 1. Measuring instrument, attached to hydraulic tensioning tool

Operating sequence 1 -- Measure the bolt elongation al

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

Steps 1. Operate the high--pressure pump/hydraulic hand pump and tighten

the bolt to the pretensioning pressure (for the value, please refer to
000.30) using the tensioning tool.
work card 000.30
2. Attach the measuring device (009.121) to the casing of the tensioning
tool. Appropriately match the dial gauge and feeler positions by
shifting the clamping piece (009.121-5). Set the dial gauge to ”0”.
3. Increase the tensioning pressure to the prescribed ultimate level (see
000.30). Tighten the nut by hand, using the tommy bar.
work card 000.30
4. Reduce the pressure to ”0” and load to pretensioning pressure again.
5. The dial gauge reading corresponds to bolt elongation/contact
pressure of components al. Convert the reading into millimeters and
compare with the set point value (refer to work card 000.30).
000.30
▲ Attention! Bolts are to be tightened applying the specified oil
pressure, and not to elongation al. al measurement is a control
measure only.
6. In case of larger deviations from the set point value, repeat the
procedure; otherwise, check the tensioning tool, the screwed
connection and the pressure gauge.
7. Reduce the pressure to ”0”. Dismount the tensioning tool.

6629 009.06--03 E 02.98 32/40 102/ 02

Operating values/Operating results

001 Operating media systems/pipes

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

6682 005--01 E 08.97 101/ 01

.
Ignition and compression pressures
Determination 000.25

Purpose of jobs to be done

Record and assess operating values,

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

Brief description

Ignition and compression pressures are a significant indicator for the

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

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Ignition pressure measuring device, Baewert 419.013 Optional
make, type 250E
1 Protective gloves -- Inventory

Preliminary remarks

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

6682 000.25--03 E 02.02 General 101/ 03

Operating sequence 1 -- Record pressures

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

Steps 1. Prior to taking indicator diagrams, open the indicator valve and keep
it open for 2-3 firing strokes to expel soot and combustion residues
that may have deposited in the indicator valve pipe.
▲ Attention! Keep away from the fire burst!
2. Close the indicator valve.
3. Screw the pressure sensor of the measuring device onto the indicator
valve.
4. Record the ignition pressures according to the Operating instruction
manual for the 250E ignition pressure measuring device (419.013).
Tip! The compression pressures can be recorded in the same way as
described above for the ignition pressures, for which purpose the control
rod of the corresponding injection pump is during the process set to zero
against the force of the buckling lever spring.

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

Operating sequence 2 -- Evaluation/valuation

The following limit values/requirements have to be observed:

- ignition pressures measured at rated output $ maximum value,
- cylinder-to-cylinder deviations $ mean value tolerance
(for the corresponding limit values, refer to the Operating instruction
manual, Section 2.5),
- equal control rod setting on all injection pumps.
It is recommended that the diagrams/results are compared with those of
the test run record and/or with those of previous measurements.
Too high ignition pressures occur if ignition is timed too early and the
amount of fuel injected is too small.
Too low ignition pressures on individual cylinders may be caused by the
following functional deficiencies:

6682 000.25--03 E 02.02 General 102/ 03

 - dripping/poor injection of the injection nozzle,
- damaged/worn injection pump, and
- untight inlet/exhaust valves.
Tip! The graphic and/or arithmetical evaluation of the measured data
can be effected by means of the delivered PC software.

6682 000.25--03 E 02.02 General 103/ 03

.
Charge air cooler/crankcase
Measuring the differential pressure 000.40

Purpose of jobs to be done

Record operating values,

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

Brief description

Supplementary to the data provided in the maintenance schedule,

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

Tools/appliances required

Quant Denomination No. Availability

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

Preliminary remarks

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

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

Measuring set--up/unit

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

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

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

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

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

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

Safety instructions

The maximum pressure on the unit is 14 bar.

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

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

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

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

Measuring using digital pressure gauge

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

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

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

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

Measuring using U-pipe pressure gauge

Steps 1. Purge the measuring connections as described above.

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

ah = 100 mm WS =10
mbar differential
pressure

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

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

Checking the crankcase pressure

The crankcase also has a measuring connection (approximately at engine

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

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

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

Work cards,
arranged by subassembly groups

1 Introduction

2 Work cards,
arranged by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 3--02 E 08.97 101/ 01

.
Table of contents

: : N 3.1 List of Assemblies

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

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

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

: : N Determine/check
012.01 Check the foundation bolts
: : N Align the engine on the foundation

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

012.02 Main bearing bolts and cross tierods

: : N Checking, untightening and tightening
012.03 Cylinder head bolts
: : N Removal and installation

N 020 Crankshaft/Coupling bolts

000.10 Crankshaft
: : N Measure the crank web deflection
020.01 Balance weight bolts
: : N Checking
020.02 Oil bore of the crankshaft
: : N Blocking
020.03 Gearwheel on the crankshaft
: : N Removing and installing
020.04 Coupling bolts
: : N Checking

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

6629 09.02 L 32/40 101 /08

 020.05 Balance weight
: : N Removing and installing

N 021 Main bearing/ Thrust bearing/Flange bearing

021.01 Main bearing cap with lower bearing shell

: : N Lowering and checking
021.02 Upper main bearing shell
: : N Removing and installing/checking
021.03 Main thrust bearing
: : N Measuring axial clearance/ checking locating bearing rings
021.04 Main flange bearing/Bearing shells
: : N Removing, refitting, checking
021.05 Main bearing cap
: : N Removing and installing

N 027 Torsional vibration damper

027.03 Torsional vibration damper of the crankshaft

: : N Removing and refitting

N 030 Connecting rod/Big--end bearing

030.01 Con--rod shank bolts

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

N 034 Piston/piston rings

034.01 Piston
: : N Removing and installing
034.02 Piston/piston rings
: : N Checking

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

6629 09.02 L 32/40 102 / 08

 034.03 Piston pin and piston pin bush
: : N Removing and installing/checking
034.04 Piston
: : N Disassembling and assembling
034.05 Piston rings
: : N Assessing
034.07 Chromium--ceramic coated Piston rings
N Assessing

N 050 Cylinder Liner/Top land ring

050.01 Top land ring

: : N Removing and installing
050.02 Cylinder liner
: : N Measuring
050.03 Cylinder liner (with backing ring)
: : N Removing and installing
050.04 Cylinder liner (without backing ring)
: : N Removing and installing
050.05 Cylinder liner
: : N Honing

N 055... Cylinder head/Saftey valve

055.01 Cylinder head bolts

: : N Checking, untightening and tightening
055.02 Cylinder head
: : N Removing and refitting
055.03 Cylinder head
: : N Cleaning
055.04 Sealing face on cylinder head and sealing groove in top land ring
: : N Grinding
055.05 Cylinder head with turnover stand
: : N Machining

N 071 Dead centre indicator/ Speed pick--up

071.01 Speed pick--up

: : N Checking, removing and installing

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

6629 09.02 L 32/40 103 /08

 N 073 Crankcase cover/Saftey valve/ Coverings

073.01 Safety valve on the crankcase cover

: : N Checking
073.02 Safety valve on the crankcase cover
: : N Disassembling and assembling

N 100 Camshaft drive

100.01 Studs for intermediate wheel axles

: : N Checking
100.02 Camshaft drive
: : N Checking

N 101... Camshaft/Thrust bearing

101.10 Injection camshaft Camshaft section

: : N Removing and installing
102.01 Valve/injection camshaft Thrust bearing
: : N Checking
102.02 Valve/injection camshaft Thrust bearing
: : N Checking
102.03 Valve/injection camshaft Thrust bearing
: : N Checking

N 101 Torsional vibration damper

101.03 Torsional vibration damper of the injection--/valve camshaft

: : N Removing and installing

N 111 Rocker arm/Rocker arm casing

111.02 Valve clearance

: : N Checking and adjusting
111.03 Rocker arm bracket with rocker arms
: : N Removing and refitting

N 112 Cam follower/Push--rod

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

6629 09.02 L 32/40 104 / 08

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

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

N rotators

113.01 Valve rotator

: : N Checking rotating motion
113.02 Inlet and exhaust valve/valve rotator
: : N Removing and installing or rather disassembling and reassembling
113.03 Inlet and exhaust valves Valve seats
: : N Checking
113.04 Valve seat rings
: : N Removing and installing
113.05 Valve guide in the cylinder head
: : N Removing and installing
113.06 Valve seating surface
: : N Machining
113.08 Valve cone
: : N Grinding
113.09 Valve plate Depth of burning marks and corrosion
: : N Checking

N 120 Camshaft adjusting device

120.01 Control piston of the injection camshaft

: : N Removing and refitting
120.02 Control piston of the injection camshaft
: : N Disassembling and assembling
120.03 Control piston of the valve camshaft
: : N Removing and refitting
120.04 Control piston of the valve camshaft
: : N Disassembling and assembling

N 125 Operating device

125.01 4/2--way valve

: : N Checking, overhauling
125.02 Three--way valve
: : N Checking, overhauling

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

6629 09.02 L 32/40 105 /08

 125.03 3/2--way solenoid valve
: : N Checking, overhauling
125.04 Three--way valve
: : N Checking, overhauling
125.05 3/2--way solenoid valve
: : N Checking, overhauling
125.06 3/2--way solenoid valve
: : N Checking, overhauling
125.07 3/2--way solenoid valve
: : N Checking, overhauling
125.08 5/2--way solenoid valve
: : N Checking, overhauling
125.09 Pressure reducing valve
: : N Checking, overhauling
125.10 Compressed air filter
: : N Checking, overhauling
125.11 Pressure regulator
: : N Checking, overhauling
125.12 Limit switch
: : N Checking, overhauling
125.13 Pressure regulator
: : N Checking, overhauling

N 140... Speed control

140.01 Electronic speed governor

: : N Checking

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

160.01 Starting air pilot valve

: : N Disassembling and assembling
161.01 Starting valve
: : N Checking, removing and installing
161.02 Starting valve
: : N Disassembling and assembling
161.03 Starting valve Seat in the cylinder head
: : N Grinding
162.01 Main starting valve
: : N Disassembling and assembling

N 200... Fuel injection pump/Control linkage

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

6629 09.02 L 32/40 106 / 08

 200.01 Fuel injection pump
: : N Checking
200.02 Fuel injection pump
: : N Shutting off
200.03 Fuel injection pump
: : N Removing and installing
200.04 Fuel injection pump
: : N Disassembling and assembling
200.05 Fuel injection pump
: : N Check the setting
200.06 Fuel injection pump Baffle screws
: : N Checking and assessing
200.07 Fuel injection pump
: : N Measuring the plunger lift
203.01 Control linkage
: : N Maintaining and checking
203.02 Control linkage
: : N Manual operation

N 221 Fuel injection valve

221.01 Fuel injection valve

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

N 280... Charge air and exhaust pipe

289.01 Exhaust pipe

: : N Checking

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

300.01 Lube oil pump

: : N Disassembling and assembling

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

6629 09.02 L 32/40 107 /08

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

N 322 Charge air cooler

N 434 Fuel injection pipe

434.01 Fuel injection pipe

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

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

6629 09.02 L 32/40 108 / 08

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

6629 3.1--03 E 07.02 L 32/40 101/ 06

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

6629 3.1--03 E 07.02 L 32/40 102/ 06

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

D GB F E

(011) Ölwanne Oil sump Carter à huile Cárter de aceite

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

027 Schwingungsdämpfer Vibration damper Amortisseur de vibrations Amortiguador de vibraciones

030 Pleuelstange Connecting rod Bielle Biela
034 Kolben Piston Piston Émbolo
050 Zylinderbuchse mit Feuerstegring Cylinder liner with top land ring Chemise de cylindre avec Camisa de cilindro con
segment couronne de piston aro de alma superior
055 Zylinderkopf Cylinder head Culasse de cylindre Culata

057 * Sicherheitsventil am Zylinderkopf Safety valve on cylinder head Soupape de sécurité dans la Válvula de seguridad en la culata
culasse de cylindre
071a Verschalungen Coverings Revêtements Revestimientos
071b * Totpunktanzeiger/ Dead centre indicator/ Indicateur de point mort/ Indicador del punto muerto/
Drehzahlaufnehmer Speed pick--up Capteur de vitesse de rotation Receptor del revoluciones
072 Verschalungen Coverings Revêtements Revestimientos
073 Verschalungen, Coverings, coverings of crankcase Revêtements, revêtements du Revestimientos, revestimientos del
Kurbelraumverschalungen mit with relief valve carter avec soupape de décharge cárter con válvula de descarga
Entlastungsventil

077 Verschalung der Nockenwelle Covering of camshaft Revêtement d’arbre à cames Revestimiento del árbol de levas
100 Steuerungsantrieb Camshaft drive Commande de la distribution Accionamiento por ruedas dentadas
101a Einspritznockenwelle Injection camshaft Arbre à cames d’injection Árbol de levas de inyección
101b Ventilnockenwelle Valve camshaft Arbre à cames de soupape Árbol de levas de válvula
(101c) * Drehschwingungsdämpfer Torsional vibration damper Amortisseur des vibrations Amortiguador de vibraciones
der Einspritznockenwelle of the injection camshaft torsionnelles torsionales
de l’arbre à cames d’injection del árbol de levas de inyección

6629 3.1--03 E 07.02 L 32/40 103/ 06

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

D GB F E

(101d) * Drehschwingungsdämpfer Torsional vibration damper Amortisseur de vibrations Amortiguador de vibraciones

der Ventilnockenwelle of the valve camshaft torsionnelles torsionales
de l’arbre à cames de soupapes en el árbol de levas de las válvulas
102 Nockenwellenlager Camshaft bearing Palier d’arbre à cames Cojinete del árbol de levas
111 Kipphebel mit Lagerung und Rocker arm with bearings and Culbuteur avec logement et chape Balancín con cojinete y tapa de
Zylinderkopfhaube cylinder head cover de culasse de cylindre culata
112 Ein-- und Auslaßschwinghebel Inlet and exhaust cam follower Basculeur d’admission et Seguidores de leva de admisión y
mit Stoßstange with push--rod d’échappement avec tige de escape con varilla de empuje
culbuteur
113 Einlaßventil Inlet valve Soupape d’admission Válvula de admisión

114 Auslaßventil Exhaust valve Soupape d’échappement Válvula de escape

(120a) Steuerkolben für Control piston for injection Piston distributeur pour arbre à Émbolo distribuidor para árbol de
Einspritznockenwelle camshaft cames d’injection levas de inyección
(120b) * Steuerkolben für Control piston for valve camshaft Piston distributeur pour arbre à Émbolo distribuidor para árbol de
Ventilnockenwelle cames de soupape levas de válvula
125 * Bedienungseinrichtung Operating device Poste de commande Dispositivo de manejo
140 * Drehzahlregler Speed governor Régulateur de vitesse Regulador de revoluciones

160 Anlaßsteuerschieber Starting air pilot valve Vanne d’asservissement de Distribuidor de arranque
lancement
161 Anlaßventil Starting valve Soupape de lancement Válvula de arranque
162 * Hauptanlaßventil Main starting valve Soupape de lancement Válvula de arranque principal
principale
200 Kraftstoffeinspritzpumpe mit Fuel injection pump with drive Pompe d’injection de combustible Bomba de inyección de combustible
Antrieb avec commande con accionamiento
203 Regelgestänge Control linkage Tringlerie de régulateur Varillaje de regulación

221 Kraftstoffeinspritzventil Fuel injection valve Soupape d’injection de Válvula de inyección de combustible
combustible
6629 3.1--03 E 07.02 L 32/40 104/ 06
Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 3.1

D GB F E

280 Ladeluftleitung Charge air pipe Conduite d’air de suralimentation Tubería de aire de sobrealimentación
(280) * Luftumblaseleitung Air bypass pipe Tuyauterie de dérivation d’air Tubería de derivación de aire
280 * Druckmeßumformer Pressure transducer Convertisseur de mesure de Convertidor de medición de presión
pression
286 Abgasturboladeranbau Mounting exhaust gas Montage turbocompresseur Montaje turbosobrealimentador
turbocharger

289 Abgasleitung Exhaust pipe Tuyauterie d’échappement Tubería de escape

289 Verschalung der Abgasleitung Covering of the exhaust gas pipe Revêtement du tuyauterie Revestimiento de la tubería de gas
d’échappement de escape
(300) * Schmierölpumpe Lube oil pump Pompe à huile de graissage Bomba de lubricación
302 Schmierölpumpe für Lube oil pump for cylinder Pompe à huile de graissage pour Bomba de lubricación para la
Zylinderschmierung lubrication lubrification du cylindre lubrificación de cilindros
311 * Kurbelraumentlüftung Crankcase venting Ventilation du carter du Ventilación del cárter del cigüeñal
vilebrequin

322 Ladeluftkühler Charge air cooler Réfrigérant d’air de Refrigerador del aire de
suralimentation sobrealimentación
(350) * Kühlwasserpumpe Cooling water pump Pompe à eau de refroidissement Bomba de agua de refrigeración
(408) * Grundlagertemperatur-- Temperature monitoring of main Surveillance de température du Control de la temperatura del cojinete
überwachung bearing palier principal principal
408 * Anbauteile zum Triebraumdeckel Fitting parts to crankcase cover Pièces pour couvercle de carter Piezas de montaje para tapa del
für Splash--Oil for splash--oil pour système Splash--oil cárter con sistema Splash--oil
413 * Verkabelung am Motor für Cabling on engine for splash--oil Cablage électrique sur le moteur Cableado en el motor para sistema
Splash--Oil--Temperatur-- temperature monitoring pour système Splash--oil Splash--oil
überwachung

413 * Ölnebeldetektor Oil mist detector Détecteur de brouillard d’huile Detector de neblina de aceite
419 Indiziereinrichtung Indicating device Dispositif indicateur Dispositivo indicador
(430) * Rohrleitungen, allgemein Pipes, general Tuyauteries, général Tuberías, general

6629 3.1--03 E 07.02 L 32/40 105/ 06

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

D GB F E

432 Anlaßluftleitungen und Starting air pipes and control Tuyauteries d’air de lancement et Tuberías de aire de arranque y
Steuerleitungen pipes tuyauteries de commande tuberías de mando
434 Kraftstoffeinspritzleitung Fuel injection pipe Tuyauterie d’injection de Tubería de inyección de combustible
combustible

434 Kraftstoffleitungen Fuel pipes Tuyauteries de combustible Tuberías de combustible

440 Schmierölleitung Lubricating oil pipe Tuyauterie d’huile de graissage Tubería de aceite lubricante
442 Kondenswasserablauf Condensed water discharge Décharge d’eau de condensation Descarga del agua de condensación
443 Zylinderschmierung Cylinder lubrication Lubrification des cylindres Lubrificación de cilindros
(443) Ventilsitzschmierung Valve seat lubrication Graissage de siège de soupape Lubricación del asiento de
válvula

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

6629 3.1--03 E 07.02 L 32/40 106/ 06

Work cards,
arranged by subassembly groups 3.2

See the following pages.

Auxiliary sheet for generating the table of contents

6629 3.2--01 E 08.97 General 101/ 01

.
Foundation/resilient mounting/
alignment of the engine

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

6682 009...--02 E 04.98 101/ 01

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

Purpose of jobs to be done

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

Brief description

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

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

Tools/appliances required

Qty Designation No. Availability

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

Related work cards

Work card Work card Work card

000.10 012.01

Preliminary remarks

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

6682 000.09--01 E 02.01 101/ 04

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

1 Driven shaft flange E Distance

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

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

Operating sequence 1 -- Measure the flange alignment

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

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

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

6682 000.09--01 E 02.01 102/ 04

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

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

1 driven shaft flange 2 engine crankshaft

* Enter values in table

** Enter values in illustration

Important! The effective radial displacement is only half the

difference (aA) calculated from the dial gauge readings.

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

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

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

Alignment control dimension (C), coupling

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

6682 000.09--01 E 02.01 103/ 04

Engine coupled not coupled

Engine state cold warm •C

Engine room temperature •C

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

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

6682 000.09--01 E 02.01 104/ 04

Check the foundation bolts
Align the engine on the foundation 012.01

Purpose of jobs to be done

Check alignment,
check state/wear condition of components,
recognise problems on components/in systems (which have an influence).

Brief description

Foundation bolts are to be checked for correct preload in regular intervals,

the state and firm seat of fitting pieces and stops is to be verified.
This includes:
checking components and
new alignment of engine

Tools/appliances required

Quant Denomination No. Availability

1 Thrust pad 030.258 Standard
1 Nut 030.205 Standard
1 Guide tube 021.032 Standard
1 Hydraulic tensioning tool 009.346 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
1 High--pressure hose 009.306 Standard
1 Open--jaw spanner 55 000.570 Standard
1 Thickness gauges 0.05--1 000.454 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar 6 000.261 Standard
1 Forcing--off bolt M32x2 -- Inventory
1 Depth gauge -- Inventory
1 Hammer (wood/plastic) -- Inventory

Related work cards

Work card Work card Work card

000.10 000.30 000.33
009.03

6629 012.01--01 E 11.97 32/40 101/ 05

Preliminary remarks

The maintenance schedule also specifies that the hydraulically tensioned

foundation bolts are checked for correct preload, and the fitting pieces and
stops are checked for firm seat. The pressures required for loosening the
nuts are determined, and compared with the specified tensioning
pressures. The foundation bolts are then retensioned to the specified
tensioning pressure.
A further item in the maintenance schedule is the checking of crank web
deflections. If this checking has revealed an inadmissibly high value
(particularly on cylinder No. 1, resp. cylinders A1/B1, see work card
000.10) and correction by alignment of the adjoining shaft (generator) was
000.10
not possible, the engine has to be lifted from the foundation for being
realigned. Please refer to the aligning instructions in the foundation
drawing.

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

touching (marine engines), or after natural disasters (stationary
engines), the position of the engine should be accurately checked,
and all foundation bolts should be retightened. The foundation bolts
at the coupling end and free engine end are most likely to be
affected.
Engine mounting on the foundation will differ, depending on the engine
installation (marine engine, stationary engine). Marine engines are bolted
to the top plates of the vessel, stationary engines are bolted to the
foundation girders.

Operating sequence 1 - Checks on the crankcase

▲ Attention! Danger to life! Whenever doing work in the crankcase,

block the starting air vessel, bleed air from the starting air pipe and
engage the turning gear to preclude inadvertent starting of the
engine and movement of the running gear. For further safety
regulations refer to sheet 3.2.

Steps 1. When doing overhaul work and on every oil change, carefully clean
the crankcase and oil sump.
2. Inspect the crankcase for cracks on the inside and outside.

Operating sequence 2 - Check on the foundation

Important! For checking the foundation bolts, start at the coupling

end.

Steps 1. Remove the protecting caps (9), and clean and degrease the
foundation bolts (12/13).
2. Verify that the pulling nut (030.205) is securely bolted to the
tensioning tool (009.346).
3. Slip the thrust pad (030.258) over the foundation bolt and screw on
the tensioning tool.
4. Turn the tensioning tool back by 180 deg.
5. Connect the high-pressure hose (009.306) to the tensioning tool and
high-pressure pump (009.338), or hydraulic hand pump (009.320).
6. Switch on the high-pressure pump, or the hydraulic hand pump (see
009.03) and close the gap produced between the thrust
work card 009.03
pad and the tensioning tool on turning the latter back.

6629 012.01--01 E 11.97 32/40 102/ 05

 7. Pressurise the tensioning tool by pumping until the nut (10) can be
loosened. Note down the loosening pressure and compare it with the
tensioning pressure.

9 Protecting cap 13 Foundation bolt 17 Disk

10 Nut (Fitting bolt) 18 Hexagon nut
11 Crankcase 14 Fitting piece
12 Foundation bolt 15 Stop A Bolt projection
(Undercut bolt) 16 Foundation

Figure 1. Mounting the engine on the foundation plate (marine engine) and attaching the hydraulic tensioning tool

▲ Attention! The pressure is allowed to be max. 7% below and

max. 5% above the tensioning pressure (cf work cards 000.30 and
000.33).
000.33

Important! In case of resin chocking, the tensioning value for the

foundation bolts is to be specified by the resin chock manufacturer.
Threads of the foundation bolts and the contact faces of nuts must be free
from any traces of resin.
8. Adjust the high-pressure pump to the specified tensioning pressure,
resp. operate the hydraulic hand pump until the specified tensioning
pressure is reached, and retighten the nut.
9. Depressurise the unit and remove the hydraulic tensioning tool.
10. Check all the other foundation bolts in the same way (points 3 to 9).
11. Apply grease to the threads of the foundation bolts against corrosion,
and mount the protecting caps.
12. Check by tapping whether fitting pieces (14) and stops (15) are firmly
seated.

Operating sequence 3 - Align the complete engine

Steps 1. Mount the hydraulic tensioning tool on the foundation bolt (12 or 13)
and loosen nut (10) - see operating sequence 2, points 1 to 7.
2. Turn back the nut.
3. Depressurise the unit and remove the hydraulic tensioning tool.
4. Unload all the other foundation bolts in the same way.
5. Screw off the nuts and remove the foundation bolts if possible.
6. Take the protecting caps off the forcing-off threads and screw in the
forcing-off bolts (19), using washers (20) to protect the foundation.

6629 012.01--01 E 11.97 32/40 103/ 05

 7. Lift the engine by means of the forcing-off bolts, remove the fitting
pieces (14) and align the engine so that the crank web deflection is
000.10).
within admissible limits (refer to work card 000.10

11 Crankcase
14 Fitting piece
16 Foundation
19 Forcing-off bolt
20 Washer

Figure 2. Arrangement of forcing-off bolt

Important! During engine alignment, take note of the connected

shaft and of the crank web deflection of cylinder 1, resp. cylinder A1/B1
(coupling end) in particular. Use thickness gauges (000.454) to verify
whether the crankshaft properly rests on the bottom bearing shells.
8. Measure the thickness of fitting pieces and make new fitting pieces if
necessary.
▲ Attention! One and the same material has to be used for engine
chocking. A mix of resin and steel chocks is not admissible.
9. Fit the fitting pieces, check that they fit snugly using the thickness
gauge (000.451).
10. Fit the foundation bolts (for the fitted bolts, do not forget to install disk
(17) and tighten the nuts hand-tight. Check the bolt projection (A) of
79 mm.
11. Remove the forcing-off bolts and washers and keep them along with
the tools. Apply grease to the forcing-off thread and cover with
protecting caps.
12. Verify that the pulling nut (030.205) has been firmly bolted to the
tensioning tool (009.346).
13. Slip the thrust pad (030.258) over the foundation bolt and screw on
the tensioning tool; the order can be seen from Figure 4, resp. 5.
14. Connect the high-pressure hose (009.306) to the tensioning tool and
high-pressure pump (009.338), resp. hydraulic hand pump.
15. Switch on the high-pressure pump, resp. the hydraulic hand pump
(refer to work card 009.03)
009.03 and load the foundation bolt to the
000.30). Using the
specified tensioning pressure (see work card 000.30
tommy bar (000.261), tighten the nut hand-tight.
Important! In the case of resin chocking, the tensioning torque for
the foundation bolts is to be specified by the resin chock manufacturer.
The threads of the foundation bolts and the contact faces of nuts should
be free of any traces of resin.
16. Depressurise the unit and remove the hydraulic tensioning tool.
17. Load all the other foundation bolts in the same way (points 13 to 16).
18. Check the crank web deflection once again and enter it in the engine
000.10).
operating records (refer to work card 000.10
19. Apply grease to the threads of foundation bolts against corrosion, and
cover them with protecting caps.

6629 012.01--01 E 11.97 32/40 104/ 05

 1-8 Order of bolt tightening

Figure 3. Order of foundation bolt tightening

1-8 Order of bolt tightening

A1-A6 Cylinder bank A

B1-B6 Cylinder bank B

Figure 4. Order of foundation bolt tightening (V-type engine)

6629 012.01--01 E 11.97 32/40 105/ 05

.
Crankcase/Bearing bolts/Cross tierods/
Cylinder head bolts

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

6682 012--02 E 04.98 101/ 01

.
Main bearing bolts
and cross tierods
Checking, untightening and tightening 012.02

Purpose of jobs to be done

Tighten and release important bolted connections at the correct values,

ensure correct execution of work.

Brief description

Main bearing bolts

and cross tierods
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Tools/appliances required

Quant Denomination No. Availability

2 Thrust pad 030.243 Standard
2 Setting gauge 021.256 Standard
2 Tension screw 021.251 Standard
2 Intermediate ring 021.250 Standard
2 Thrust pad 021.231 Standard
2 Threaded piece 021.228 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
4 High--pressure hose 009.306 Standard
2 Hydraulic tensioning tool 009.097 Standard
2 Hydraulic tensioning tool 009.096 Standard
2 Measuring device 009.051 Standard
2 Angle piece 009.028 Standard
1 Thickness gauges 0.05--1 000.451 Standard
2 Tommy bar 10 000.263 Standard
2 Tommy bar 8 000.262 Standard
1 Ring spanner (cranked) 24x27 000.247 Standard
1 Depth gauge -- Inventory

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.01 009.03

6629 012.02--01 E 01.98 L 32/40 101/ 06

Preliminary remarks

The maintenance schedule also specifies that the hydraulically tensioned

main bearing bolts and cross tierods are checked for correct preloading.
Note down the force required for loosening and compare it with the loading
pressure. Operating sequences 1 and 2 describe how to proceed.
Operating sequences 3 -- 5 describe the untightening and retightening of
main bearing bolts and cross tierods. This work has to be done in
connection with other jobs, e.g. together with the checking of main bearing
shells.

Operating sequence 1 -- Check the cross tierods

Starting condition Protecting caps removed from the cross tierods.

Steps 1. Clean the threads of cross tierods (9).

2. Mount hydraulic tensioning tools on both cross tierods of a main
bearing, screw down the threaded piece (021.228) to contact,
hand--tight.
▲ Attention! Prior to mounting the tensioning cylinders make sure
that the pistons have been fully driven home.
3. Turn the tensioning cylinders (009.097) back by 280E.
4. Connect the high--pressure hoses (009.306) to the tensioning
cylinders and high--pressure pump (009.338).
009.03) and close
5. Switch on the high--pressure pump (see work card 009.03
the gap between the thrust pad (021.231) and ring (7) produced by
the turning back of the tensioning cylinder.
6. Pressurise the tensioning cylinder by pumping until nuts (8) can be
loosened. Note down the loosening pressure and compare with the
loading pressure.
▲ Attention! The pressure is permitted to be max. 7% below and
max. 5% above the tensioning pressure (refer to work cards 000.30
000.33).
and 000.33
7. Adjust the high--pressure pump to the specified loading pressure and
retighten both the nuts.
8. Release the pressure and remove the hydraulic tensioning tools.
9. Mount the protecting caps on the cross tie rods.
10. Reset the pistons of the tensioning cylinders (refer to work card
009.01).
009.01

2 Crankcase
7 Ring
8 Nut
9 Cross tierod

Figure 1. Mounting the hydraulic tensioning tool on the cross tierod

6629 012.02--01 E 01.98 L 32/40 102/ 06

Operating sequence 2 -- Check the main bearing bolts

Starting condition Crank case opened, running gear turned into a position permitting good
access to main bearing cap.

▲ Attention! Prior to mounting the tensioning cylinders make sure

that the pistons have been fully reset.

Arbeitsschritte 1. Clean the threads of the main bearing bolts (4).

2. Screw the tension screws (021.251) onto the tensioning cylinders
(009.096) up to stop.
3. Slip the thrust pads (030.243) over nuts (6) and screw the tensioning
cylinders by a few thread turns onto the main bearing bolts.
4. Insert the setting gauges (021.256) between the thrust pads and
main bearing caps (3) and screw on the tensioning cylinders until the
thrust pads snugly contact the setting gauges.
5. Attach the spacer rings (021.250) and tensioning cylinders (009.096).

3 Main bearing cap

Figure 2. Mounting the hydraulic tandem tensioning tool to the main bearing bolt
6. Slip the angle pieces (009.028) onto the tensioning cylinders.
7. Connect four high--pressure hoses (009.306) to tensioning cylinders
and high--pressure pump (009.338).
8. Remove the setting gauges.
009.03) and
9. Switch on the high--pressure pump (refer to work card 009.03
close the gap between the thrust pad and the main bearing cap.
10. Pressurise the tensioning cylinder by pumping until nuts can be
loosened. Note down the loosening pressure and compare with the
loading pressure.
▲ Attention! The pressure is permitted to be max. 7% below and
max. 5% above the tensioning pressure (refer to work cards 000.30
000.33).
and 000.33
11. Adjust the high--pressure pump to the specified loading pressure and
retighten both the nuts.
12. Release the pressure and remove the hydraulic tandem tensioning
tool.
13. Close the crank case.
14. Reset the pistons of the tensioning cylinders (refer to work card
009.01).
009.01

6629 012.02--01 E 01.98 L 32/40 103/ 06

 3 Main bearing cap
4 Main bearing bolt
5 Dial gauge
6 Nut

A Bolt projection

Figure 3. Hydraulic tandem tensioning tool attached to the main bearing bolt

Operating sequence 3 -- Unload the cross tierods

Starting condition Protecting caps removed from the cross tierods.

Steps 1. Mount the hydraulic tensioning tool and loosen nuts (8) (see
operating sequence 1, points 1 to 6).
2. Turn both nuts back (for angular amount of screwing back, see work
000.30).
card 000.30
3. Release the pressure and remove the hydraulic tensioning tools.
4. Reset the pistons of the tensioning cylinders (009.097) (refer to work
009.01).
card 009.01

Operating sequence 4 -- Unload the main bearing bolts

Starting condition Crank case opened, with running gear turned to a position providing good
access to main bearing cap. Cross tierods unloaded.

Important! Prior to untightening the main bearing bolts, make sure

to unload the cross tierods.

Steps 1. Mount hydraulic tandem tensioning tools on both main bearing bolts
(4) and loosen nuts (6). (Refer to operating sequence 2, points 1 to
10.)
2. Turn back both nuts (for angular amount of screwing back, see work
card 000.30).
000.30
3. Release the pressure and remove the hydraulic tandem tensioning
tools.
4. Reset the pistons of the tensioning cylinders (009.096 and 009.097).
009.01).
(See work card 009.01

Operating sequence 5 -- Tension the main bearing bolts and cross tierods

Important! Tensioning is done in several steps. The correct order

of tightening should be observed. Prior to tensioning the main bearing
bolts, verify that the bolt projection A is correct, namely 116 mm.

6629 012.02--01 E 01.98 L 32/40 104/ 06

 1 Crankshaft
2 Crankcase
3 Main bearing cap

Figure 4. Hydraulic tensioning tools mounted on the cross tierods

Steps 1. Screw the nuts (6) of the main bearing bolts (4) hand--tight, using the
tommy bar (000.263).
2. Verify that the gap of the joint between the main bearing cap (3) and
the crankcase (2) is the same on both sides (max. 1 mm).
3. Screw the nuts (8) of cross tierods (9) hand--tight, using the tommy
bar (000.262).
4. Mount hydraulic tensioning tools on both cross tierods,
simultaneously screw on the threaded piece (021.228) hand--tight to
contact.
▲ Attention! Prior to mounting the tensioning cylinders, make sure
that the pistons have been completely reset.
5. Screw the tension screws (021.251) onto tensioning cylinder
(009.096) until contact is established.
6. Slip the thrust pad (030.243) over nuts (6) and screw tightening
cylinders onto main bearing bolts (4).
▲ Attention! Prior to mounting the tensioning cylinders, make sure
that the pistons have been fully forced home.
7. Slip the spacer rings (021.250) over the tension screws onto the
tensioning cylinders, introduce tommy bars through bores provided in
the spacer rings into tension screws.
Tip! With the tommy bars introduced, the fitting and removal of spacer
rings on changing the tensioning cylinders (009.097) is avoided.
8. Connect high--pressure hoses (009.306) to tensioning cylinders
mounted on the cross tierods and to the high--pressure pump
(009.338).
009.03) and
9. Switch on the high--pressure pump (refer to work card 009.03
load the cross tierods to 250 bar. Tighten both the nuts hand--tight
using the tommy bar.
10. Release the pressure, disconnect the high--pressure hoses, remove
the tensioning cylinders.
11. Reset the pistons of the tensioning cylinders (see work card 009.01).
009.01
12. Screw tensioning cylinders (009.097) onto main bearing bolts,
remove the tommy bars from the tension screws.
13. Slip angle pieces (009.028) onto tensioning cylinders.
14. Connect high--pressure hoses to tensioning cylinders mounted on the
main bearing bolts.

6629 012.02--01 E 01.98 L 32/40 105/ 06

 1 Crankshaft
2 Crankcase
3 Main bearing cap

Figure 5. Hydraulic tensioning tools mounted on the main bearing bolts

15. Switch on the high--pressure pump and load the main bearing bolts to
250 bar. Screw both the nuts hand--tight using the tommy bar.
16. Release the pressure, disconnect the high--pressure hoses and angle
pieces, reinsert the tommy bars through spacer rings into tension
screws, and screw off the tensioning cylinders (009.097).
17. Reset the pistons of the tensioning cylinders.
18. Screw the tensioning cylinders onto cross tierods again.
19. Connect high--pressure hoses to tensioning cylinders on the cross
tierods.
20. Switch on the high--pressure pump and load the cross tierods to the
000.30). Screw both the nuts
specified end pressure (see work card 000.30
hand--tight using the tommy bar.
21. Release the pressure, disconnect the high--pressure hoses and
remove the hydraulic tensioning tools from the cross tierods.
22. Reset the pistons of the tensioning cylinders.
23. Screw the tensioning cylinders onto the main bearing bolts, remove
tommy bars from the tension screws.
24. Slip angle pieces onto the tensioning cylinders.
25. Connect high--pressure hoses to the tensioning cylinders mounted on
the main bearing bolts.
26. Switch on the high--pressure pump and load the main bearing bolts to
250 bar.
27. Attach measuring instruments (009.051) to tensioning cylinders
(009.097) and set the dial gauges (5) to ”Zero”.
28. Load the main bearing bolts to the specified end pressure (see work
000.30). Screw both the nuts hand--tight using tommy bar.
card 000.30
29. Release the pressure.
30. Load the main bearing bolts to 250 bar again. Read the elongation
aL on the dial gauges and compare the readings with the specified
000.30).
elongations (see work card 000.30
Important! Main bearing bolts should be tightened to the specified
tensioning pressure, not according to elongation. Elongations are stated
for control purposes only. In case of unusual deviations, repeat the ten-
sioning process and check the measuring units and/or pressure gauges.
31. Release the pressure and remove the hydraulic tandem tensioning
tools from the main bearing bolts.
32. Close the crankcase and mount the protecting caps on the cross
tierods.
33. Reset the pistons on all tensioning cylinders.

6629 012.02--01 E 01.98 L 32/40 106/ 06

Cylinder head bolt
Removal and installation 012.03

Purpose of jobs to be done

Insert/replace components,
ensure proper application.

Brief description

Cylinder head bolts are to be dismantled in case cylinder liners must be

removed at a low removal height. Cylinder head screws are also to be
dismantled if their sealing rings are damaged.
The work/steps extend to:
Removal of components,
Installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Bolt extractor 009.089 Optional
1 Ring nut 009.089--1 Optional
1 Ring nut 009.089--2 Optional
1 Tommy bar 16 000.266 Standard
1 Ring spanner (cranked) 13x17 000.243 Standard
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.30 055.02

Technical details

Term Information
Cylinder head bolt 19.5 kg

6629 012.03--01 E 08.97 32/40 101/ 03

Operating sequence 1 -- Dismantle the cylinder head bolts

Starting condition Cylinder head removed.

Steps 1. Mount the bolt extractor (009.089) on cylinder head bolt (1). (Observe
the projection A = 53 mm -- see Figure 1).
2. Loosen the cylinder head bolt and screw it out.
3. Dismantle all the other cylinder head bolts in the same way.
4. Clean the cylinder head bolts and check them for damage.
5. Check the ring (3) for damage and install a new one, if required.

Operating sequence 2 -- Install the cylinder head bolts

Starting condition Bores and threads in the crankcase and cylinder head bolts thoroughly
cleaned and degreased.

Steps 1. Slip new O--ring seals (2) and the ring (3) -- if required, new -- over
the thread onto the cylinder head bolts.
2. Mount the bolt extractor (009.089) on cylinder head bolt (1) (observe
projection A = 53 mm).
3. Introduce cylinder head bolt into bore, screw down and screw
hand--tight using tommy bar (000.266) (see work card 000.30).
000.30
4. Remove the bolt extractor.
5. Apply acid--free grease to O--ring seals.
6. Insert the O--ring seals and ring with the aid of an appropriate means
into bore, taking care not to twist and/or damage the O--ring seals.
7. Install the other cylinder head bolts in the same way.
8. Mount the cylinder head (refer to work card 055.02).
055.02
▲ Attention! Before proceeding to the job following next, namely
the hydraulic tensioning of the cylinder head bolts, make sure that
the crankcase and the cylinder head bolts have the same
temperature.This is of particular importance when replacing cylinder
head bolts with the engine at operating temperature.
055.01).
9. Tension the cylinder head bolts (see work card 055.01

6629 012.03--01 E 08.97 32/40 102/ 03

 1 Cylinder head bolt
2 O--ring seal
3 Ring
4 Crankcase
5 Hexagonal nut
6 Stud bolt
7 O--ring seal

A Projection

Figure 1. Cylinder head bolt in the crankcase/mounting the bolt extractor (right--hand top)

6629 012.03--01 E 08.97 32/40 103/ 03

.
Crankshaft/Coupling bolts

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

6682 020--02 E 04.98 101/ 01

.
Crankshaft
Measure the crank web deflection 000.10

Purpose of jobs to be done

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

Brief description

The crank web deflection permits to draw conclusions on the alignment of

the crankshaft bearing and the bearing/the alignment of the driven shaft. It
is to be checked regularly.
This includes the following:
checking the alignment,
recording the measuring values, and
evaluating the results.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.15
1 Assistant 0.15

Tools/appliances required

Qty Designation No. Availability

1 Crank--web--deflection measuring device DI--4 008.175 Optional
1 Thickness gauges 0.05--1 000.454 Standard
1 Tools, basic scope 000.002 Standard
1 Felt--tip pen/Marking pen -- Inventory

Related work cards

Work card Work card Work card

000.09

6682 000.10--02 E 12.00 32/40, 40/45, 40/54, 48/60, 58/64 101/ 05

Preliminary remarks

The crank web deflection permits to draw conclusions on the alignment of

the main bearings and the bearings of the driven shaft. Should the
measured values exceed the admissible maxima, the cause must be
remedied/the crankshaft has to be realigned. Possible causes are:
- Uneven wear of main bearings,
- the position of the driven shaft has changed, or
- the engine mounting on the foundation and/or the foundation itself has
changed.
The results of the crank web deflection measurements have a coherence
with the check of the crankshaft flange alignment relative to the driven
flange.

Figure 1. DI--4 crank-web-deflection measuring device with transducer and vari-

ous extension rods

▲ Attention! The measuring points (2) for taking measurements with

the running gear components in place are located in the balance
weights. Exception: 58/64 engine, where they are located in the
crank webs.

Operating sequence 1 -- Measuring the crank web deflection

Measuring is to be carried out at the points BDCR and BDCL if the con-
necting rod is in place. With the connection rod removed, readings of the
measured values are to be taken in BDC position.
Decisive for the designation is the position of the crank pin, not that of the
transducer.
The side designation and the sense of rotation are to be understood from
the end permitting a view onto the coupling flange.

Steps 1. Remove the cover of the crank case openings or swing them open.
2. Turn the crankshaft, cylinder 1, to its starting position; depending on
the engine’s normal sense of rotation, into BDCL or BDCR.
3. Using the thickness gauges, check whether the crankshaft rests on
the lower bearing shells.
Important! If this is not the case, incorrect results will be obtained
when measuring the crank web deflection!

6682 000.10--02 E 12.00 32/40, 40/45, 40/54, 48/60, 58/64 102/ 05

 4. Check whether the cables of the crank-web-deflection measuring de-
vice are connected correctly.

Figure 2. DI--4 crank-web-deflection measuring device as attached to the crank-

shaft
5. Select suitable extension rods and fasten them to the transducers.
6. Switch the crank-web-deflection measuring device on by depressing
the “POWER” button. Actuate the “RESET” button, thus returning
the measuring device to the basic position.
7. Insert the transducer into measuring point (2). Using the adjusting
ring, set a value between --0.500 and +0.500 on the transducer and
block it by means of the locking ring. Reset the measured value in-
dication by depressing the “ZERO” bottom.

OT Top dead centre (TDC) ROT 90• right of TDC (RTDC) UTR right of BDC (BDCR)
UT Bottom dead centre (BDC) LOT 90• left of TDC (LTDC) UTL left of BDC (BDCL)

Figure 3. Designation of the measuring points

6682 000.10--02 E 12.00 32/40, 40/45, 40/54, 48/60, 58/64 103/ 05

 Important! If the measurement of the crankshaft web deflection is
carried out with the engine still warm, the transducer must previously have
been in the crankcase for approx. 15 minutes to adapt to the prevailing
temperature.
8. Turn the crankshaft in the normal sense of rotation up to the desired
measuring positions (refer to Figure 3 ). At every position, take
readings of the magnitude and direction (+ oder --) of the indicated
measured values in comparison with the initial value (Zero) and enter
them into the table (similar to the example).
▲ Attention! In case of a V-type engine, make sure that the
measuring device is not damaged by the slave connecting rod while
turning the crankshaft.
9. Measure the other crank throws in the same way.
10. Remove the transducer by pressing against it on one side and insert
it at the next measuring point. It is not necessary to loosen and read-
just the locking ring and adjusting ring respectively.

Operating sequence 2 -- Record the measured values

Cylinder number
C k position
Crank iti 1 2 3
Crank in BDCR 0 0
Crank in RTDC +3 +5
Crank in TDC +8 +1
Crank in LTDC +4 -4
Crank in BDCL 0 -2
Crank web deflection TDC-BDC +8 +2
Crank web deflection RTDC-LTDC -1 +9

Difference of the TDC values

of the neighbouring cylinders 7
Table 1. Measurement record (example). Dimensions given in 1/100 mm
The measurement record should, besides the entries shown in Table 1,
contain the following information:
- Assembly condition (e.g. pistons/connecting rods installed/removed),
- condition of couplings and bearings (e.g. ship in drydock/afloat),
- temperatures of oil and cooling water if measurements are taken with
the engine at operating temperature, and
- the main sense of rotation of the engine if measurements are taken
with running gear components in place.

Operating sequence 3 -- Evaluation/judgement

The crank web deflection is the maximum difference of the values

measured at two crank positions which are offset by 180•. The reference
position for vertical deflection is the BDC, that for horizontal deflection is
LTDC. If the crank web deflection is to be measured with the running gear
components in place, the value for BDC is to be obtained from 0.5 (BDCL
+ BDCR), which then permits to calculate the difference between TDC and
BDC.
If the crank web distance increases as compared with the reference posi-
tion, plus values (+) are entered in the table; if the distance becomes
smaller, minus values (--) are entered.

6682 000.10--02 E 12.00 32/40, 40/45, 40/54, 48/60, 58/64 104/ 05

 Table 2 contains the maximum deflection values and the measuring point
distances A. The maximum values apply to all cylinders with the engine
either cold or at operating temperature, either rigidly or flexibly coupled
(exceptions for the 32/40 engine - please see below). If the actual deflec-
tion values exceed the ones listed in the table, the crankshaft is to be re-
aligned.
Please also note the following:
The difference of the TDC measurements of neighbouring cylinders should
not be larger than the maximum admissible crank web deflection.

Engine type 32/40 40/45 40/54 48/60 58/64

Web deflection in 1/100 mm á14 1) 2) á13 á18 1) á23 1) á23 1)
Measuring point distance (A) in mm 460 460 505 580 560
1) With the engine at operating temperature, negative values which are by 20% higher are admissible.

2) Valid for crank No. 1 (on coupling side) with rigid coupling, and for all other cranks optionally.
For crank No. 1 (on coupling side) maximum value -- 20, if connection to the driving flange is effected by flexible coupling.
Table 2. Permissible maximum web deflections (differences) and related measuring point distances

6682 000.10--02 E 12.00 32/40, 40/45, 40/54, 48/60, 58/64 105/ 05

.
Balance weight bolts
Checking 020.01

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Bolted connections which are tightened by means of hydraulic tensioning

tools must, according to the maintenance schedule, be checked for correct
tension.
The work/steps include:
Establishment and evaluation of loosening pressure and
tensioning of the connection at nominal pressure.

Safety requirements

- Engine shut--down
- Engine secured against starting

Tools/appliances required

Quant Denomination No. Availability

2 Thrust pad 030.243 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
2 High--pressure hose 009.306 Standard
2 Hydraulic tensioning tool 009.097 Standard
1 Tommy bar 10 000.263 Standard

Related work cards

Work card Work card Work card

000.30 000.32 009.01
009.03

Preliminary remarks

Within the scope of this work, the pressure required for loosening the nuts
is established. This pressure is then compared with the specified
tensioning pressure. After that, the screw connections are tensioned at the
specified tensioning pressure.

6629 020.01--01 E 11.97 L 32/40 101/ 02

Operating sequence 1 -- Check the balance weight bolts

Starting condition Crankcase opened, with crankshaft turned to a position in which balance
weight faces the crankcase door.

Steps 1. Clean the threads of stud bolts (2).

2. Mount hydraulic tensioning tools on both stud bolts, taking care of
centerings.
▲ Attention! Prior to mounting the tensioning cylinders make sure
that pistons have been fully reset.
Once the tensioning tools have been mounted, the crankshaft must
not be turned any more.
3. Turn the tensioning cylinder (009.097) by 250E back.
4. Connect high-pressure hoses (009.306) to tensioning cylinder and
high--pressure pump (009.338).
009.03), and close
5. Switch on the high-pressure pump (see work card 009.03
the gap between the thrust pad (030.243) and balance weight (1)
produced by turning back.
6. Pressurise the tensioning cylinder by pumping until nuts (4) can be
loosened. Note down the force required for loosening and compare it
with the tensioning pressure.
▲ Attention! The pressure is allowed to be max. 7% below and
max. 5% above the tensioning pressure (see work cards 000.30 and
000.33).
000.33
7. Adjust the high--pressure pump to the specified tensioning pressure
and retighten both the nuts.
8. Release the pressure and remove the hydraulic tensioning tools.
9. Reset the pistons of the tensioning cylinders (see work card 009.01).
009.01

1 Balance weight 3 Crankcase

2 Stud bolt 4 Nut

Figure 1. Hydraulic tensioning tools, as mounted.

6629 020.01--01 E 11.97 L 32/40 102/ 02

Oil bore of the crankshaft
Blocking 020.02

Purpose of jobs to be done

Ensure correct execution of work,

enable emergency operation.

Brief description

Should it be necessary in case of emergency, to continue engine operation

although one piston/connecting rod assembly has been removed, the oil
bores in the respective crankpin are to be blocked.
The work/steps include:
proper mounting
and, if necessary,
dismounting.

Safety requirements

- Engine shut--down
- Engine secured against starting

Tools/appliances required

Quant Denomination No. Availability

1 Blocking tool 020.050 Standard
1 Threaded rod 020.050--1 Standard
2 Sealing plug 020.050--5 Standard
1 Screw driver 0.8x5.5 000.391 Standard
1 Ring spanner (cranked) 13x17 000.243 Standard

Related work cards

Work card Work card Work card

030.05 112.01 200.01

Preliminary remarks

It may become necessary in case of emergency to continue engine

operation although one piston/connecting rod assembly has been
removed. To keep the oil circulating and thereby ensure lubrication of other
engine components, the oil bore in the crankpin has to be blocked.

▲ Attention! Engine operation with a piston/connecting rod unit

removed should only be continued in a real case of emergency, and

6629 020.02--01 E 07.97 32/40 101/ 02

 at reduced output and speed. Please refer to the detailed description
given in the operating instruction manual, Section 3.6.

Operating sequence 1 - Block the oil bore

Starting condition Piston with connecting rod, big end bearing and pushrod removed.

Steps 1. Slip one screw plug (020.050-5) onto threaded rod (020.050-1) and
insert it in the oil bore (3).
2. Slip the second screw plug onto threaded rod, screw on the castle
nut (4), tighten it and secure it with split pin (5).
3. Mount the complete cylinder head, do not insert pushrods. Put inlet
and exhaust cam follower out of operation (lock them in postion
outside the cam area), block the lube oil bores.
4. Put the injection pump of the relevant cylinder out of operation (move
the control rod to zero admission and fix it by means of clamp; refer
200.01).
to work card 200.01
5. Block the oil pipe to the rocker arm lubrication.
6. Block the starting air pipe of the cylinder that has been put out of
operation.

1 O-ring seal
2 Crankpin
3 Oil bore
4 Castle nut M8
5 Split pin

Figure 1. Blocking the oil bore in the crankpin (figure showing L 32/40)

6629 020.02--01 E 07.97 32/40 102/ 02

Gear wheel on the crankshaft
Removing and Installing 020.03

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

If damage should be found on the gear wheel on the crankshaft, the gear
rim is to be replaced or renewed.
The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Torque wrench 008.017 Standard
2 Shackle A0.6 002.452 Standard
1 Adapter 12.5x20 001.927 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Screw driver insert 17x12.5 001.859 Standard
1 Socket wrench insert 30x12.5 001.759 Standard
1 Ratchet 001.521 Standard
2 Eye bolt M12 000.142 Standard
2 Lifting tackle with rope -- Inventory
4 Threaded rod M22/22 -- Inventory
2 Wood (for placing underneath) -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.32 100.01

Technical data

Term Information
Crankshaft gear wheel 66 kg

6629 020.03--01 E 10.97 L 32/40 101/ 05

Preliminary remarks

The maintenance schedule also specifies visual inspection of the gear

wheels of the camshaft drive.
In case of marine engines it is recommended to have overhaul work on the
camshaft drive done in a service base (ship’s safety/intricacy of the job).

Operating sequence 1 -- Disassemble the crankshaft gear wheel

Starting condition Covering at the coupling end and crankshaft outboard bearing dismantled.
Markings on the gear wheels coincide (see Figure 4).

Steps 1. Loosen and screw out the hexagon head bolts (27).
2. Screw four threaded rods (29) through crankshaft gear wheel (23)
into crankshaft (22).
3. Pull the crankshaft gear wheel forward until it is out of the crankcase.
Support the crankshaft gear wheel on a wooden block.

21 Flywheel 26 Cylindrical pin 29 Threaded rod

22 Crankshaft 27 Hexagon head bolt 30 Wood block
23 Crankshaft gear wheel 28 Rope

Figure 1. Position of crankshaft gear wheel (left)/crankshaft gear wheel pulled forward out of the crankcase (right)
4. Screw two ring bolts (000.142) into upper part of gear wheel (24).
5. Attach ropes (28) to ring bolts by means of shackle (002.452) and
suspend from lifting tackle.
6. Loosen and screw out the hexagon socket bolts (32).
7. Screw out the two upper threaded rods.

6629 020.03--01 E 10.97 L 32/40 102/ 05

 22 Crankshaft 28 Rope 31 Cylindrical pin
24 Gear wheel upper part 29 Threaded rod 32 Hexagon socket bolt
25 Gear wheel lower part 30 Wood block

Figure 2. Suspending the gear wheel upper part and lifting the gear wheel lower part
8. Lift the upper part of gear wheel, remove over the crankshaft and put
on appropriate support.
Important! Do not put down gear wheel upper part on cylindrical
pins (31).
9. Separate shackle from ring bolts and remove it from ropes.
10. Sling ropes around lower part of gear wheel (25) and suspend from
lifting tackle.
11. Screw out the lower threaded rods.
12. Lift the gear wheel lower part, replace the wooden block by wooden
pad, lower the gear wheel lower part onto this pad, and pull it out
underneath the crankshaft.
13. Remove the ropes, put the gear wheel lower part onto appropriate
support.
▲ Attention! Only turn the running gear when rocker arm casings
have been completely removed because otherwise the opened
valves may suffer damage by upward movement of the piston
(movement of crankshaft no longer synchronised with camshaft/s).

Operating sequence 2 -- Install the crankshaft gear wheel

Starting condition Damaged crankshaft gear wheel has been replaced by a new one. The
supporting and contacting faces on the crankshaft gear wheel, and the
joint faces between the gear wheel upper and lower parts have been
cleaned. Markings on the gear wheels coincide (see Figure 4).

Steps 1. Sling two ropes (28) around gear wheel lower part (25), suspend from
lifting tackle, push underneath the crankshaft (22) on a wooden
support, and lift. Push the wood block (30) underneath gear wheel
lower part to support it. Take off the ropes.
Tip! Prior to mounting the gear wheel lower part, note the position of
bores for the cylindrical pins (31).
2. Screw two threaded rods (29) through the gear wheel lower part into
the crankshaft.

6629 020.03--01 E 10.97 L 32/40 103/ 05

 3. Screw ring bolts (000.142) into gear wheel upper part (24), attach
ropes to ring bolts by means of shackle (002.452), and suspend from
lifting tackle.
4. Lift gear wheel upper part over the crankshaft and place onto the
gear wheel lower part, paying attention to the cylindrical pins/bores.

1-4 Marking the order of

tightening
23 Crankshaft gear wheel
31 Cylindrical pin
32 Hexagon socket bolt

KS Coupling end

Figure 3. Order of tightening the radial fixing bolts

23 Crankshaft gear wheel

33 Camshaft gear wheel
34 Spur wheel (idler gear)
35 Double spur wheel
(idler gear)

M Marking

Figure 4. Marking on the gear wheels

5. Apply MoS2 Lubricant onto threads and contact faces of hexagon
socket bolts (32), screw the bolts home and tighten to the specified
000.30); for order, refer to Figure 3.
torque (see work card 000.30
6. Screw the upper threaded rods through gear wheel upper part into
crankshaft.
7. Detach ropes from lifting tackle, detach shackle from ring bolts and
screw the ring bolts out of the gear wheel upper part.
8. Push the crankshaft gear wheel (23) into crankcase until it contacts
the crankshaft, taking due note of the shoulder on the crankshaft and
the position of the bores for the cylindrical pins (26).

6629 020.03--01 E 10.97 L 32/40 104/ 05

 ▲ Attention! Verify that the markings (M) of the gear wheels of the
camshaft drive coincide (refer to Figure 4).
9. Screw off and remove the threaded rods.
10. Apply MoS2 lubricant to the threads and contact faces of hexagon
head bots (27), screw the bolts home and tighten them to the
000.30); for order, refer to Figure 5.
specified torque (see work card 000.30
11. Mount the crankshaft outboard bearing and the covering at the free
071.01).
end (refer to work cards 021.04 and 071.01

5-20 Marking the order of

tightening
22 Crankshaft
23 Crankshaft gear wheel
27 Hexagon head bolt

Figure 5. Order of tightening the axial fixing bolts

6629 020.03--01 E 10.97 L 32/40 105/ 05

.
Coupling bolts
Checking 020.04

Purpose of jobs to be done

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

ensure operational reliability of bolted connections.

Brief description

Coupling bolts are to be checked at regular intervals for tight fit. Where
connections are found to have loosened, the cause is to be found.
The work includes:
checking bolted connections.

Tools/appliances required

Quant Denomination No. Availability

1 Tools, basic scope 000.002 Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.32

Preliminary remarks

The maintenance schedule also specifies that the coupling bolts are
checked for tight fit. Where connections are found to have loosened, the
cause is to be found (inadvertent tightening, overloading and the like).

Operating sequence 1 - Check the coupling bolts

Starting condition Coupling (1) at the coupling end dismounted.

Steps 1. Verify that the coupling bolts are properly tight and the torque is as
specified (see the flywheel arrangement drawing of the respective
system); retighten the hexagon nuts (7) if required.
Tip! When checking the coupling bolts and/or retightening them, hold
the hexagon nuts (9) in position using open-jaw wrench.
2. When mounting the coupling (1) make sure that MoS2 lubricant has
been applied to the threads and contact faces of hexagon head bolts
(10), that they are screwed in and tightened to the specified torque

6629 020.04--01 E 07.97 32/40 101/ 02

 (refer to the flywheel arrangement drawing of the respective system)
and that washers (11) have been placed between the hexagon head
bolts and the coupling.

1 Coupling
2 Flywheel
3 Hexagon socket bolt
4 Crankshaft
5 Covering
6 Oil pipe
7 Hexagon nut
8 Coupling bolt
9 Hexagon nut
10 Hexagon head bolt
11 Washer

Figure 1. Connection between crankshaft, flywheel and coupling

6629 020.04--01 E 07.97 32/40 102/ 02

Balance weight
Removing and installing 020.05

Purpose of jobs to be done

Ensure correct execution of work,

enable emergency operation.

Brief description

Removal of a balance weight does not belong to the usual maintenance

work. This will only be necessary in special cases, e.g. if the engine has
to be operated under emergency conditions with the running gear
removed.
The work/steps extend to:
removal of components,
installation of components.

Safety requirements

- Engine shut--down
- Engine secured against starting

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 2
1 Assistant 2

Tools/appliances required

Quant Denomination No. Availability

2 Wire rope 030.255 Optional
2 Thrust pad 030.243 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
2 Hydraulic tensioning tool 009.097 Standard
4 High--pressure hose 009.306 Standard
1 Measuring device 009.121 Standard
1 Bolt extractor 009.089 Optional
1 Ratchet 008.023 Standard
1 Torque wrench 008.017 Standard
1 Ratchet hoist 002.552 Optional
2 Shackle A0.6 002.452 Standard

6629 020.05--01 E 06.98 L 32/40 101/ 05

 Quant Denomination No. Availability
1 Tommy bar 10 000.263 Standard
2 Eye bolt M12 000.142 Standard
1 Socket wrench (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 009.03 009.06

Technical details

Term Information
Balance weight 87 kg

1 Balance weight 4 Nut

2 Stud 7 Crank web
3 Crankcase 8 Tap hole

Figure 1. Opened crankcase

6629 020.05--01 E 06.98 L 32/40 102/ 05

Operating sequence 1 -- Removal of the blance weight

Starting condition The crankcase is open, the crankshaft has been turned in such a way that
the balance weight points towards the crankcase opening.

Steps 1. Clean the thread of the stud (2).

2. Mount the hydraulic tensioning tools (009.097) on both studs, paying
attention to the centring (refer to Figure 2).
▲ Attention! Prior to mounting the hydraulic tensioning tools,
ensure that the pistons have been pressed in completely. Once the
tensioning tools have been attached, the crankshaft must not be
turned any more.

1 Balance weight 3 Crankcase

2 Stud 4 Nut

Figure 2. Attachment of the tensioning tools

3. Turn the tensioning tools back by 250ƒ .
4. Connect the high--pressure hoses (009.306) to the tensioning tools
and high--pressure pump (009.338) and/or hydraulic hand pump
(009.320).
5. Switch on the high--pressure pump and/or the hydraulic hand pump
009.03) and close the gap between the thrust pad
(see work card 009.03
(030.243) and the balance weight (1) which has been produced by
turning back.
6. Pump up the tensioning tools until the nuts (4) can be loosened.
Note down the loosening pressure and compare with the specified
tensioning pressure.
▲ Attention! The pressure exerted during this process may be max.
7% below resp. 5% above the specified tensioning pressure (see
000.33).
work cards 000.30 and 000.33
7. Turn the nuts back.
8. Release the pressure and remove the hydraulic tensioning tools.
Important! Do not screw the nuts (4) off.
9. Turn the running gear to TDC and screw two eye bolts (000.142)
laterally into the tap holes (8) on the balance weight (refer to
Figures 1 and 4).

6629 020.05--01 E 06.98 L 32/40 103/ 05

 1 Balance weight
2 Stud

Figure 3. Pulling out and inserting the studs on the balance weight
10. Attach the balance weight to the ratchet hoist (030.255) and lifting
tackle by means of ropes and tighten the ropes.
11. Screw off one nut (4) and loosen the stud (2) using the bolt extractor
(009.089) and screw it out (refer to Figure 3).
Remove the second nut and stud the same way.
12. Lower the balance weight evenly until parallel pin (6) and clamping
sleeve (5) become free.
13. Carefully pull the balance weight out of the crankcase by alternately
slackening and tightening the ratchet hoist and/or the lifting tackle
(refer to Figure 4).
Important! Note that the clamping sleeve (5) and the parallel pin (6)
have been inserted in the balance weight and do not remain in the crank
web (7).

1 Balance weight 3 Crankcase 5 Clamping sleeve

2 Stud 4 Nut 6 Parallel pin

Figure 4. Removal and installation of the balance weight

6629 020.05--01 E 06.98 L 32/40 104/ 05

Operating sequence 2 -- Installation of the balance weight

For the installation of the balance weight, proceed in the reverse order
followed for removal, paying attention to the following points:
1. Prior to installation, note the position of the clamping sleeve (5).
2. Apply MoS2 lubricant to the threads of the studs (2) and screw them
000.30).
in to the specified screw--in torque (see work card 000.30
3. Screw on the nuts (4) and tighten them by means of the tommy bar
(000.263).
4. Check that the gap at the joint between the crank web (7) and the
balance weight (1) is of the same size on both sides.
5. Attach the measuring device (009.121) to the tensioning tool (see
009.06).
work card 009.06
6. Mount the tensioning tools to the two balance weight bolts, paying
attention to the centring.
7. Connect the high--pressure hoses (009.306) to the tensioning tools
and high--pressure pump (009.338) and/or to the hydraulic hand
pump (009.320).
8. Switch on the high--pressure pump and/or the hydraulic hand pump
009.03) and tension the balance weight bolts applying
(see work card 009.03
a pressure of 50 bar, set the dial gauge to “Zero”.
9. Tension the balance weight bolts applying the specified final pressure
000.30) and tighten both nuts hand--tight Release the
(see work card 000.30
pressure.
10. Tension the balance weight bolts again applying a pressure of 50 bar.
Read the bolt elongation DI on the dial gauge and compare it with the
000.30).
specified value (see work card 000.30
Important! Tighten the balance weight bolts to the specified
tensioning pressure, not to bolt elongation DI . The indication of the
elongation only serves as a means of verification. In case of more
significant deviations, repeat the tensioning process and check the
measuring devices resp. the pressure gauge .
11. Release the pressure and dismantle the tensioning tools. Remove
the eye bolts from the balance weight.

6629 020.05--01 E 06.98 L 32/40 105/ 05

.
Main bearing/
Thrust bearing/Flange bearing

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

6682 021--02 E 04.98 101/ 01

.
Main bearing cap
with lower bearing shell
Lowering and checking 021.01

Purpose of jobs to be done

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

ensure operational reliability of bearings.

Brief description

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

loaded bearing shell is checked. From wear condition and appearance of
the bearing shell running surface, conclusions can be drawn on the load
conditions, the lube oil care etc.
The work/steps include:
dismantling the cross tierods,
lowering the bearing cap,
checking the bearing shell and
restoring the initial condition.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 6
1 Assistant 6

Tools/appliances required

Qty Denomination No. Availability

1 Lifting/lowering device 021.235 Standard
2 Support 021.238 Standard
2 Guide tube 021.237 Standard
1 Cross tie 021.236 Standard
1 Guide tube 021.032 Standard
1 Scissor--type jack 009.085 Standard
1 Ratchet 008.023 Standard
1 Thickness gauges 0.05--1 000.454 Standard
1 Tommy bar 10 000.263 Standard
4 Tommy bar 8 000.262 Standard
1 Open--jaw and ring wrench (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory

6629 021.01--01 E 11.98 L 32/40 101/ 04

Related work cards

Work card Work card Work card

000.10 000.11 012.02

Technical details

Term Information
Main bearing cap 118 kg

Operating sequence 1 -- Check the lower main bearing shell

Starting condition Main bearing bolts and cross tierods unloaded. Running gear turned to a
position permitting easy access to the main bearing cap. Foot board
(special tool) placed in oil sump and/or oil sump cleaned using appropriate
means. Temperature sensor (if fitted) removed.

5 Crankcase
9 Cross tierod
10 Nut
11 Ring
12 O-ring seal

Figure 1. Illustration of the cross tierod

Steps 1. Screw nuts (10) off the cross tierods (9), take off rings (11) and O-
ring seals (12).
2. Screw out and remove both cross tierods.
3. Screw guide tubes (021.237) into main bearing bolts (16), handtight.
4. Put the cross tie (021.236) into oil sump (17), push it under the guide
tubes, lift and fix it by inserting one tommy bar (000.262) each into
the lower bore (4) of the guide tubes.
5. Place two supports (021.238) onto the cross tie and fasten them in
the crankcase by turning the hexagon nuts (18). The cross tie is
thereby forced against the tommy bars.
6. Slide the scissor--type jack (009.085) into the groove on the cross tie
and insert the catch (20) in the cross tie. Turn the scissor--type jack
up until it contacts the main bearing cap (7) and fasten it by means of
two hexagon bolts (15).
7. Screw off the nuts (14) and lower onto cross tie.
8. Insert two further tommy bars into bores (2) of the guide tubes. Using
the scissor-type jack, pull the main bearing cap down onto these
tommy bars.

6629 021.01--01 E 11.98 L 32/40 102/ 04

 Important! If the engine is at operating temperature, it may
become necessary to unload the cross tierods of the neighbouring main
bearings.

▲ Attention! Do not dismantle the main bearing shell for the check
to avoid that the matching condition is disturbed, if possible.
9. Carefully clean the running surface of the main bearing shell (8),
taking care not to damage it.
10. Check the condition of the running surface (see work card 000.11).
000.11
Important! Replace main bearing shells that have been damaged
or heavily scored by dirt particles. Insert a new main bearing shell in the
main bearing cap, taking care of bearing shell fixing (back of bearing shell
oil-dry). The new main bearing shells supplied are ready to be installed,
they must not be scraped or touched up in any other way. The bearing
points are numbered. If new main bearing shells are installed, this
marking is to be transferred to the new shells.
11. Thoroughly oil the running surface of the main bearing shell (8).
12. Lift the main bearing cap (7) by means of the scissor-type jack, taking
care that the cap is not tilted; if necessary, slightly loosen the
hexagon head bolts (15) to allow the main bearing cap to align.
13. Screw nuts (14) onto the main bearing bolts (16), hand-tight, down to
contact with the main bearing cap.
14. Remove the complete lifting/lowering device.
15. Apply MoS2 lubricant to the screwing-in thread of the cross tierods (9)
and screw into main bearing cap, hand-tight, down to contact.
16. Put the O-ring seals (12) and rings (11) over the cross tierods, screw
nuts (10) down to contact, hand-tight.
17. Load the main bearing bolts and cross tierods (refer to work card
012.02).
012.02

1-4 Marking the bores in the 9 Cross tierod 15 Hexagon head bolt
guide tube 10 Nut M12x45
5 Crankcase 11 Ring 16 Main bearing bolt
6 Crankshaft 12 O-ring seal 17 Oil sump
7 Main bearing cap 13 Ratchet 18 Hexagon nut M24x2
8 Lower main bearing shell 14 Nut 20 Catch

Figure 2. Main bearing with attached lifting/lowering device

▲ Attention! In case the cross tierods of neighbouring main

bearings have bee unloaded, first load the main bearing bolts and

6629 021.01--01 E 11.98 L 32/40 103/ 04

 cross tierods of the main bearing that has been checked, and then
the cross tierods of the neighbouring main bearings.
18. Check the main bearing clearance using thickness gauges (000.454)
(see Section 1), introducing the feeler gauges approx. 10 mm deep,
from the coupling end and free engine end.
000.10) and
19. Measure the crank web deflection (refer to work card 000.10
enter in engine operating record.
20. Take the foot board (if one was used) out of the oil sump.
21. Mount the temperature sensor (if applicable).
▲ Attention! For the running-in of new main bearing shells,
observe the relevant instructions in Section 3 of the engine
operating manual.

5 Crankcase
7 Main bearing cap
8 Lower main bearing
shell
14 Nut
16 Main bearing bolt
19 Fixing pin
20 Catch

Figure 3. Main bearing cap lowered for checking the main bearing shell

6629 021.01--01 E 11.98 L 32/40 104/ 04

Upper main bearing shell
Removing and installing/checking 021.02

Purpose of jobs to be done

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

ensure operational reliability of bearings.

Brief description

The upper main bearing shell is to be removed and checked if damage or

pronounced scoring by dirt particles was found on the lower main bearing
shell during checking.
The work includes:
checking the bearing shell.

Tools/appliances required

Quant Denomination No. Availability

1 Centring template 021.234 Standard
1 Turning stone 021.233 Standard
1 Turning stone 021.232 Standard
1 Eye bolt M6 000.023 Standard

Related work cards

Work card Work card Work card

000.11 021.01

Technical details

Term Information
Upper main bearing shell 2.5 kg

Operating sequence 1 -- Check the main bearing shell (removal/reinstallation)

Starting condition Main bearing cap lowered, lower main bearing shell removed.

Steps 1. Insert the turning stone (021.232) into the oil bore of the crankshaft
(6), turn the crankshaft somewhat if necessary.
▲ Attention! The turning stone must fully contact the crankshaft.

6629 021.02--01 E 10.97 L 32/40 101/ 03

 2. Carefully turn out the upper main bearing shell (20), be careful not to
damage it (see Figure 1).
▲ Attention! Pay attention to the position of the bearing shell
fixation (bent up lug). The crankshaft must be turned in such a way
that the fixation comes free. It must not be pulled into the bearing
casing.
3. Pull out the turning stone, using the eye bolt (000.023).
4. Carefully clean the running surface of the main bearing shell, taking
care not to damage it.
5. Check the condition of the running surface (refer to work card
000.11).
000.11
Steps (Part 2 -- Installation) Important! Replace damaged or worn main bearing shells.
New main bearing shells are delivered ready for installation and must not
be rescraped or machined in any other way. The bearing points are
numbered (refer to operating manual, Section 5). In case new main
bearing shells are installed, these markings are to be transferred
accordingly.
6. Place the centring template (021.234) against the crankcase (5). The
centring bolt of the centring template should for this purpose be
inserted into the bore provided for fixing the main bearing cap
(centring template is held by magnetic force).
7. Thoroughly lubricate the running surface of the main bearing shell
(20) with oil (back of the main bearing shell to remain dry).

5 Crankcase
6 Crankshaft
16 Main bearing bolt
20 Main bearing shell
21 O--ring seal

Figure 1. Removing the upper main bearing shell

8. Place the main bearing shell against the centring template and push it
in by hand as far as possible.
Important! Pay attention to the position of the bearing shell fixation
prior to pushing in.
9. Turn the crankshaft (6) until the turning stone (021.233) can be
inserted into the oil bore of the crankshaft through one of the bores in
the main bearing shell.
▲ Attention! To avoid deformation of the thin main bearing shell in
the process of turning it in, place the turning stone as closely as
possible to the joint of the main bearing.

6629 021.02--01 E 10.97 L 32/40 102/ 03

 10. Turn in the main bearing shell in several steps (corresponding to pitch
of bore holes). This is done by pulling out the turning stone after the
first turning step, turning the crankshaft back by one pitch of bore
holes and reinserting the turning stone. Repeat this step up to the last
bore.
11. Turn the crankshaft back until the lube oil bore comes free.
12. Insert the turning stone (021.232) directly into the oil bore of the
crankshaft and turn the main bearing shell in completely.
Important! Make sure that the joint faces of bearing shells are in
uniform end position.
13. Remove the centring template and pull out the turning stone by
means of the eye bolt (000.023).
14. Mount the main bearing cap with the lower main bearing shell (refer
to work card 021.01).
021.01
▲ Attention! For the running- in of new main bearing shells, refer
to the engine operating manual, Section 3.4.

5 Crankcase
6 Crankshaft
16 Main bearing bolt
20 Main bearing shell

Figure 2. Installing the upper main bearing shell

6629 021.02--01 E 10.97 L 32/40 103/ 03

.
Main thrust bearing
Measuring end play/
checking locating bearing rings 021.03

Purpose of jobs to be done

Carry out work in time according to maintenance plan,

measure components,
assess wear pattern/condition.

Brief description

The end play as well as the locating bearing rings are to be checked at
regular intervals.
The work /steps include:
Measure components and
assess wear pattern/condition.

Tools/appliances required

Quant Denomination No. Availability

1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Extension piece 12.5x125 001.911 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Crow bar 001.391 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Magnetic post -- Inventory
1 Dial gauge -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.11

Technical details

Term Information
Locating bearing ring 3.0 kg

6629 021.03--01 E 08.97 32/40 101/ 03

Operating sequence 1 - Measure the crankshaft axial play

Steps 1. Use crow bar (001.391) to shift the crankshaft in one coaxial direction
up to the stop.
▲ Attention! Using a hydraulic press with support between
crankcase side and balance weight is strictly prohibited.
2. Mount a dial gauge on the magnetic post, attach the magnetic post
and place the dial gauge on the coupling flange or any other easily
accessible point. Set the dial gauge to “ZERO”.
3. Shift the crankshaft axially in the opposite direction up to the stop.
During this process, the distance is measured by means of the dial
gauge.
4. Note down the end play and compare it with the admissible play
(refer to engine operating manual, Section 2.5). Enter this end play in
the engine operating records.
Important! If the admissible play is exceeded, the crankshaft
locating bearing rings have to be removed and checked (see operating
sequence 2).
5. Remove the magnetic post and the dial gauge.

Operating sequence 2 - Check the crankshaft locating bearing rings

Starting condition Crankcase door removed.

Steps 1. Use appropriate means to fix the crankshaft (4) in axial position such
that the crankshaft locating bearing rings (2) are accessible.
2. Dismantle one stop (6), refer to Figure 1.

2 Crankshaft locating
bearing ring
5 Hexagon head bolt
6 Stop
A Control dimension
= 1.0 mm
(Distance between
locating bearing ring
and stop
Figure 1. Securing the crankshaft locating bearing ring

▲ Attention! Take care that crankshaft locating bearing rings

cannot drop out.
3. Turn out both locating bearing rings in the direction of rotation.
▲ Attention! Do not turn the crankshaft.
4. Carefully clean the crankshaft locating bearing rings, taking care not
to damage them.
5. Check the condition of the running surfaces (refer to work card
000.11).
000.11
6. Slightly oil the crankshaft locating bearing rings (2).
7. Apply MoS2 lubricant to the threads and contact surfaces of
hexagonal head bolts (5).
8. Tunr in the crankshaft locating bearing rings, mount the stop (6) and
screw down the hexagonal head bolts hand-tight.
Important! Watch the control dimension A on both sides.
See Figure 1.

6629 021.03--01 E 08.97 32/40 102/ 03

 9. Tighten the hexagon head bolts to the specified torque (refer to work
000.30).
card 000.30
10. Remove the axial fixation of the crankshaft (refer to point 1).
11. Measure the crankshaft axial play (refer to operating sequence 1)
and enter in the engine operating records.
12. Mount the crankcase door.

1 Bearing casing 3 Crankcase 5 Hexagon head bolt

2 Crankshaft locating bearing 4 Crankshaft 6 Stop
ring

Figure 2. Axial fixation of the crankshaft (locating bearing)

6629 021.03--01 E 08.97 32/40 103/ 03

.
Main flange bearing/Bearing shells
Removing, attaching, checking 021.04

Purpose of jobs to be done

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

ensure operational reliability of bearings.

Brief description

The main bearing shells on the main outer bearing are to be checked at
regular intervals.
The work/steps include:
Checking bearing shells,
removing components,
attaching components.

Tools/appliances required

Quant Denomination No. Availability

1 Guide tube (V--type engine) 021.258 Standard
1 Guide tube 021.032 Standard
1 Torque wrench 008.017 Standard
1 Adapter 20x12.5 001.923 Standard
1 Extension piece 12.5x125 001.911 Standard
1 Cross handle 001.891 Standard
2 Socket wrench insert 36x20 001.771 Standard
1 Thickness gauges 0.05--1 000.454 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Hexagon nut M10 -- Inventory
1 Wood (for placing underneath) -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.10 000.11 000.30

6629 021.04--01 E 07.97 32/40 101/ 05

Technical details

Term Information
Flange bearing, compl. 165 kg
Flange bearing, upper part 77 kg
Flange bearing, lower part 76.5 kg
Lower main bearing shell 3.0 kg
Upper main bearing shell 2.5 kg

Operating sequence 1 - Check the main bearing shells

Starting condition Crankcase door and covering at coupling end removed, flywheel and
coupling propped, temperature sensors (if fitted) removed.

29 Coupling bolt 36 Hexagon head bolt 41 Cylindrical pin

30 Crankshaft 37 Rope 42 Covering
31 Hexagon head bolt 38 Hexagon head bolt 43 Taper pin
32 Flange bearing 39 Hexagon nut 44 Lower main bearing shell
35 Upper main bearing shell 40 Wooden block

Figure 1. Crankshaft outboard bearing

Steps (part 1) - 1. Extract four taper pins (43).
Checking the bearing shells 2. Screw out hexagon head bolts (31).
3. Clean and oil the crankshaft surface.

6629 021.04--01 E 07.97 32/40 102/ 05

 4. Pull the flange bearing (32) forward and support it on wooden block
(40); see Figure 1.
5. Loosen the hexagon nuts (39) and screw them off, dismantle the
hexagon head bolts (36 and 38).
6. Attach the flange bearing upper part (33) to lifting tackle by means of
rope (37), lift it, remove it over the crankshaft (30) and place it on a
wooden pad. Remove the rope.
▲ Attention! When dismounting the flange bearing upper part take
care that the main bearing shell does not drop out and suffer
damage.
7. Attach the flange bearing lower part (34) to lifting tackle by means of
ropes, tension the ropes, remove the wooden pad and lower the
flange bearing lower part.

1 - 4 Marking the order of

tightening
32 Flange bearing
36 Hexagon head bolt
38 Hexagon head bolt
39 Hexagon nut

KS Coupling end

Figure 2. Order of tightening the radial fixing bolts

8. Carefully clean the running surface of the bearing shells (35 and 44),
taking care not to damage them.
9. Check the condition of the running surfaces (refer to work card
000.11).
000.11
▲ Attention! Do not remove main bearing shells for the check,
because this would necessitate new matching.

Replacing bearing shells Damaged or worn out main bearing shells to be taken out of flange
bearing upper and/or lower part, and insert new ones (back side of main
bearing shell to be dry), taking care of bearing shell fixation.

Important! New main bearing shells come supplied ready for

installation, scraping or any other touching up is not permitted. The
bearing points are numbered (refer to engine operating instructions,
Section 5). Where new main bearing shells are installed, the marking is to
be transferred to these.
Steps (part 2) - 10. Clean and oil the journals of crankshaft (30).
Assembling the main 11. Thoroughly lubricate the running surface of the lower main bearing
enter bearing shell (44) with oil.
12. Lift the flange bearing lower part (34) and slide the wooden pad (40)
under neath the flange bearing lower part to prop it. Remove the
ropes.
13. Suspend flange bearing upper part (33) from lifting tackle by means
of rope (37).
14. Thoroughly lubricate the upper main bearing shell (35) with oil.

6629 021.04--01 E 07.97 32/40 103/ 05

 15. Lift the flange bearing upper part, move it over the crankshaft and
place it on the flange bearing lower part, taking care of cylindrical pins
(41).
▲ Attention! When mounting the flange bearing upper part be
careful that the main bearing shell does not drop out and suffer
damage.
16. Introduce hexagon head bolts (36 and 38) in bore holes.
17. Apply MoS2 lubricant to the threads and contact surfaces of hexagon
nuts (39), screw the nuts onto the hexagon head bolts hand-tight, and
000.30); for order of
load to the specified torque (see work card 000.30
tightening, see Figure 2.
18. Push the flange bearing (32) in the direction of the crankcase until it
contacts the covering (42), taking note of the bore holes for taper
pins (43).
19. Apply MoS2 lubricant to the threads and contact surfaces of hexagon
head bolts (31), and screw the bolts down gently.
20. Press four taper pins (43) into bore holes.
21. Tighten hexagon head bolts to specified torque (refer to work card
000.30); for order of tightening, see Figure 3.
000.30
22. Check the crankshaft bearing clearance with thickness gauges
(000.454) - refer to engine operating manual, Section 2.5 - Introduce
thickness gauges approx. 10 mm deep from the coupling end and
free end.
000.10) and enter
23. Measure the crank web deflection (see work card 000.10
in the engine operating logs.
24. Mount the temperature sensors (if fitted).
25. Mount the crankcase door and covering at the coupling end.
▲ Attention! For running in of new main bearing shells, see
Section 3.

5-28 Marking the order of

tightening

31 Hexagon head bolt

33 Flange bearing upper
part
34 Flange bearing lower
part
43 Taper pin

Figure 3. Order of tightening the axial fixing bolts

Operating sequence 2 - Dismantle the flange bearing

Starting condition Crankcase door and covering at the coupling end removed, flywheel and
coupling propped, temperature sensors (if fitted) removed.

Steps 1. Disassemble the flange bearing (32) - refer to operating sequence 1,

points 1 to 6.

6629 021.04--01 E 07.97 32/40 104/ 05

 2. Suspend flange bearing lower part (34) from lifting tackle by means of
ropes (37), tension the ropes, replace the wooden block by a flat
wooden pad, and lower the flange bearing lower part onto this pad.
3. Take the lower main bearing shell (44) out of the flange bearing lower
part.
4. Pull the flange bearing lower part out underneath the crankshaft (30),
and put it down on a second pad.

Operating sequence 3 - Install the flange bearing

Starting condition Contact surface on the covering and flange bearing, and joint between
flange bearing upper and lower part cleaned.

Steps 1. Put the flange bearing lower part (34) onto wooden pad and slide it
underneath the crankshaft (30).
2. Place the lower main bearing shell (44) in flange bearing lower part
(back of the bearing shell to be dry), taking note of the bearing shell
fixation.
3. Mount the flange bearing (32) - refer to operating sequence 1, points
10 to 25.

6629 021.04--01 E 07.97 32/40 105/ 05

.
Main bearing cap
Removing and installing 021.05

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Main bearing caps are not to be removed during usual maintenance work.
However, where overheating is suspected or in case of serious damage of
the bearing cap, removal may become necessary.
The work/steps extend to:
removal of components,
installation of components.

Safety requirements

- Engine secured against starting

- Driving shaft secured against turning

Tools/appliances required

Quant Denomination No. Availability

1 Lifting/lowering device 021.235 Standard
2 Guide tube 021.237 Standard
4 Support 021.239 Optional
2 Support 021.240 Optional
1 Protection sheet 021.244 Optional
1 Butt strap 021.241 Optional
2 Wire rope 021.242 Optional
1 Support 021.243 Optional
4 Shackle A0.6 002.452 Standard
1 Shackle A1.0 002.453 Standard
1 Suspension link 002.481 Optional
1 Ratchet hoist 002.552 Optional
1 Tommy bar 10 000.263 Standard
2 Tommy bar 8 000.262 Standard
1 Thickness gauges 0.05--1 000.454 Standard
2 Eye bolt M16 000.143 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory

6629 021.05--01 E 02.98 L 32/40 101/ 04

Related work cards

Work card Work card Work card

000.11 000.30 021.01

Technical details

Term Information
Main bearing cap 118 kg

Operating sequence 1 -- Lowering and removing the main bearing cap

1 Bore 16 Main bearing bolt 21 Crank pin

5 Crankcase 17 Oil sump 23 Hexagon head bolt
7 Main bearing cap 20 Balance weight M12x30
8 Lower main bearing shell

Figure 1. Lowering the main bearing cap

Starting condition Tension of main bearing bolts and cross tierods released. Running gear
turned in such a way that the balance weight (20) is inclined upwards by

6629 021.05--01 E 02.98 L 32/40 102/ 04

 60ƒ (Figure 1). Foot board (special tool) inserted in oil sump or oil sump
cleaned by appropriate means, to ensure safe footing.
Temperature sensor (if available) removed. Main bearing cap lowered
onto the bores (1) of the guide tubes (021.258). Lifting/lowering device
removed again (see work card 021.01).
021.01

Steps 1. Screw support (021.243) onto main bearing cap by means of

hexagon head bolts (23). Screw four supports (021.239) onto the
crankcase (5). Using one shackle (002.452) each, attach wire ropes
(021.242) to supports (refer to Figure 1/I).
2. Run wire ropes over rope pulleys of support and holders and, using
one shackle (002.452) each, attach them to the butt strap (021.241) -
refer to Figure 2.
3. Attach suspension link (002.481) to the butt strap by means of
shackle (002.453) and suspend ratchet hoist (002.552). Then
suspend ratchet hoist from appropriate suspension point in the
engine room (e.g. craneway).
4. Slightly lift the main bearing cap by means of the ratchet hoist and
pull the tommy bars out of the bores (1) of the guide tubes.
5. Using the ratchet hoist, lower the main bearing cap onto the oil sump
(17).
6. Insert the tommy bars into the bores (1) of the guide tubes and screw
them off the main bearing bolts (16).
Important! Do not pull out the tommy bars. The guide tubes
remain in the main bearing cap.
7. Remove the wire ropes and supports on the balance weight side
(refer to Figure 3).

5 Crankcase
17 Oil sump
24 Hexagon nut M12

Figure 2. Lowering and shifting the main bearing

8. Shift the main bearing cap sidewards up to the centre of the next
crankcase opening (refer to Figure 2). Pull out the guide tubes by
means of tommy bars. Take off the main bearing shell.

6629 021.05--01 E 02.98 L 32/40 103/ 04

 9. Turn the running gear in such a way that the balance weight is
inclined downwards by 45ƒ (refer to Figure 3).
10. Screw the protection sheet (021.244) onto the big-end bearing cover
of the neighbouring connecting rod (refer to Figure 3).
Tip! The protection sheet serves as rope guide and to protect the
big-end bearing bolts from damage.
11. Screw one eye bolt (000.143) each into the main bearing cap and
attach wire ropes by means of shackle (002.452).
12. Using the ratchet hoist, suspend wire rope (X) from appropriate
suspension point in the engine room. Suspend wire rope (Y) from
crane on the balance weight side.
13. Slowly pull wire rope (Y) upwards by means of the crane, paying
attention that wire rope (X) is guided by the protection sheet
(021.244).
14. By simultaneously releasing the wire rope (X) and tightening the wire
rope (Y), slowly pull main bearing cap out of the crankcase opening.
▲ Attention! Do not damage any other components while pulling
the main bearing cap out.

5 Crankcase
7 Main bearing cap
8 Lower main bearing
shell
20 Balance weight
22 Hexagon head bolt
M12x20

X Wire rope
Y Wire rope

Figure 3. Pulling out the main bearing cap

Operating sequence 2 -- Installing the main bearing cap

For installation, proceed in the reverse order followed for removal. The
last steps for lifting and tightening are to be carried out according to work
021.01. After completion of work, verify that all auxiliary means have
card 021.01
been removed and that no tool has been left in the oil sump.

6629 021.05--01 E 02.98 L 32/40 104/ 04

Torsional vibration damper

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

6682 027--02 E 04.98 101/ 01

.
Torsional vibration damper
of the crankshaft
Removing and refitting 027.03

Purpose of jobs to be done

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

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

The torsional vibration damper on the crankshaft is to be replaced in

accordance with the intervals specified in the maintenance schedule.
The work/steps include:
dismounting components,
mounting components.

Safety requirements

- Engine shut down

- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 027.032 Optional
1 Screw--on plate 027.032--1 Optional
1 Suspension plate 027.032--7 Optional
2 Pipe 027.032--13 Optional
2 Attachment swivel 027.032--19 Optional
1 Torque wrench 008.017 Standard
1 Power amplifier 008.030 Standard
1 Shackle A0.6 002.452 Standard
2 Shackle A1.0 002.453 Standard
1 Shackle A2.0 002.455 Standard
1 Lifting eye bolt M10 000.141 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Screw driver insert 17x12.5 001.859 Standard
1 Socket wrench insert 46x25 001.785 Standard
1 Ratchet 001.521 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Socket wrench insert (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

6629 027.03--02 E 09.02 L 32/40 101/ 06

Related work cards

Work card Work card Work card

000.30

Technical details

Term Information
Cover 28 kg
Torsional vibration damper 1331 -- 1490 kg
Gearwheel 71 kg

Preliminary remarks

Every torsional vibration damper is a special component designed to suit

the respective plant. Improper installation may result in severe damage to
the plant and/or the torsional vibration damper.

1 Crankshaft 4 Stud 7 Hexagon socket bolt

2 Cylinder crankcase 5 Gearwheel 8 Cover
3 Torsional vibration damper 6 Nut 9 Hexagon socket bolt

Figure 1. Torsional vibration damper

6629 027.03--02 E 09.02 L 32/40 102/ 06

Operating sequence 1 -- Removal of the gearwheel

1 Crankshaft 4 Stud 9 Hexagon socket bolt

2 Cylinder crankcase 5 Gearwheel 13 Hexagon socket bolt
3 Torsional vibration damper 6 Nut 15 Rope

Figure 2. Removal of the gearwheel

Starting condition The crankcase cover and the covering on the free engine end have been
removed.

Steps 1. Screw the lifting eye bolt (000.141) into the cover (8). Attach the
rope to the lifting eye bolt by means of the shackle (002.452), and
suspend the rope from the lifting tackle.
2. Unscrew the hexagon bolts (7), and remove the cover. Place the
cover on an appropriate support (refer to Figure 1 ).
3. Turn the crankshaft (1) so that one of the two tap holes on the face of
the gearwheel (5) is up.
4. Unscrew the nuts (6) from the studs (4).
5. Screw the lifting eye bolt (000.143) into the tap hole, attach the rope
to the lifting eye bolt by means of the shackle (002.453), and suspend
the rope from the lifting tackle. Slightly tighten the rope.
6. Unscrew the hexagon socket bolts (13), and remove the gearwheel.
Place the gearwheel on an appropriate support (refer to Figure 2 ).

6629 027.03--02 E 09.02 L 32/40 103/ 06

Operating sequence 2 -- Removal of the torsional vibration damper

1 Crankshaft 10 Prop 14 Hexagon bolt M24x50

2 Cylinder crankcase 11 Hexagon bolt M16x100 15 Rope
3 Torsional vibration damper 12 Hexagon bolt M16x100
4 Stud
9 Hexagon socket bolt

Figure 3. Fitting/unfitting tool mounted in place

Steps 1. Turn the crankshaft (1) to a position in which the marking

“Kurbel 1/Crank 1” on the torsional vibration damper (3) is up.
2. Mount the screw-on plate (027.032-1) on the crankshaft by means of
the hexagon bolts (14) - refer to Figures 3 and 4 .
3. Slip the pipes (027.032-13) onto the pins of the screw-on plate, and
secure them in place using the hexagon bolts (12).
4. Slip the suspension plate (027.032-7) with its pins onto the pipe ends,
and secure it in place by means of the hexagon bolts (11).
5. Place appropriate props (10) under the suspension plate.
6. Screw the hexagon bolts (12) down into the pins of the screw-on
plate until the pipes contact the torsional vibration damper.
7. Unscrew the hexagon socket bolts (9).
8. Slightly oil the pipes. Pull the torsional vibration damper to the front
(refer to Figure 3 ) and, while doing so, pay attention to the
centrings in order to avoid that they are damaged.

6629 027.03--02 E 09.02 L 32/40 104/ 06

 9. Screw the lifting attachment swivel (027.032-19) into the torsional
vibration damper. Attach the ropes to the lifting attachment swivel by
means of the shackle (002.453), and suspend the ropes from the
lifting tackle.
10. Slightly lift the torsional vibration damper. Remove the props (10),
the suspension plate (027.032-7) und the pipes (027.032-13).
11. Using the lifting tackle, move the torsional vibration damper outwards
and place it on an appropriate support.

12 Sechskantschraube
M16x100
14 Sechskantschraube
M24x50

Figure 4. Screw-on and suspension plate

Operating sequence 3 -- Transport of the torsional vibration damper

Transport of the torsional vibration damper is only permissible in horizontal

position. In this connection, only the auxiliary means provided for this
purpose, i.e. the lifting attachment swivel (027.032-19), are to be used.
Both for removal and transport, the torsional vibration damper is at least to
be attached at two points (refer to Figure 5 ).

3 Drehschwingungs-
dämpfer
15 Seil

sa max. 60ƒ

Figure 5. Lifting and transport of the torsional vibration damper

6629 027.03--02 E 09.02 L 32/40 105/ 06

Operating sequence 4 -- Fitting the torsional vibration damper and the gearwheel

For fitting the torsional vibration damper and the gearwheel, proceed in the
reverse order followed for removal, taking note of the following:
1. Prior to fitting the new torsional vibration damper, completely remove
all the anti-corrosion agent.
2. During the fitting process, pay attention to the centricity as well as to
the marking provided on the components crankshaft - torsional
vibration damper, and torsional vibration damper - gearwheel, taking
care not to damage the centricity.
3. Apply MoS2 lubricant to the threads and contact faces of the studs
(4) and nuts (6), screw the nuts on, hand-tight, and tighten them
000.30).
crosswise to the specified torque (see work card 000.30
4. Remove the complete fitting/unfitting tool.
5. Prior to taking the engine into operation, a sufficient amount of
hydraulic oil is to be supplied to the torsional vibration damper by the
prelubricating pump, until oil emerges from the oil circulation bores of
the side discs.

6629 027.03--02 E 09.02 L 32/40 106/ 06

Connecting rod/Big-- end bearing

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

6682 030--02 E 04.98 101/ 01

.
Con-- rod shank bolts
Checking, untightening and tightening 030.01

Purpose of jobs to be done

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

ensure operational reliability of bolted connections.

Brief description

Conrod shank bolts are to be checked at regular intervals by means of

hydraulic tensioning tools.
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Safety requirements

- Driving shaft secured against turning

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

2 Thrust pad 030.258 Standard
2 Nut 030.205 Standard
2 Hydraulic tensioning tool 009.346 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
2 High--pressure hose 009.306 Standard
2 Measuring device 009.051 Standard
2 Angle piece 009.028 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar, 6 mm 000.261 Standard

Related work cards

Work card Work card Work card

000.30 000.32 009.03

6629 030.01--01 E 01.01 32/40 101/ 04

Operating sequence 1 -- Check the conrod shank bolts

Starting condition Crankcase opened, piston/connection rod assembly of the respective

cylinder in BDC position.

Steps 1. Clean the threads of conrod shank bolts (8).

2. Mount hydraulic tensioning tools on conrod shank bolts (1 and 3) -
refer to Figure 1 .
▲ Attention! Once the hydraulic tensioning tools have been
mounted, the running gear must not be turned.
3. Turn the tensioning tools (009.346) back by 290ƒ .
4. Connect high-pressure hoses (009.306) to tensioning tools and
high-pressure pump (009.338) or hydraulic hand pump (001.320).
5. Switch on the high-pressure pump or the hydraulic hand pump(see
009.03) and close the gap between the thrust pad
work card 009.03
(030.258) and the tensioning tool resulting from the turning back.
6. Pressurise the tensioning cylinder by pumping until nuts (7) can be
cloosed.
Note down the force required for loosening and compare it with the
tensioning pressure.

▲ Attention! The pressure is allowed to be max. 7% below max. 5%

000.33).
above the tensioning pressure (see work cards 000.30 and 000.33

1 - 4 Order of tightening 5 Conrod shank 8 Conrod shank bolt

6 Big-end bearing 10 Balance weight

Figure 1. Working on the conrod shank bolts. On the right side of the figure - Placing of the tensioning tools/running gear
position. On the left side - Order of tightening (illustrtion shows L-type engine)
7. Adjust the specified tensioning pressure with the high-pressure pump
or by operating the hydraulic hand pump and retighten both the nuts.
8. Release the pressure and remove the hydraulic tensioning tools.
9. Repeat the procedure (points 2 to 8) in the same way as on conrod
shank bolts (2 and 4).

6629 030.01--01 E 01.01 32/40 102/ 04

Operating sequence 2 -- Untighten the conrod shank bolts

Steps 1. Clean the threads of the conrod shank bolts (8).

2. Untighten the conrod shank bolts (1 and 3) - see operating sequence
1, points 2 to 6.
3. Turn the nuts (7) back (for angular amount of turning back, see work
card 000.30).
000.30
4. Release the pressure and remove the hydraulic tensioning tools.
5. Repeat the procedure (points 2 to 8) in the same way as on conrod
shank bolts (2 and 4).

Operating sequence 3 -- Tighten the conrod shank bolts

Starting condition Running gear in BDC position, conrod shank resting on big-end bearing
034.01). The nuts are loosened.
(see work card 034.01

Steps 1. Screw the nuts (7) of conrod shank bolts hand-tight, using the tommy
bar (000.261).
2. Verify that the gap of the joint between the conrod shank (5) and the
big-end bearing (6) is less than 0.05 mm all around.
3. Mount the hydraulic tensioning tool on conrod shank bolts (1 and 2) -
see Figure 2 .
4. Connect high-pressure hoses (009.306) to tensioning tools (009.346)
and high-pressure pump (009.338).
5. Place measuring devices (009.051) to tensioning tools.
6. Switch on the high-pressure pump or the hydraulic hand pump (see
009.03) and load the conrod shank bolts (8) to a pressure
work card 009.03
of 50 bar. Set the dial gauges (9) to “Zero”.

5 Conrod shank
7 Nut
8 Conrod shank bolt
9 Dial gauge

Figure 2. Hydraulic tensioning tool and measuring device in place

7. Load the conrod shank bolts (8) to the specified pressure (refer to
000.30). Screw both the nuts (7) hand-tight.
work card 000.30
8. Release the pressure.

6629 030.01--01 E 01.01 32/40 103/ 04

 9. Load the conrod shank bolts (8) to 50 bar again. Read the elongation
aL on the dial gauges and compare with the specified value (see
work card 000.30).
000.30
▲ Attention! Tighten the conrod shank bolts to the specified
tensioning pressure, and not by elongation. The elongationonly
serves as a means of control. In case of excessive deviations, repeat
the tensioning procedure and check the measuring devices and/or
pressure gauges.
Extraordinary conditions may result in permanent elongation of the
conrod shank bolts. Conrod shank bolts as new have the dimension
of 253  0.1 mm and are allowed to sustain a permanent elongation
by 0.5 mm; this means that if the length of 253.6 mm (in unloaded
condition) is exceeded, the conrod shank bolt has to be replaced.
10. Release the pressure and remove the hydraulic tensioning tools.
11. Repeat the procedure (points 3 to 10) in the same way on conrod
shank bolts (2 and 4) - see Figure 1 and 2 .

6629 030.01--01 E 01.01 32/40 104/ 04

Big-- end bearing bolts
Checking, untightening and tightening 030.02

Purpose of jobs to be done

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

ensure operational reliability of bolted connections.

Brief description

Big--end bearing bolts are to be checked at regular intervals using

hydraulic tensioning tools.
The work/steps include:
Establishment and evaluation of loosening pressure and
tensioning the connection at nominal pressure.

Safety requirements

- Engine secured against starting

- Driving shaft secured against turning

Tools/appliances required

Quant Denomination No. Availability

2 Thrust pad 030.243 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
2 High--pressure hose 009.306 Standard
2 Hydraulic tensioning tool 009.097 Standard
2 Measuring device 009.051 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar 10 000.263 Standard

Related work cards

Work card Work card Work card

000.30 000.32 009.01
009.03

Operating sequence 1 -- Check the big-end bearing bolts

Starting condition Crankcase opened, crank pin of the respective cylinder vertically up
(running ger at TDC) on the L-type engine, and vertically down on the

6629 030.02--01 E 11.97 32/40 101/ 04

 V-type engine. Foot board (special tool) placed in oil sump, or oil sump
cleaned by appropriate means.

Steps 1. Clean the threads of the big-end bearing bolts (5).

2. Mount hydraulic tensioning tools on both big-end bearing bolts (5),
taking care of the centerings (refer to Figures 1 and 2).
▲ Attention! Once the hydraulic tensioning tools have been
installed, it is not permitted any longer to turn the running gear.
Prior to mounting the tensioning cylinder, make sure that the piston
has been fully forced home.

1 Big-end bearing body

2 Big-end bearing cap

Figure 1. Mounting the hydraulic tensioning tools to the big-end bearing bolts
3. Turn the tensioning cylinder (009.097) back by 310ƒ .
4. Connect high-pressure hoses (009.306) to tensioning cylinder and
high-pressure pump (009.338) or hydraulic hand pump (009.320).
5. Switch on the high-pressure pump or the hydraulic hand pump (see
009.03) and close the gap produced by the turning back
work card 009.03
between the thrust pads (030.243) and big-end bearing cap (2).
6. Pressurise the tensioning cylinder by pumping until nuts (3) can be
loosened.
Note down the force required for loosening, and compare it with the
tensioning pressure.

▲ Attention! The pressure is permitted to be max. 7% below and

max. 5% above the tensioning pressure (refer to work card 000.30
and 000.33).
000.33
7. Adjust the high--pressure pump to the specified tensioning pressure
or actuate the hydraulic hand pump until the specified tensioning
pressure is reached and retighten the nuts (3).
8. Release the pressure and remove the hydraulic tensioning tool.
9. Take the foot board (if one has been provided) out of the oil sump.
10. Reset the pistons of the tensioning cylinders (see work card 009.01).
009.01

Operating sequence 2 -- Untighten the big-end bearing bolts

Steps 1. Unload the big-end bearing bolts (see operating sequence 1,

points 1 to 6).
2. Turn nuts (3) back (for angular amount of turning back, see work
card 000.30).
000.30
3. Release the pressure and remove the hydraulic tensioning tools.

6629 030.02--01 E 11.97 32/40 102/ 04

 4. Reset the pistons of the tensioning cylinders (see word card 009.01
009.01).

2 Big-end bearing cap

3 Nut
4 Dial gauge
5 Big-end bearing bolt

Figure 2. Sectional view of the hydraulic tensioning tool/dial gauge mounted.

Operating sequence 3 -- Tighten the big-end bearing bolts

Starting condition Big-end bearing preassembled (refer to work card 030.03

030.03), crankpin of the
respective cylinder vertically up (running ger at TDC) on the in-line engine,
and vertically down on the V-type engine.

Steps 1. Tension nuts (3) of the big-end bearing bolts hand-tight using the
tommy bar (000.263).
2. Verify that the gap at the joint between the big-end bearing body (1)
and the big-end bearing cap (2) is the same on both sides.
3. Mount hydraulic tensioning tools on the big-end bearing bolts (5) --
see Figure 1.
▲ Attention! Prior to mounting the tensioning cylinder make sure
that piston has been fully forced home.
4. Connect high-pressure hoses (009.306) to tensioning cylinders
(009.097) and high-pressure pump (009.338) or hydraulic hand pump
(009.320).
5. Place measuring devices (009.051) to tenioning cylinders
(see Figure 2).
6. Switch on the high-pressure pump or the hydraulic hand pump (see
009.03) and tension the big-end bearing bolts to a pressure
work card 009.03
of 500 bar. Set the dial gauges (4) to “Zero”.
7. Load the big-end bearing bolts to the specified pressure (refer to
000.30). Tension both the nuts (3) hand-tight.
work card 000.30
8. Release the pressure.
9. Tension the big-end bearing bolts to a pressure of 500 bar again.
Read the elongation al on the dial gauges, and compare it with the
000.30).
specified value (refer to work card 000.30
▲ Attention! Big-end bearing bolts should be tightened to the
specified tensioning pressure, not according to elongation. The
elongation only serves as a means of control. In case of excessive
deviations, repeat the tensioning procedure and check the

6629 030.02--01 E 11.97 32/40 103/ 04

 measuring instruments and/or pressure gauges.

Extraordinary conditions may cause a permanent elongation of

big-end bearing bolts. The big-end bearing bolt as a new is
462 +/- 0.1 mm long and must not suffer a permanent elongation of
more than 1.0 mm, i.e. it has to be replaced if its length (in unloaded
condition) exceeds 463.1 mm.
10. Release the pressure and remove the hydraulic tensioning tools.
11. Take the foot board (if one has been provided) from the oil sump.
009.01).
12. Reset the pistons of tensioning cylinders (see work card 009.01

6629 030.02--01 E 11.97 32/40 104/ 04

Big end bearing cap - lowering
Big end bearing bolt - removal
Lower big end bearing shell - checking 030.03

Purpose of jobs to be done

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

ensure operational reliability of bearings.

Brief description

Big end bearing shells are to be checked at regular intervals. For this
purpose, the big end bearing cap must be lowered and the big end bearing
bolts removed.
The work/steps include:
Checking bearing shells,
removing components,
attaching components.

Tools/appliances required

Quant Denomination No. Availability

1 Fitting/unfitting tool 030.249 Standard
1 Wire rope 030.255 Optional
2 Rope guide 030.252 Standard
1 Rope guide 030.251 Standard
2 Support 030.250 Standard
2 Support 030.249--29 Standard
1 Bolt extractor 009.089 Optional
1 Ring nut 009.089--1 Optional
1 Ring nut 009.089--2 Optional
1 Ratchet hoist 002.552 Optional
2 Shackle A0.6 002.452 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar 16 000.266 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Depth gauge -- Inventory

Related work cards

Work card Work card Work card

000.11 030.02 030.04

6629 030.03--01 E 04.98 L 32/40 101/ 06

Technical details

Term Information
Big end bearing cap 44.5 kg
Bearing shell 2.5 kg

Preliminary remarks

To check the unloaded, lower bearing shell it is only necessary to lower the
big end bearing cap into the oil sump. The shell can then be taken out for
being checked (part of operating sequence 1, and sequences 2 and 3). To
check the upper bearing shell, which is under load and the condition of
which is decisive for drawing conclusions on the bearing, it is also
necessary to lower the big end bearing cap. Moreover, the big end
bearing bolts have to be removed (as described in operating sequence 1).
Only in this condition can the crankshaft be turned to come clear of the
030.04). It is permitted to replace
upper bearing shell (refer to work card 030.04
bearing shell halves individually.

Operating sequence 1 -- Lower the big--end bearing cap/remove the big--end bearing bolts

Starting condition Big--end bearing bolts unloaded, running gear position 10ƒ before/after
TDC.

1 Hexagon head bolt

M12x25
2 Crankcase
3 Oil sump
4 Big end bearing bolt
5 Crankshaft
6 Big end bearing cap
10 Big end bearing body

Figure 1. Removal of big end bearing bolts

Steps 1. Attach two supports (030.250) to big end bearing cap (6) and big end
bearing body (10). Please see Figure 1.
2. Unscrew the nuts.
3. Remove the big end bearing bolts (4) as follows:
4. Mount the bolt extractor (009.089) to inner big end bearing bolt
(projection A in Figure 2 to be noted).
5. Loosen, unscrew and remove the big end bearing bolt.
6. Remove the bolt extractor.
7. Turn the crankshaft by 20• (running gear 10• before/after TDC).
8. Remove the second big end bearing bolt in the same way.

6629 030.03--01 E 04.98 L 32/40 102/ 06

 9. Turn the crankshaft (5) downwards.
10. Screw two rope guides (030.252) onto balance weights (8) so that
these can still be moved.
▲ Attention! The engine must not be turned any more in this
condition (rope guides).
11. Place the wire rope (030.255) over rope guides and fasten to
supports using shackles (002.452). See Figure 3.
12. Mount the rope guide (030.251) to crankcase (2).
13. Suspend ratchet hoist (002.552) from an appropriate point, attach
wire rope to ratchet hoist and secure it with the wire rope clamp (9) --
see illustration. Tension the wire rope.
14. Place supports (030.249--29) in oil sump (3).
15. Screw two hexagon head bolts (1) out of the big end bearing body.
16. Using the ratchet hoist, lower the big end bearing cap onto support.
See Figure 4.
17. Take off the rope guides between the balance weights, as well as the
wire rope.
18. Clean the running surface of the big end bearing shell (13).

4 Big end bearing bolt

6 Big end bearing cap
10 Big end bearing body
17 O--ring seal
18 Stud M10
19 Hexagon nut

A Projection = 53 mm

Figure 2. Illustration showing bolt extractor as mounted, and big end bearing bolt

Operating sequence 2 -- Check the lower big end bearing shell

Starting condition Big end bearing cap put down in oil sump, upper big end bearing shell in
safe operating condition.

Important! Conclusions on the big end bearing can primarily be

drawn from the condition of the upper bearing shell. Please refer to work
card 030.04.
030.04 The lower bearing shell is also to be checked in connection
with this job, the more so if damage has been found on the upper bearing
shell.

Steps 1. Take the lower big--end bearing shell (13) out of the big end bearing
cap (6).
2. Check the condition of the running surface of the lower big end
000.11).
bearing shell (see work card 000.11

6629 030.03--01 E 04.98 L 32/40 103/ 06

 Important! Replace damaged or worn--out big end bearing shells.
The bearing shells are consecutively numbered on initial assembly. When
fitting new bearing shells, these are also to be marked with the
corresponding number.
New bearing shells are supplied in a condition ready for installation. Under
no circumstances whatsoever attempt to reduce the clearance by filing the
joint surfaces, or by mechanically treating them in any other way. This
equally applies to new bearing shells as well as to bearing shells already
used. Although it is true that this would reduce the clearance, it also
means that the shells are no longer clamped sufficiently in the big end
bearing and its cap. Also, subsequent scraping of the running surface is
to be refrained from under all circumstances.
3. Place the lower big end bearing shell into the big end bearing cap
(back of the big end bearing shell to be oil dry).

1 Hexagon head bolt M12x25 5 Crankshaft 9 Wire rope clamp

2 Crankcase 6 Big end bearing cap 10 Big end bearing body
3 Oil sump 7 Hexagon nut 11 Stud
8 Balance weight 12 Suspension point

Figure 3. Big end bearing with tool mounted

Operating sequence 3 -- Mount the big end bearing cap

Starting condition Bearing shell cleaned, running surface well oiled, big end bearing bolts
cleaned and threads dry, running gear in BDC position.

Steps For installation, proceed in the reverse order of removal, taking note of the
following points:

6629 030.03--01 E 04.98 L 32/40 104/ 06

 1. When fitting the big end bearing cap (6) to the big end bearing body
(10), take note of the positioning pins (14).
2. For fitting the big end bearing bolts (4), proceed as follows:
3. Turn the crankshaft (5) to a position 10ƒ before/after TDC.
4. Screw the inner big end bearing bolt from below through the big end
bearing cap into the bearing body by hand until the collar of the big
end bearing bolt contacts the big end bearing body (see Figure 2).
5. Turn the crankshaft by 20• (running gear at a position 10• before/after
TDC).
6. Fit the second big end bearing bolt likewise (see point 4).
7. Screw the nuts on hand--tight, so that they contact the big end
bearing cap.
8. After the big end bearing bolts have been tensioned, measure the
bearing clearance using thickness gauge (000.451); introduce
thickness gauge approx. 10 mm deep from the coupling end and free
end.
9. Enter readings in the engine operating records.

6629 030.03--01 E 04.98 L 32/40 105/ 06

 1 Hexagon head bolt M12x25 6 Big end bearing cap 11 Stud
2 Crankcase 7 Hexagon nut 12 Suspension point
3 Oil sump 8 Balance weight 13 Lower big end bearing
5 Crankshaft 9 Wire rope clamp shell
10 Big end bearing body 14 Positioning pin

Figure 4. Big end bearing cap lowered into oil sump

6629 030.03--01 E 04.98 L 32/40 106/ 06

Upper big-- end bearing shell
Removing and installing/checking 030.04

Purpose of jobs to be done

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

ensure operational reliability of bearings.

Brief description

Big--end bearing shells are to be checked at regular intervals. For this

purpose, the big end bearing cap must be lowered and the big end bearing
bolts removed.
The work/steps include:
Checking bearing shells,
removing components,
attaching components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 4
1 Assistant 4

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 030.249 Standard
1 Support 030.254 Standard
2 Support (for piston of S.G. iron) 030.253 Standard
2 Support (for steel piston) 030.330 Standard
1 Open--jaw and ring wrenches (set) -- Standard

Related work cards

Work card Work card Work card

000.11 030.03

6629 030.04--01 E 01.02 L 32/40 101/ 03

Technical details

Term Information
Bearing shell 2.5 kg

Preliminary remarks

Checking one or several big-end bearing shells is one of the jobs specified
in the maintenance schedule. The running surface appearance permits to
draw conclusions on the prevailing or admissible loading conditions and
the lube oil quality. Of particular importance is the checking of the bearing
shell that is under load.

1 Hexagon bolt M12x24

2 Cylinder crankcase
3 Oil sump
5 Crankshaft
6 Big-end bearing cap
7 Hexagon nut M12
10 Big-end bearing body
11 Stud
15 Cylinder liner
16 Upper big-end bearing
shell
20 Hexagon bolt M12x40
21 Piston of S.G. iron
22 Steel piston

Figure 1. Tool for checking the upper big-end bearing shell mounted in place

Operating sequence 1 -- Removal of the upper big-end bearing shell

Starting condition Big-end bearing bolts removed, big-end bearing cap put down in oil sump,
running gear at BDC position.

Steps 1. Turn the crankshaft (5) until the running gear is approximately 60ƒ
before/after TDC.
2. Depending on the engine design, screw one support (030.253) each
for piston of S.G. iron (21) or one support (030.330) each for steel

6629 030.04--01 E 01.02 L 32/40 102/ 03

 piston (22) in place at the coupling side/free end side of the cylinder
liner (15) - refer to Figure 1 .
3. Move the piston downward to stop, by careful turning.
▲ Attention! During turning, make sure that the big-end bearing
body follows the crankshaft.
4. Mount support (030.254) to the cylinder crankcase (2).
5. Fasten the big-end bearing body (10) to the support using hexagon
head bolt (1) - refer to Figure 1 .
6. Move crankpin downward by turning until big-end bearing shell (16) is
easily accessible.
▲ Attention! While turning the crankpin out of the way, take care
that the big-end bearing shell does not drop out and suffer damage.
7. Take the big-end bearing shell out.
000.11), replace if
8. Check the big-end bearing shell (see work card 000.11
necessary.

Operating sequence 2 -- Installation of the upper big-end bearing shell

Starting condition Big-end bearing shell cleaned, back of the shell oil-dry, running surface
well oiled.

Important! The bearing shells are on initial assembly marked by

continuous numbering. When new bearing shells are installed, these have
to be correspondingly marked with the same number.

New bearing shells are supplied in a condition ready for installation. Under
no circumstances whatsoever attempt to reduce the clearance by filing the
joint faces or by any other mechanical treatment. This equally applies to
new bearing shells as well as to ones already used. Although it is true that
this would reduce the clearance, it also means that the shells are no
longer clamped sufficiently in the big-end bearing body and the big-end
bearing cap. Also, subsequent scraping of the running surface is to be re-
frained from under all circumstances.

For installation, proceed in the reverse order followed for removal. When
inserting the upper big-end bearing shell (16) in the big-end bearing body
(10), take note of the bearing shell fixation.

▲ Attention! When turning the crankshaft into BDC position, make

sure that the supports (030.253 or 030.330) have been removed and
the connecting rod with the piston follows the crankshaft movement.

6629 030.04--01 E 01.02 L 32/40 103/ 03

.
Big end bearing
Removing and installing 030.05

Purpose of jobs to be done

Ensure correct execution of work,

enable emergency operation.

Brief description

Big end bearings are not to be disassembled for doing maintenance work.
This will only be necessary under certain circumstances, e.g. if the engine
has to be operated under emergency conditions with the running gear
removed and the oil bore blocked.
The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Fitting/unfitting tool 030.275 Standard
1 Butt strap 030.275--1 Standard
1 Slide piece 030.275--10 Standard
1 Bracket 030.275--20 Standard
1 Support 030.275--30 Standard
1 Guide rod 030.275--40 Standard
1 Plate 030.275--45 Standard
1 Turning stirrup 030.245 Standard
1 Shackle A0.6 002.452 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar 10 000.263 Standard
1 Eye bolt M10 000.141 Standard
1 Lifting tackle with rope -- Inventory
1 Open--jaw and ring spanner (set) -- Standard

Related work cards

Work card Work card Work card

030.02 034.01

6629 030.05--02 E 10.97 L 32/40 101/ 07

Technical details

Term Information
Big end bearing body 48.5 kg
Big end bearing cap 44.5 kg

Operating sequence 1 - Dismantle the big-end bearing

Starting condition Big-end bearing bolts unloaded, big-end bearing fastened to balance
weight by means of turning stirrup (030.245), piston and connecting rod
shank removed.

Steps 1. Turn the crankshaft (5) so that the big-end bearing is in horizontal
position (refer to Figure 1).
2. Screw the nut (3) off the lower big-end bearing bolt (4).
3. Attach the slide piece (030.275-10) to the big-end bearing cap (6) -
refer to Figure 1.
4. Remove the turning stirrup (030.245), holding the big-end bearing by
means of the slide piece.
5. Turn the crankshaft by 90E, holding the big-end bearing in horizontal
position by means of the slide piece (refer to Figure 2).
▲ Attention! Keep holding the big-end bearing until both
components are resting on the support.
6. Introduce the support (030.275-30) into the crankcase and put down
on hexagon head bolts (2) - refer to Figure 2.
7. Turn the crankshaft back until the big-end bearing and the slide piece
are resting on the support. Loosen the hexagon head bolts (1) and
align the slide piece, if necessary (refer to Figure 3).
8. Screw a conrod shank bolt (7) that is down out of the big-end bearing
body (10).
9. Mount the plate (030.275-45) and screw the pilot rod (030.275-40)
through the plate and into the big-end bearing (refer to Figure 4).
10. Put the bracket (030.275-20) onto stud bolts (11) and attach it to the
crankcase (9) by means of hexagon nuts (12) - refer to Figure 4.
11. Screw the nut (3) off the upper big-end bearing bolt (4).
12. Carefully pull the big-end bearing body out (refer to Figure 5).
▲ Attention! During pulling out, take care of the big-end bearing
shell (15) to prevent falling out and/or damage.
13. Take the big-end bearing shell (15) out.
14. Attach the butt strap (030.275-1) to the big-end bearing body. Screw
the ring bolt (000.141) into the butt strap.
15. Attach the rope (17) to the ring bolt by means of shackle (002.452).
Attach the rope to the lifting tackle and tension it.
16. Pull the big-end bearing body out completely, taking care not to dam-
age the big-end bearing bolts (4).
17. Lift the big-end bearing body and put it down on wooden pad. Detach
the butt strap from the big-end bearing body.
Important! When putting down the big-end bearing body take care
that the big-end bearing and conrod shank bolts do not suffer damage.
18. Detach the bracket and mount it on the opposite side (refer to
Figure 6).
19. Pull the big-end bearing cap outward (refer to Figure 6).

6629 030.05--02 E 10.97 L 32/40 102/ 07

 ▲ Attention! During pulling out, take care that the big-end bearing
shell (14) does not fall out and suffer damage.

1 Hexagon head bolt

M12x25
3 Nut
4 Big-end bearing bolt
5 Crankshaft
6 Big-end bearing cap
8 Balance weight
10 Big-end bearing body

Figure 1. Big-end bearing fixed to balance weight, slide piece attached to big-end bearing cap

2 Hexagon-head bolt 6 Big-end bearing cap

5 Crankshaft 10 Big-end bearing body

Figure 2. Support installed in crankcase

6629 030.05--02 E 10.97 L 32/40 103/ 07

 3 Nut
4 Big-end bearing bolt
5 Crankshaft
6 Big-end bearing cap
10 Big-end bearing body

Figure 3. Big-end bearing put down on support

4 Big-end bearing bolt 7 Conrod shank bolt 11 Stud bolt

5 Crankshaft 9 Cylinder crankcase 12 Hexagon nut M12
6 Big-end bearing cap 10 Big-end bearing body

Figure 4. Big-end bearing with tool attached

6629 030.05--02 E 10.97 L 32/40 104/ 07

 4 Big-end bearing bolt 7 Connecting rod shank 15 Upper big-end bearing
5 Crankshaft bolt shell
6 Big-end bearing cap 10 Big-end bearing body 16 Hexagon bolt M12x35
13 Positioning pin 17 Rope

Figure 5. Big-end bearing cap dismantled

1 Hexagon head bolt

M12x25
5 Crankshaft
6 Big-end bearing cap
11 Stud bolt
12 Hexagon nut M12
14 Lower big-end bearing
shell
16 Hexagon bolt M12x35
17 Rope

Figure 6. Big-end bearing cap dismantled

6629 030.05--02 E 10.97 L 32/40 105/ 07

 20. Take the big-end bearing shell (14) out.
21. Attach the butt strap to the big-end bearing. Tension the rope.
22. Lift the big-end bearing cap and put down on wooder pad. Detach the
butt strap from the big-end bearing cap.
23. Clean the individual parts.

Operating sequence 2 - Reinstall the big-end bearing

Starting condition Individual parts cleaned, back of the big-end bearing shells oil-dry, running
surface well oiled, threads of the big-end bearing bolts dry, running gear at
position approx. 84E before/after TDC (refer to Figure 3). Support
(030.275-30) placed in crankcase, bracket (030.275-20) attached to crank-
case, for installation of the big-end bearing cap.

Steps 1. Prior to installing the big-end bearing cap (6) and/or body (10), note
the position of the marking for exhaust gas counter side.
2. Attach the butt strap (030.275-1) to the big-end bearing cap. Screw
the ring bolt (000.141) into the butt strap.
3. Attach the rope (17) to the ring bolt by means of shackle (002.452).
Attach the rope to the lifting tackle.
4. Mount the slide piece (030.275-10) to the big-end bearing cap (refer
to Figure 6).
5. Lift the big-end bearing cap and put it down on bracket (refer to
Figure 6). Remove the butt strap.
6. Insert the big-end bearing shell (14) in big-end bearing cap, taking
note of the bearing shell fixing.
7. Push the big-end bearing cap on the bracket and support forward up
to the crank pin, turn the crankshaft (5) for some amount if
necessary.
▲ Attention! When inserting the big-end bearing cap, take care of
the big-end bearing shell to avoid that it drops down and suffers
damage.
8. Detach the bracket and mount it on the opposite side.
9. Attach the butt strap to the big-end bearing body.
10. Screw the plate (030.275-40) into the big-end bearing body (refer to
Figure 5).
11. Lift the big-end bearing body and put down on bracket, taking care
not to damage the big-end bearing bolt (4) and the conrod shank bolt
(7). Take the butt strap off.
12. Insert the big-end bearing shell (15) into big-end bearing body, taking
note of the big-end bearing shell fixing.
13. Shift the big-end bearing body on the bracket and support up to the
crank pin, taking care not to damage the big-end bearing bolt (4)
when introducing it into the big-end bearing cap (refer to Figure 4).
▲ Attention! When introducing the big-end bearing body, take care
that the big-end bearing shell does not drop out and suffer damage.
14. When assembling the big-end bearing body with the big-end bearing
cap, take note of two positioning pins (13).
15. Screw the nuts (3) onto the upper big-end bearing bolt down to
contact with the big-end bearing cap.
16. Detach the bracket, the pilot rod and the plate.
17. Screw the conrod shank bolt (7) into the big-end bearing body by
hand until the shoulder of the conrod shank bolt contacts the big-end
bearing body (refer to Figure 7).
18. Turn the crankshaft by approx. 84E, holding the big-end bearing in
horizontal position by means of the slide piece (refer to Figure 2).
▲ Attention! Keep holding the big-end bearing by means of the
slide piece until the big-end bearing has been attached to the
balance weight by means of the turning stirrup.

6629 030.05--02 E 10.97 L 32/40 106/ 07

 19. Take the support out of the crankcase.
20. Turn the crankshaft back by 90E (crankshaft with balance weight
being in horizontal position, refer to Figure 1).
21. Attach the big-end bearing to the balance weight (8) by means of
turning stirrup (030.245) - refer to Figure 1.
22. Detach the slide piece.
23. Screw the nut (3) onto the lower big-end bearing bolt down to contact
with the big-end bearing cap.
24. Turn the running gear until crank pin is at TDC position. Tighten the
030.02).
big-end bearing bolts (refer to work card 030.02
25. After tensioning of the big-end bearing bolts, measure the bearing
clearance using the thickness gauge (000.451), introducing the
gauge approx. 10 mm deep from the coupling end and free engine
end sides. Enter the results in the engine operating logs.
26. Turn the running gear so that the crank pin is at BDC. Install the
piston complete with conrod shank and fire land ring (refer to work
card 034.01).
034.01

7 Conrod shank bolt

10 Big-end bearing body

Figure 7. Conrod shank bolt

6629 030.05--02 E 10.97 L 32/40 107/ 07

.
Piston/piston rings

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

6682 034--02 E 04.98 101/ 01

.
Piston
Removing and installing 034.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Pistons are to be disassembled within the scope of maintenance and

repair work.
The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Tapered sleeve for inserting the piston rings 034.100 Standard
1 Tap wrench 034.097 Standard
1 Tap 034.096 Standard
1 Suspension device 034.095 Standard
1 Support 034.095--1 Standard
1 Pilot rod 034.006 Standard
2 Guide tube 030.246 Standard
1 Turning stirrup 030.245 Standard
1 Shackle A1.0 002.453 Standard
1 Tommy bar 5 000.507 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Lifting tackle with rope -- Inventory

Related work cards

Work card Work card Work card

030.03 034.02

Technical details

Term Information
Piston with connecting rod shank 234 kg

6629 034.01--01 E 10.97 L 32/40 101/ 04

 5 Rope
6 Cylinder head bolt
7 Piston
8 Backing ring
9 Cylinder liner
10 connecting rod shank
11 Balance weight
12 Hexagon head bolt
M12x25
13 Connecting rod shank
bolt
14 Positioning pin
15 Big-end bearing body
16 Big-end bearing cap
17 Crankshaft
18 Hesagon head bolt
M12x80
19 Hexagon nut M12

Figure 1. Removing and installing the piston

Operating sequence 1 - Dismantle the piston

General Prior to piston removal, the fire land ring has to be taken out because this
has a smaller diameter than the piston has.

Starting condition Fire land ring removed, crankcase opened, foot board (special tool) placed
in oil sump, or oil sump cleaned for this purpose by appropriate means;
connecting rod shank bolts unloaded, running gear at TDC.

Steps 1. Clean the threaded bores in the piston crown using the hand tap
(034.096).
2. Place the support (030.095-1) onto piston (7), screw in two hexagon
head bolts (18) and fasten the support to the piston by means of
hexagon nuts (19). Attach the rope (5) to support using shackle
(002.453).
3. Turn the engine until the piston is exactly at BDC and attach the rope
to the lifting tackle.

6629 034.01--01 E 10.97 L 32/40 102/ 04

 4. Attach the turning stirrup (030.245) to the big-end bearing body (15)
and balance weight (11) - see the illustration.
5. Screw nuts off the connecting rod shank bolts (13).
6. Pull the piston upwards over the cylinder liner until the pilot rod
(034.006) can be screwed into the support.
7. Carefully pull the piston out of the cylinder liner, guiding it with the
pilot rod.
▲ Attention! In pulling out the piston take care that the piston rod
plam is not caught by the cylinder liner and that the cylinder liner
running surface and the cylinder head bolts do not suffer damage.
8. Place the piston and connecting rod (10) onto wooden pad.
9. Blank off the lube oil bore in the connecting rod shank and big-end
bearing body to prevent that dirt can penetrate.
10. Cover the cylinder liner which now is open.
▲ Attention! Fastening the big-end bearing to the balance weight
by means of the turning stirrup is only permitted with the engine out
of operation, for turning the runninge gear with the piston removed,
and for some other servicing jobs. The engine must not be operated
in these condition!

Operating sequence 2 - Install the piston

Starting condition Piston clean, checked and assembled with connecting rod. Cylinder liner
and faces of big-end bearing/connecting rod shank joint cleaned. Big-end
bearing fastened to balance weight by means of turning stirrup, and turned
exactly to BDC.

1-4 Location of piston ring

gaps

St Camshaft side
(exhaust counter side)

Figure 2. Diagram showing the location of piston ring gaps

Steps 1. Diagonally screw two guide tubes (030.246) onto connecting rod
shank bolts (13) till contact is established.
2. Remove the covering applied to the cylinder liner opening.
3. Put the tapered sleeve (034.100) onto the cylinder liner (9), oil the
inner surface well.
4. Attach the support (034.095-1) to piston (7) - see operating sequence
1, point 2; attach rope (5) to support using shackle (002.453) and
screw the pilot rod (034.006) into support. Attach the rope to the
lifting tackle.
5. Lift the piston. Oil the piston rings and the running surface of the
piston with clean lube oil.
6. Adjust the piston ring gaps as shown in Figure 2.
7. Open the lube oil bores in the big-end bearing (15) and connecting
rod shank (10).
8. Move the piston with lifting tackle over the cylinder liner and carefully
lower it into the liner, guiding the piston with the pilot rod until the
piston skirt enters the cylinder liner.
▲ Attention! When introducing the piston take care that the piston
rod palm does not damage the cylinder liner running surface.

6629 034.01--01 E 10.97 L 32/40 103/ 04

 Important! Turn the piston so that the marking on the piston top
points in the direction of the exhaust counter side.
9. Screw out the pilot rod, carefully lower the piston further down while
the piston rings are passing through the inserting bush and into the
cylinder liner. Align the piston and the connecting rod shank so that
the bores in the connecting rod shank point to the corresponding
guide tubes.
10. Carefully lower the piston further down until the connecting rod shank
rests on the big-end bearing body, taking care of the positioning pins
(14) at the joint. To facilitate introduction, slightly loosen the hexagon
head bolt (12) on the balance weight (11).
11. Verify with the thickness gauge (000.451) that the gap at the joint is
<0.05 mm over the whole circumference.
12. Screw out the guide tubes taking care that the connecting rod shank
bolts do not follow the movement. Screw the nuts onto the
connecting rod shank bolts, hand tight.
13. Dismount the turning stirrup and load the connecting rod shank bolts
030.01).
(see work card 030.01
14. Turn the piston into TDC position, detach the rope and dismount the
tool.
15. Install the fire land ring (see work card 050.01).
050.01
16. Take the foot board (if there is one) out of the oil sump, close the
crankcase.

6629 034.01--01 E 10.97 L 32/40 104/ 04

Piston/piston rings
Checking 034.02

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Pistons and piston rings are to be checked with regard to the appearance
of their contact faces as well as the lubricating and wear condition.
The work /steps include:
Measure components and
assess contact pattern/wear.

Tools/appliances required

Qty Designation No. Availability

1 Piston ring expander 034.110 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Felt--tip pen/Marking pen -- Inventory

Related work cards

Work card Work card Work card

034.01 034.05 034.07

Operating sequence 1 -- Check the piston

Starting condition Piston has been pulled and placed on an appropriate wooden pad.

Steps 1. Check the condition of the piston and piston rings.

Important! The running surface of the piston should present a
uniform without scores and other signs of damage. Pronounced scoring or
fretting suggests overloading of the engine, unsatisfactory cooling,
inadequate lubrication or foreign particles having entered between the
piston and cylinder liner.
2. Clean carbon deposits away from the piston, taking care not to
roughen the piston crown top face. Carefully clean the running
surface.
▲ Attention! The graphitised layer on the piston skirt (22) must not
be damaged by the cleaning treatment.

6629 034.02--01 E 04.02 32/40 101/ 03

 3. Measure and note down the axial clearance of piston rings in their
grooves, compare the readings with the admissible maxima, and
enter them in the engine operating logs. For piston rings diagnosis,
please refer to work card 034.05.
034.05

5 Securing ring
6 Nut
7 Thrust pad
8 Slide piece
9 Stud bolt
10 Piston crown
11 Spring cup
12 Compression spring
13 Spring cup
14 Securing ring
15 Securing ring
16 Tensioning sleeve
17 Compression ring
18 Compression ring
19 Compression ring
20 Oil scraper ring
22 Piston skirt

Figure 1. Piston (with connecting rod and piston pin dismantled)

Operating sequence 2 -- Removal and installation of the piston rings

Starting condition Piston rings need not normally be removed for checking the piston, they
are submitted to considerable stresses while being fitted unfitted. Should
piston rings have to be removed because of advanced wear or dirt
accumulation, you have to do the following:

17 Compression ring
18 Compression ring
19 Compression ring
23 Locking lever

Figure 2. Piston ring expander with the piston ring inserted

6629 034.02--01 E 04.02 32/40 102/ 03

Steps 1. Remove piston rings (17 - 20) one after the other using piston ring
expander (034.110) and mark with marking pin (cylinder No. and
number of piston ring groove).
▲ Attention! Marking the piston rings is necessary so as to avoid
an exchange of the piston rings (piston rings which have already
been in use must be refitted to the same piston and into the same
piston ring groove).
Important! The piston ring expander has in each case to be used
for the fitting and unfitting of piston rings (see Figure 2 ). To expand the
ring, press the locking lever (23) down. The locking lever will automatically
return to its normal position when released.
2. Check piston rings thoroughly and renew, if necessary.
3. Thoroughly clean the ring grooves in the piston and check them for
wear.
▲ Attention! Conically worn ring grooves suggest excessive wear
of the cylinder liner. Ring grooves affected by pounding can be
reconditioned. We recommend that in such cases MAN B&W be
consulted. Replacement piston rings fitting the reconditioned ring
grooves have to be installed, the new ring width has to be entered in
the engine operating logs.
Steps 4. Using the ring expander, mount the piston rings on the piston. In
doing so, watch for position of corresponding marking. Measure the
groove clearance and enter it in the engine operating logs.
Important! If a piston that has already been in use is going to be
fitted in another cylinder liner, it is absolutely necessary to replace the
compression ring and the oil scraper ring, and to rehone the cylinder liner.
New running in of the engine will then be necessary (refer to engine
operating manual, Section 3).
For dimensions and clearances of piston rings, refer to the engine
operating manual, Section 2.5.
A ceramic chrome--plated compression ring (17) is fitted in the topmost
groove (ring groove 1) of the piston crown. The ring side marked ”TOP” is
to be up. The bevel on the inside diameter is to be up.
Chrome--plated compression rings (18 and 19) are fitted in the second and
third grooves from top (ring grooves 2 and 3). The ring side marked ”TOP”
is to be up. The bevel on the inside diameter is to be up.
The oil scraper ring (20) with hose spring has to be fitted with the ring side
marked ”TOP” being up.

10 Piston crown
17 Compression ring
18 Compression ring
19 Compression ring
20 Oil scraper ring
22 Piston skirt

Figure 3. Arrangement of piston rings

6629 034.02--01 E 04.02 32/40 103/ 03

.
Piston pin and piston pin bush
Removing and installing/checking 034.03

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Piston pin and piston pin bush are to be checked at regular intervals, and
are hence to be dismounted.
The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Fitting/unfitting tool 034.109 Optional
1 Retaining clamp 034.109--1 Optional
1 Shackle A0.6 002.452 Standard
1 Shackle A1.0 002.453 Standard
1 Pliers for locking ring 002.165 Standard
1 Eye bolt M16 000.143 Standard
1 Lifting takle with rope -- Inventory

Related work cards

Work card Work card Work card

034.01

Technical details

Term Information
Connecting rod shank 93.5 kg
Piston pin 31.5 kg

6629 034.03--01 E 07.97 32/40 101/ 03

Operating sequence 1 -- Remove the piston pin (and piston pin bush)

1 Rope
2 Conrod shank
3 Piston pin
4 Piston
5 Wooden pad
6 Securing ring
7 Piston pin bush

Figure 1. Remove/reinstall the piston pin

Starting condition Piston and conrod shank removed and put down on wooden pad with
piston crown (see Figure 1). Conrod shank secured against tilting. Piston
free of oil and oil coke on the inside.

Steps 1. Screw eye bolt (000.143) into conrod shank (2).

2. Attach rope (1) to eye bolt using shackle (002.453). Suspend rope
from the lifting tackle.
3. Slightly lift the conrod shank (2) to relieve the piston pin (3).
4. Remove the safeguard used to secure the conrod shank (2) against
tilting.
5. Remove the securing rings (6) and push the piston pin (3) out as far
as shown in the illustration, securing the piston (4) against tilting.
¡Tip! The piston pin can be easily pushed out if the temperature relative
to the piston differs by 30 -- 40EC. To reach this, carefully heat the piston
in the pin area using, e.g. a gas flame that is moved in circles and at a
distance not too close to the piston.
6. Lift the conrod shank (2) out of the piston (4) and carefully put it down
onto a pad. Detach the rope (1) from the lifting tackle and shackle.
7. Install the retaining clamp (034.109--1) in piston pin (3) -- see the
illustration.
8. Attach rope (1) to the retaining clamp using shackle (002.452).
Suspend the rope from the lifting tackle.
9. Pull the piston pin (3) completely out with care.
10. Clean piston pin (3) and bush (7) and check for wear (for admissible
maximum clearance, see engine operating manual, Section 2.5).
▲ Attention! If it is necessary to replace the piston pin bush, this
should preferably be done by an authorised workshop because
deep- freezing has to be applied to fit it. Install a spare conrod shank
temporarily if necessary. Scraping treatment of the running surface
is not permitted, neither on new piston pin bushings nor on used
ones.

6629 034.03--01 E 07.97 32/40 102/ 03

Operating sequence 2 -- Install the piston pin

Steps 1. Verify that the sliding piece easily moves in the piston skirt.
2. For reinstallation of the piston pin (3), proceed in the reverse order of
dismantling it, taking care that the piston (4) with the retaining clamp
(034.109--1) is not damaged during pushing in, and making sure that
when mounting the conrod shank (2) the markings (AS) on the piston
and conrod shank coincide.

6629 034.03--01 E 07.97 32/40 103/ 03

.
Piston
Disassembling and assembling 034.04

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

Pistons are to be disassembled within the scope of maintenance and

repair work.
The work/steps include:
disassembly of components,
assembly of components.

Tools/appliances required

Qty Designation No. Availability

1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Pliers for retaining rings C 19--60 002.162 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Socket wrench insert 11x12.5 001.751 Standard
1 Lifting tackle with rope -- Inventory
1 Depth gauge -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

034.03

Technical details

Term Information
Piston skirt 70 kg
Piston crown 38 kg

6629 034.04--01 E 06.02 32/40 101/ 03

Operating sequence 1 -- Disassemble the piston

Starting condition Piston put down on wooden pad (piston crown pointing up), piston pin and
connecting rod dismantled. Piston cleaned on the outside.

5 Securing ring
6 Nut
7 Thrust pad
8 Sliding piece
9 Stud bolt
10 Piston crown
11 Spring cup
12 Compression spring
13 Spring cup
14 Securing ring
15 Securing ring
16 Tensioning sleeve
17 Compression ring
18 Compression ring
19 Compression ring
20 Oil scraper ring
22 Piston skirt

Figure 1. Piston (with connecting rod and piston pin dismantled)

Steps 1. Loosen and screw off four nuts (6). Disassemble thrust pad (7).
2. Suspend the piston skirt (22) from the lifting tackle by means of the
rope threaded through the piston pin bore, lift it and put it down on
wooden pad (do not rest it on sliding piece (8).
▲ Attention! When lifting the piston skirt, take care not to damage
the stud bolts.
3. Verify that the sliding piece moves easily, remove it if necessary.
4. Carefully clean the piston crown (10) and piston skirt (22). The
cooling spaces (interior) have to be cleaned down to the bare metal
surface (using a rotating wire brush or emery belt). Purge the oil
bores with compressed air. Check the parts for damage (cracks).
5. If necessary, turn the stud bolts (9) out of the piston crown.

Operating sequence 2 -- Assemble the piston

Starting condition Piston components cleaned, checked and replaced as far as necessary
Piston crown put down on appropriate wooden pad.

6629 034.04--01 E 06.02 32/40 102/ 03

 Important! Do points 1--13 if parts are tobe replaced. Carry out
points 1-6 and 9-13 as a general rule, when the piston has been
disassembled.

6 Nut
7 Thrust pad
9 Stud bolt
22 Piston skirt

A Nut -- Stud bolt

distance

Figure 2. Bolted connection of piston

Steps 1. Screw the sutd bolts (9) into piston crown (10), with a torque of
50 Nm.
2. Check the contact faces of the piston crown and piston skirt, they
have to be absolutely clean and dry.
3. Suspend the piston skirt (22) from the lifting tackle by means of a
rope run through the piston pin bore, lift it and carefully place it onto
the piston pin bore, lift it and carefully place it onto the piston crown.
Important! Prior to placing the piston skirt, make sure that the bore
in the piston skirt has the correct position relative to the tensioning sleeve
(16) in the piston crown.
When placing the piston skirt onto the piston crown, take care not to
damage the stud bolts.

1 - 4 Order of tightening

Figure 3. Order of stud bolt tightening

4. Insert the thrust pads (7) over the stud bolts into the bores.
5. Apply HSC Molycote paste or Copaslip to the threads and contact
faces of nuts (6), and screw the nuts home until seated.
6. Check the distance A Desired: 10 – 2 mm.
7. Tighten the nuts to a torque of 90 Nm, order of tightening 1--2--3--4,
and loosen them again.
8. Check the stud bolt tightening of 50 Nm and the distance A (nuts
screwed down until seated).
9. Do final tightening in two steps.
10. Tighten the nuts to a preliminary 25 Nm, in the order 1--2--3--4.
11. Turn the nuts by a further increment of 90E, in the order 4--3--2--1.
Check: Turning of the nuts further should not be possible at a torque of
65 Nm.
12. Check the ease of motion of the sliding piece (8).
034.03).
13. Install the conrod shank and piston pin (refer to work card 034.03

6629 034.04--01 E 06.02 32/40 103/ 03

.
Piston rings
Assessing 034.05

Purpose of jobs to be done

Carry out work in time according to maintenance plan,

measure components,
assess wear pattern/condition.

Brief description

Piston rings are to be diagnosed at regular intervals on the basis of the

wear pattern.
The work includes:
checking components.

Related work cards

Work card Work card Work card

034.07

Preliminary remarks

Piston rings have to be replaced after they have been in use for the time
periods given in the maintenance schedule. Replacement will also be
necessary if interim checking reveals damage to the running surface or
excessive clearances.
The rings being in use are compression rings with chromium-plated,
plasma-coated or (the most recent solution) chromium/ceramic-coated
running surfaces, and chromium-plated oil scraper rings. Please refer to
Table 1.

Ring Running surface Appearance

Compression rings
Groove1 chrome/ later network of cracks
ceramic-coated
Grooves 1/2 plasma-coated uniformly grey
Grooves 2/3 chromium-coated uniformly grey
Oil scraper ring
Groove 4 chromium-coated uniformly grey
Table 1. Piston rings/coating
On plasma-coated and chrome-plated rings, the appearance of the coating
does not change, or changes but slightly, under steady wearing conditions.
The behaviour of chromium/ceramic-coated rings is different. The running
surface of these rings has a polished metal appearance of uniformly grey
colour when not yet worn. After several hundreds of operating hours, a

6682 034.05--01 E 07.97 101/ 03

 network of cracks will appear on the surface. This is the normal
appearance.
It is the result of hard metal oxide/ceramic particles embedded in the
reticular structure of the chromium layer.
The ring type can be sun from the code number on the top side of the
piston ring.

Wear appearance of plasma-coated, chrome-plated or chromium/ceramic-coated piston rings

Due to its shape, the running face of new compression rings does not
have contact across its full width but only the width of the actual contact
surface A. With the progress of wear, the actual contact surface width will
increase.

A Actual contact surface B Ring width

width

Figure 1. Running face of plasma-coated and chrome-plated piston rings

(time in use > 1000 hrs)

Figure 2. System of cracks on chromium/ceramic-coated piston rings

(time in use approx. > 8000 hrs)
At the end of the useful life, the actual contact surface extends up to the
chamfers or radii of the ring sides, please see Figure 3.

Figure 3. Piston ring of good running pattern at the end of the useful life.
The chamfers or radii are still distinctly visible on the piston ring shown in
Figure 3. Coated compression rings have to be replaced when the actual
contact surface extends over the entire piston ring width, i.e. when the
chamfers or radii are hardly visible any more. In this condition, the residual

6682 034.05--01 E 07.97 102/ 03

 thickness of the coating will not safely endure the subsequent
maintenance interval.
Burns (C) produce local discoloration of the piston ring face. Such rings
have to be replaced. (See Figure 4).

Figure 4. Piston ring with burns on the face

Coated compression rings and oil scraper rings have also to be replaced if
the coating has worn through at one spot.

Figure 5. Piston with worn-through coating

Figure 5 shows a chrome-plated compression ring. Turn chromium layer
has completely worn spotwise at (D).
Broken-off particles or cracks in the coating of a piston ring also call for its
replace.

Figure 6. Piston ring with broken-off particles in the face

Figure 6 shows a plasma-coated compression ring. Parts of the coating
have broken off at (E).
Chromium/ceramic-coated compression rings have to be replaced when
the continous, micro-cracked surface has decayed to a crazed cracke
appearance. The cracks will then have extended down to the base
material, which involves the danger of particles breaking away.

6682 034.05--01 E 07.97 103/ 03

.
Chromium-- ceramic coated
Piston rings
Assessing 034.07

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

Piston rings are to be diagnosed at regular intervals on the basis of the

wear pattern.
The work includes:
checking components.

Related work cards

Work card Work card Work card

034.05

Preliminary remarks

Piston rings have to be replaced after they have been in use for the time
periods specified in the maintenance schedule. Replacement will also
become necessary if interim checking reveals damage to the running
surface or excessive wear.
Piston rings with a chromium-ceramic coating on the running surface are
fitted in the topmost groove. The ring specification is defined by the code
number applied to the top side of the piston rings.
Contrary to plasma-coated or chromium-plated rings, the appearance of
the coating on chromium-ceramic rings changes distinctly as wear
proceeds. In the new condition, the face of these rings has a polished
metal appearance of uniform silvery grey colour. After several hundreds of
operating hours, a network of cracks or individual longitudinally and
transversely oriented cracks will appear. This is the normal appearance. It
is the result of hard metal oxide/ceramic particles embedded in the
reticular structure of the chromium layer and offers the advantage of very
high resistance to wear and a distinctly improved resistance to thermal
loads and simultaneously minimised cylinder liner wear. The characteristic
crack network serves as a lube oil reservoir.
The illustrations following below show piston rings in approximately 5-fold
magnification. They are thought as an aid in diagnosing the condition of
used chromium-ceramic coated piston rings and as supplementary
information to work card 034.05.
034.05

6682 034.07--01 E 07.97 101/ 04

1. Normal wear pattern. The piston ring can be used without any restrictions.

1. Wide network of cracks

This appearance of the running face is representative for the normal
wear condition of a chromium-ceramic coated ring.
Result: The piston ring is available for further use without any restriction.

2. Narrow network of cracks

This appearance of the running face also reflects the normal state of
wear. The surface is smooth throughout. No bulging of the running
layer towards the cracks can be seen. Surfaces of such appearance
do not suggest separation of layers.
Result: The piston ring ring is available for further use without any
restriction.

6682 034.07--01 E 07.97 102/ 04

 3. Narrow longitudinal cracks in the running direction
This appearance of the running face also reflects normal wear
conditions. The surface is smooth throughout.
Result: Provided the cracks have a width of < approx. 0.1 mm, the piston
ring is available for further use without any restriction.

2. Wear is critical -- Piston ring has to be replaced.

1. Burn
This appearance of the running face reflects a condition which is
actually to be diagnosed as normal, but the burn spot that is visible
will not recover. Besides, there is a potential risk of blow-by.
Result: The piston ring cannot be used any longer and has to be replaced.

2. Pronounced crazed cracking

This appearance of the running face shows pronounced crazed
cracking of relatively large crack width. The surface is no longer
continuously smooth but bulged near the cracks.
Result: The piston ring cannot be used any longer and has to be replaced.

6682 034.07--01 E 07.97 103/ 04

 3. Longitudinal cracks of large width in the running direction
This appearance of the running face, showing longitudinal cracks of
considerable width, is indicative of the danger of separation even
though the surface may be smooth throughout.
Result: As the cracks have a width of > approx. 0.1 mm, the piston ring
cannot be used any longer and has to be replaced.

3. Total damage. Piston ring has to be replaced.

Piston rings that have suffered total damage such as, e.g.:
- breakage
- separation of the running layer
- pieces of material broken off, etc.
require replacement. Neighbouring components such as the cylinder liner,
piston, cylinder head should be checked for damage.

6682 034.07--01 E 07.97 104/ 04

Cylinder Liner/Top land ring

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

6682 050--02 E 04.98 101/ 01

.
Top land ring
Removing and installing 050.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

The top land ring must be removed every time the pertaining piston is to
be removed/the sealing ring is to be replaced.
The work/steps consist of:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1
1 Assistant 1

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 050.165 Standard
1 Support 050.165--1 Standard
3 Hexagon bolt 050.165--3 Standard
2 Spacer pipe 050.133 Standard
1 Fitting/unfitting tool 050.099 Standard
1 Support 050.099--1 Standard
2 Thrust screw 050.099--15 Standard
1 Pilot rod 034.006 Standard
1 Shackle A0.6 002.452 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Grease (acid--free) -- Inventory

6629 050.01--04 E 05.01 32/40 101/ 04

Related work cards

Work card Work card Work card

055.02

Technical details

Term Information
Top land ring 33.5 kg

Operating sequence 1 -- Remove the top land ring

Starting condition Cylinder cooling water completely drained. Cylinder head dismantled, run-
ning gear at approx. 60• before/after TDC.

▲ Attention! Do not discharge the cooling water into the bilge or

waste water. Instead, pump water into a separate container for
further use.

Steps 1. Remove any carbon deposits on the top land ring (6) and in the upper
zone of cylinder liner (5). Before doing so, cover the gap between the
piston (7) and the cylinder liner so that no debris can penetrate in
between.

1 Backing ring
2 Rope
3 Hexagon head bolt
M16x140
4 Sealing ring
5 Cylinder liner
6 Top land ring
7 Piston
8 O-ring seal
9 Cylinder head bolt
10 Nut

Figure 1. Removing of the top land ring (figure shows in-line engine)

6629 050.01--04 E 05.01 32/40 102/ 04

 2. Clean three pocket bore holes on the inner diameter of the top land
ring and remove loose dirt particles on the piston top side.
3. Put support (050.165-1) onto the top land ring, ensuring that it is
positioned correctly. In doing so, pay attention that the pin on the
support is located in the sleeve (12) of the backing ring (1) - refer to
Figure 1 .
4. Screw three hexagon head bolts (050.165-3) into pocket holes of the
top land ring, hand-tight.
5. Slip spacer pipes (050.133) diagonally over cylinder head bolts (9)
and fasten with nuts (10).
6. By evenly, alternately turning the hexagon head bolts (3), pull the top
land ring out until it becomes loose.
7. Fasten rope (2) with shackle (002.452) to support and attach rope to
lifting tackle. (Depending on engine type, choose the correct
suspension point).
8. Screw pilot rod (034.006) into support.
9. Carefully pull top land ring out in upward direction, guiding it with pilot
rod.
10. Put top land ring down on a wooden pad and remove tools.
11. Loosen sealing ring (4) and remove it.

1 Backing ring
2 Rope
6 Top land ring

Figure 2. Removal and installation of the top land ring in the backing ring (figure shows in-line engine)

Operating sequence 2 -- Install the top land ring

Starting condition Top land ring cleaned.

Steps 1. Fit new O-ring seals (8) lubricated with acid-free grease in the ring
grooves, taking care that these are evenly tensioned over the entire
circumference and that they are not distorted.
2. Fit a new sealing ring (4) in the groove.
3. Place the support (050.165-1) onto the top land ring (6) and screw
back the hexagon head bolts (3).
4. Screw three hexagon head bolts (050.165-3) into pocket holes on the
top land ring, hand-tight.
5. Fasten rope (2) with shackle (002.452) to support and attach rope to
lifting tackle. (Depending on engine type, choose the correct
suspension point).
6. Screw pilot rod (034.006) into support.
7. Carefully insert top land ring into backing ring (1), guiding it with the
pilot rod (cf. Figure 2 ).
Important! When installing the top land ring, pay attention to the
correct position of marking (M) backing ring / top land ring.

6629 050.01--04 E 05.01 32/40 103/ 04

 1 Backing ring
6 Top land ring

M Marking
AGS Exhaust counter side

Figure 3. Marking backing ring / top land ring

8. Remove tools.
9. Screw back thrust bolts (050.099-15) of support (050.099-1).
10. Place support on backing ring. In doing so, watch for position of
recess for sleeve (12).
11. Fasten support to backing ring using hexagon head bolts (11).
12. Screw the thrust bolts down to upper edge of top land ring.
13. Press down top land ring by turning thrust bolts uniformly and
alternately, until top land ring contacts the cylinder liner.
▲ Attention! When pressing down top land ring, take care that it
does not tilt in the backing ring.

1 Backing ring
4 Sealing ring
5 Cylinder liner
6 Top land ring
8 O-ring seal
9 Cylinder head bolt
11 Hexagon head bolt
M16x35
12 Sleeve

A Control bore for

cooling water leakage
and gas tightness

Figure 4. Pressing down top land ring (figure shows in-line engine)

14. Remove tools.

15. Mount the engine components that had been dismantled; mount the
pipes and screwed connections. Fill cooling water in engine.
16. On completion of assembly work, and with the appropriate cooling
water pressure existing, verify that the O-ring seals are in order. No
water should leak from control bores (A).
17. With the engine running, verfiy that no gas leaks through the control
bores (A).

6629 050.01--04 E 05.01 32/40 104/ 04

Cylinder liner
Measuring 050.02

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Cylinder liners are to be checked within the scope of maintenance and

repair work.
The work /steps include:
Measure components and
assess wear pattern/condition.

Tools/appliances required

Quant Denomination No. Availability

1 Gauge bar 32/40 050.097 Standard
1 Gauge bar 40/54 050.096 Standard
1 Gauge bar 48/60 050.095 Standard
1 Gauge bar 58/64 050.094 Standard
1 Micrometer (inside) 32/40 050.038 Optional
1 Micrometer (inside) 40/54 050.002 Optional
1 Micrometer (inside) 48/60 050.062 Standard
1 Micrometer (inside) 58/64 050.107 Standard

Preliminary remarks

Cylinder liners are not worn out completely evenly on the circumference
and along the running face. The wear values are limited and that for both
the ovality and the maximum wear. This way, sealing problems and
overloading of the piston rings are to be avoided.
Regular checks provide a basis for optimising the operating conditions and
for decisions concerning a possible replacement of the cylinder liner.

Operating sequence 1 - Measure the cylinder liner

Starting condition Cylinder head, top land ring (if existing) as well as piston and connecting
rod removed. Cylinder liner thoroughly cleaned, especially in the upper
area and in the area of the gauge bar stop, on the top face.

6682 050.02--01 E 04.98 32/40, 40/54, 48/60, 58/64 101/ 03

Steps 1. Insert the gauge bar in the cylinder liner. See Figure 1. The
measuring bar is held magnetically on the running face and on the
top face of the collar. The number and positions of the measuring
points are fixed by means of the bores in the bar.
Important! Measuring point 1 is only relevant for cylinder liner
designs without top land ring. For measuring, the spacer (8) is to be
removed. For cylinder liner designs with top land ring, measuring is
started at measuring point 2.
2. Heat up the inner screw gauge to the temperature of the cylinder liner
and insert one after the other in the bores of the gauge bar.
Determine the dimensions in longitudinal direction of the engine and
transversely to it and note them down.
3. Determine the temperature of the cylinder liner during measurement
and note it down.
4. Enter dimensions in engine log book and compare with the max.
permissible values (refer to operating manual, Section 2.5).
▲ Attention! In case the values measured exceed the max.
permissible values for wear or ovality, the cylinder liner must be
renewed.
The wear is the difference from the values measured minus nominal
dimension. The ovality is the difference from the values measured (in
transverse and in longitudinal direction) of each plane.

1-6 Measuring point

7 Knurled screw
8 Spacer
9 Cylinder liner
10 Gauge bar
11 Inner screw gauge

Figure 1. Measuring the cylinder liner

6682 050.02--01 E 04.98 32/40, 40/54, 48/60, 58/64 102/ 03

 Cylinder diameter (mm)

Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

M
Measuring
i plane
l trans- longitu- trans- longitu- trans- longitu- trans- longitu- and
d so
verse dinal verse dinal verse dinal verse dinal on
1 -- --
2 580.82 580.75
3 580.76 580.60
4 580.30 580.30
5 580.20 580.20
6 580.83 580.75
Cylinder liner
temperature during 30ƒ &
measuring
Condition of running perfect
surface
Table 1. Measuring log (example: L 58/64 engine)

6682 050.02--01 E 04.98 32/40, 40/54, 48/60, 58/64 103/ 03

.
Cylinder liner (with backing ring)
Removing and installing 050.03

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Cylinder liners are to be removed and cleaned at regular intervals.

The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Qty Denomination No. Availability

1 Suspension device 050.157 Standard
1 Support 050.157--1 Standard
3 Retaining clamp 050.157--3 Standard
1 Fitting/unfitting tool 050.099 Standard
1 Support 050.099--1 Standard
2 Thrust bolt 050.099--15 Standard
1 Pilot rod 034.006 Standard
1 Shackle A1.6 002.454 Standard
2 Shackle A0.6 002.452 Standard
2 Eye bolt M20 000.155 Standard
1 Open--jaw and ring wrench (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

034.01 050.02

6629 050.03--04 E 09.98 32/40 101/ 04

Technical details

Term Information
Cylinder liner 172.5 kg
Cylinder liner (with backing ring) 407.5 kg
Backing ring 233.5 kg

Preliminary remarks

Wear condition and ovality are to be determined, the running surface

appearance is to be assessed, the internal and exterior surfaces and the
oil bores are to be cleaned, and the sealing rings to be renewed. This
work provides information that is essential for system operation, and
contributes to ensuring operational reliability.
Cylinder liners are usually pulled without dismantling the backing ring.
They have only to be dismantled together if the backing ring is to be
replaced or if better accessibility is required.

1 Cylinder head bolt

2 Rope
3 Hexagon head bolt
M16x35
4 Backing ring
5 Crankcase
6 Cylinder liner
7 O-ring seal
8 Sleeve
9 O-ring seal
10 O-ring seal
11 Sleeve

A Control bore for

cooling water leakage

Figure 1. Removal and installation of the cylinder liner (with backing ring) - illustration shows in-line engine

Operating sequence 1 - Removal of the cylinder liner/dismantling of the backing ring

Starting condition Big-end bearing attached to balance weight by means of turning stirrup,
piston with connecting rod shank dismantled, all the piping and screwed
connections on the backing ring removed.

Steps 050.02.
1. Clean and measure the cylinder liner (6) - see work card 050.02
2. Screw back the thrust bolts (050.099-15) in the support (050.099-1).

6629 050.03--04 E 09.98 32/40 102/ 04

 3. Attach the support to the backing ring by means of hexagon head
bolts (3), making sure that the branch socket for the pilot rod
(034.006) is on the exhaust counter side. Figure 1.
4. Screw the thrust bolts up to the cylinder liner top edge to avoid that
the backing ring (if loose) drops down as the pulled-out cylinder liner
is put down.
5. Suspend the rope (2) in shackle (002.454) and lifting tackle and
attach the shackle to the support (depending on the type of engine,
choose correct suspension point). Screw the pilot rod into the branch
socket on the support.
6. Cover the crankcase by appropriate means, especially on the sides,
so as to prevent the penetration of dirt from the cooling spaces into
the big-end and main bearings.
7. Pull the cylinder liner and backing ring upward out of the crankcase in
parallel with the cylinder centre line, guiding the cylinder liner with the
pilot rod.
▲ Attention! When removing the cylinder liner, take care not to
damage the cylinder head bolts.

6 Cylinder liner
16 Hexagon head bolt
M8x20

Figure 2. Suspending the cylinder liner

8. Put the cylinder liner and backing ring down onto a wooden pad.
9. Screw two eye bolts (000.155) into the backing ring.
10. Detach the shackle from the support. Unhook the rope and attach it
to the eye bolts by means of shackles. Tension the rope.
11. Screw two thrust bolts back by a few turns, slightly slacken the lifting
tackle and work the backing ring loose by careful knocking (use a
wood or copper rest).
12. Detach the support and lower the backing ring onto a wooden pad.
13. Suspend rope in shackle (002.452) and lifting tackle, and attach the
shackle to the support (050.157-1).
14. Lower the support (050.157-1) onto the cylinder liner and attach it to
the cylinder liner (6) by means of retaining clamp (050.157-3) and
hexagon head bolts (16) - Figure 2.
15. Lift the cylinder liner out of the backing ring and put it down onto a
wooden pad.
16. Clean cylinder liner and backing ring.

Operating sequence 2 - Installation of the cylinder liner

Starting condition Cylinder liner thoroughly cleaned on the inside and outside. Cylinder liner
measured on the inside (deep scoring of the piston running surface, or
excessive wear call for a replacement of the cylinder liner, especially if the
maximum admissible wear has been reached in the area of the top
compression ring at TDC or ovality has become excessive; refer to
operating manual, Section 1). Lube oil bores purged, sealing faces
thoroughly cleaned, without defects. Crankcase covered by appropriate
means. Cylinder liner standing in the backing ring.

Steps 1. Lubricate new O-ring seals (7) with acid-free grease and insert them
in the ring grooves making sure that they are evenly tensioned over
the whole circumference, and not distorted.

6629 050.03--04 E 09.98 32/40 103/ 04

 2. Attach the rope to two eye bolts (000.155) by means of shackle
(002.452) and suspend rope from lifting tackle.
3. Pull the backing ring (4) over the cylinder liner (6) from below, taking
note of the O-ring seals.
▲ Attention! Ensure correct position of marking (M) backing
ring/cylinder liner (refer to Figure 3).
4. Screw back the thrust bolts (050.099-15) in the support (050.099-1).
5. Fasten support to backing ring by means of hexagon head bolts (3)
and screw two thrust bolts up to the cylinder liner top edge.
Tip! When placing the support on the backing ring make sure that the
branch socket for the pilot rod is on the exhaust counter side (AGS).
6. Detach the rope from the eye bolts.
7. Suspend rope in shackle (002.454) and attach shackle to support.
Screw the pilot rod (034.006) into support.
8. Carefully introduce the backing ring with cylinder liner into crankcase
(5), guiding the cylinder liner by means of the pilot rod.
▲ Attention! Ensure correct position of backing ring relative to
sleeves (8). Take care not to damage cylinder head bolts (1) during
installation.
9. Dismount the tool, remove the covering of the crankcase.
10. Measure the cylinder liner.
11. Mount the pipes and the screwed connections.
12. On completion of assembly work (cylinder head in place, cylinder
head bolts tensioned) and with the proper cooling water system
pressure built up, check whether O-ring seals are in order and make
sure that no water leaks from the control bores (A).
▲ Attention! If a new cylinder liner has been installed, this has to
be run in as specified (refer to operating manual, Section 3).

3 Hexagon head bolt

M16x35
4 Backing ring
6 Cylinder liner
11 Sleeve
13 Disk
14 Hexagon head bolt
15 Sleeve

AGS Exhaust counter side

M Marking backing ring/
cylinder liner

Figure 3. Suspending the backing ring, marking backing ring/cylinder liner

6629 050.03--04 E 09.98 32/40 104/ 04

Cylinder liner (without backing ring)
Removing and installing 050.04

Purpose of jobs to be done

Carry out work in time according to maintenance schedule,

measure components,
assess wear pattern/condition.

Brief description

Cylinder liners are to be removed and cleaned at regular intervals.

The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

2 Spacer pipe 050.133 Standard
1 Fitting/unfitting tool 050.129 Standard
1 Cross tie 050.129--1 Standard
1 Support (upper) 050.129--5 Standard
1 Support (lower) 050.129--12 Standard
1 Spindle (short) 050.129--21 Standard
1 Spindle (long) 050.129--27 Standard
1 Spherical disk 050.129--33 Standard
1 Ball cup 050.129--34 Standard
1 Suspension device 050.157 Standard
1 Support 050.157--1 Standard
3 Retaining clamp 050.157--3 Standard
1 Shackle A0.6 002.452 Standard
1 Shackle A1.6 002.454 Standard
1 Ring nut M30x3 000.186 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Lifting tackle with rope -- Inventory
2 Wood (for placing underneath) -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

012.03 034.01 050.02

6629 050.04--06 E 12.97 32/40 101/ 04

Technical details

Term Information
Cylinder liner 172.5 kg

Preliminary remarks

On cylinder liners, wear condition and ovality are to be determined, the

running surface appearance is to be assessed, the internal and exterior
surfaces and the oil bores are to be cleaned, and the sealing rings to be
renewed. This work provides information that is essential for system
operation, and contributes to ensuring operational reliability.
Cylinder liners are usually pulled without dismantling the backing ring.
They have only to be dismantled together if the backing ring is to be
replaced or if better accessibility is required.

1 Cylinder head bolt

3 Collar nut M30
4 Backing ring
5 Crankcase
6 Cylinder liner
7 O-ring seal
8 Hexagon nut M30
10 O-ring seal
11 Sleeve
12 Nut

Figure 1. Removal of the cylinder liner (illustration shows in-line engine)

Operating sequence 1 -- Removal of the cylinder liner

Starting condition Piston with connecting rod shank removed, big-end bearing attached to
the balance weight by means of the turning stirrup and turned in such a
way that the cylinder liner is easily accessible from below.

Steps 050.02.
1. Clean and measure the cylinder liner (6) - see work card 050.02
2. Insert the lower support (050.129-12) through the crankcase opening
and place it against the cylinder liner. Figure 1.
▲ Attention! Once the lower support has been fitted, do not turn
the crankshaft.

6629 050.04--06 E 12.97 32/40 102/ 04

 3. Slip the long spindle (050.129-27) into the support and fasten by
means of hexagon nut (8).
4. Slip the upper support (050.129-5) onto spindle, place on cylinder
liner and fasten by means of hexagon nut (8).
5. Screw spindle (050.129-21) onto long spindle, slip cross tie
(050.129-1) over spindle and place on backing ring (4).
Important! When positioning the cross bar, pay attention to the
sleeves (11).
6. Slip ball cup (050.129-34) over spindle and place on cross bar.
7. Grease the spherical disk (050.129-33) and place over the spindle on
the ball cap. Screw on collar nut (3).
8. Slip spacer pipes (050.133) diagonally over cylinder head bolts (1)
and fasten by means of nuts (12).
9. Cover the crankcase by appropriate means, especially on the sides,
to prevent penetration of dirt from the cooling spaces into big-end
bearings and main bearings.
10. By tightening the collar nut, loosen the cylinder liner and pull it
upwards.
▲ Attention! In case of V-type engines, remove cross tie
(050.129-1) and attach shackle to the suspension point of the rib.
11. Screw ring nut (000.186) onto spindle, suspend rope (2) in shackle
(002.454) and lifting tackle and attach shackle to ring nut.
12. Pull the cylinder liner out upwards in parallel with cylinder centre line.
Important! When removing the cylinder liner, pay attention that the
cylinder head bolts are not damaged.
13. Put cylinder liner down onto wooden pad.
14. Detach the tools.

6 Cylinder liner
16 Hexagon head
boltM8x20

Figure 2. Suspending the cylinder liner

15. For further transport, suspend the rope in shackle (002.452) and
lifting tackle and fasten shackle to support (050.157-1). Figure 2.
16. Lower the support onto the cylinder liner (6) and fasten to cylinder
liner by means of retaining clamp (050.157-3) and hexagon head
bolts (16). Figure 2.
17. Clean the cylinder liner.

Operating sequence 2 -- Installation of the cylinder liner

Starting condition Cylinder liner thoroughly cleaned internally and externally. Cylinder liner
measured on inside (deep scoring in the piston running surface or
excessive wear call for replacement of the cylinder liner, especially if the
maximum admissible wear has been reached in the area of the top
compression ring at TDC, or ovality has become excessive). Lube oil
bores purged, sealing faces thoroughly cleaned and without defects.
Crankcase covered by appropriate means. Cylinder liner standing on
wooden pads, lower support (050.129-12) inserted in cylinder liner.

6629 050.04--06 E 12.97 32/40 103/ 04

Steps 1. Lubricate new O-ring seals (7) with acid-free grease and fit in ring
grooves, making sure that they are evenly tensioned over the entire
circumference, and not distorted.
2. Slip the long spindle (050.129-27) into support and fasten by means
of hexagon nut (8). Figure 3.

1 Cylinder head bolt

2 Rope
4 Backing ring
5 Crankcase
6 Cylinder liner
8 Hexagon nut M30
10 O-ring seal
11 Sleeve

A Control bore for

cooling water leakage

Figure 2. Installation of the cylinder liner (illustration shows in-line engine)

3. Place the upper support (050.129-5) over spindle onto cylinder liner
(6) and fasten by means of hexagon nut (8).
▲ Attention! In case of V-type engines, fasten shackle to
suspension point of rib.
4. Screw ring nut (000.186) onto spindle, suspend rope (2) in shackle
(002.454) and lifting tackle, and attach shackle to ring nut. Lift the
cylinder liner.
5. Carefully insert cylinder liner in backing ring (4) and crankcase (5).
Important! When fitting the cylinder liner, pay attention to the
correct position of marking (M) backing ring/cylinder liner and make sure
that cylinder head bolts are in order. Figure 4.
6. Remove the tool.
7. Take the covering out of the crankcase.
8. Measure the cylinder liner.
9. On completion of assembly work (cylinder head in place, cylinder
head bolts tensioned) and with the appropriate cooling water system
pressure built up, verify that O-ring seals are in order and water does
not leak from control bore (A).
▲ Attention! If a new cylinder liner has been installed, it is to be
run in as specified (see operating manual, Section 3).

4 Backing ring
6 Cylinder liner
11 Sleeve
13 Washer
14 Hexagon head bolt
15 Sleeve

AGS Exhaust counter side

M Marking backing ring/
cylinder liner

Figure 3. Marking on backing ring and cylinder liner for correct installation

6629 050.04--06 E 12.97 32/40 104/ 04

Cylinder head/Saftey valve

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

6682 055...--02 E 04.98 101/ 01

.
Cylinder head bolts
Checking, untightening and tightening 055.01

Purpose of jobs to be done

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

ensure operational reliability of bolted connections.

Brief description

Cylinder head bolts are to be checked at regular intervals by means of

hydraulic tensioning tools.
The work/steps include:
checking bolted connection,
untightening,
tightening.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

2 Tension screw 055.157 Standard
2 Thrust pad 055.156 Standard
2 Thrust pad 030.243 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
4 High--pressure hose 009.306 Standard
2 Hydraulic tensioning tool 009.097 Standard
2 Hydraulic tensioning tool 009.096 Standard
1 Tommy bar, 10 mm 000.263 Standard
1 Open--jaw and ring wrenches (set) -- Standard

6629 055.01--02 E 05.01 32/40 101/ 04

Related work cards

Work card Work card Work card

000.30 009.01 009.03

Operating sequence 1 -- Check the cylinder head bolts

Starting condition Protecting caps removed from the cylinder head bolts of the respective
cylinder. Cylinder head cover (5) removed.

Steps 1. Clean the threads of cylinder head bolts (4).

2. Screw the tension screws (055.157) all the way onto the cylinder
head bolts on the exhaust side (refer to Figure 1 ).
3. Slip thrust pads (055.156) over tension screws.
4. Screw hydraulic tensioning tool (009.096) onto tension screws, noting
centricity of hydraulic tensioning tool/thrust pad.
5. Slip thrust pads (030.243) over the cylinder head bolts on the exhaust
counter side.
6. Screw hydraulic tensioning tool (009.097) onto cylinder head bolts,
noting centricity of hydraulic tensioning tool/thrust pad.
▲ Attention! Prior to mounting the hydraulic tensioning tools,
make sure that pistons have been fully reset.
7. Turn the hydraulic tensioning tool back by 530ƒ .
8. Connect high-pressure hoses (009.306) to hydraulic tensioning tool
and high-pressure pump (009.338) or hydraulic hand pump
(009.320).
9. Switch the high-pressure pump or the hydraulic hand pump on (see
009.03), and close the gap produced between the thrust
work card 009.03
pads and hydraulic tensioning tool by turning the hydraulic tensioning
tool back.
10. Pump up the hydraulic tensioning tool until nuts (3) can be loosened.
▲ Attention! The pressure is permitted to be max. 7% below and
max. 5% above the specified tensioning pressure
(refer to work cards 000.30 and 000.33).
000.33
Note down the loosening pressure and compare it with the specified ten-
sioning pressure.
11. Adjust the high-pressure pump to the specified tensioning pressure or
actuate the hydraulic hand pump until the specified tensioning pres-
sure has been reached, and re-tighten the nuts.
12. Release the pressure and remove the hydraulic tensioning tools.
13. Put the protecting caps onto the cylinder head bolts.
14. Cylinder head cover.
15. Reset the pistons of the hydraulic tensioning tools (see work card
009.01).
009.01

Operating sequence 2 -- Untighten the cylinder head bolts

Starting condition Protecting caps removed from the cylinder head bolts of the respective
cylinder.
1. Mount hydraulic tensioning tools on cylinder head bolts (4), and
loosen nuts (3) - see Operating sequence 1, points 1 to 10.
2. Turn back the nuts (for angular amount of turning back, see work
card 000.30).

6629 055.01--02 E 05.01 32/40 102/ 04

 3. Release the pressure, and remove the hydraulic tensioning tools.
4. Reset the pistons of the hydraulic tensioning tools (see work card
009.01).
009.01

1 Cylinder head
2 Fixing bolt
3 Nut
4 Cylinder head bolt
5 Cylinder head cover

AGS Exhaust counter side

Figure 1. Fitting the hydraulic tensioning tools on the cylinder head bolts
Operating sequence 3 -- Tighten the cylinder head bolts

Starting condition Cylinder head in place, nuts screwed onto cylinder head bolts.

Steps 1. Screw down nuts (3) of cylinder head bolts (4), hand-tight, using
tommy bar (000.263).
2. Screw tension screws (055.157) all the way onto the cylinder head
bolts on the exhaust side (refer to Figure 1 ).
3. Slip thrust pads (055.156) over tension screws.
4. Screw hydraulic tensioning tool (009.096) onto tension screws, noting
centricity of hydraulic tensioning tool/thrust pad.
5. Slip thrust pads (030.243) over cylinder head bolts on the exhaust
counter side.
6. Screw the hydraulic tensioning tool (009.097) onto the cylinder head
bolts, observing centricity of hydraulic tensioning tool/thrust pad.
▲ Attention! Prior to mounting the hydraulic tensioning tools,
make sure that the pistons have been fully reset.
7. Connect high-pressure hoses (009.306) to hydraulic tensioning tool
and high-pressure pump (009.338) or hydraulic hand pump
(009.320).
8. Switch the high-pressure pump or hydraulic hand pump on (see work
card 009.03), and load the cylinder head bolts to the specified ten-

6629 055.01--02 E 05.01 32/40 103/ 04

 sioning pressure (see work card 000.30
000.30). Screw the nuts down, hand-
tight, using the tommy bar.
9. Release the pressure and remove the hydraulic tensioning tools.
10. Slip protecting caps onto the cylinder head bolts.
11. Reset the pistons of the hydraulic tensioning tools (see work card
009.01).
009.01

6629 055.01--02 E 05.01 32/40 104/ 04

Cylinder head
Removing and refitting 055.02

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Cylinder heads are to be disassembled within the scope of maintenance

and repair work.
The work/steps consist of:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Suspension device 055.205 Standard
1 Support 055.205--1 Standard
1 Pilot rod 034.006 Standard
1 Shackle A1.6 002.454 Standard
1 Lifting tackle with rope -- Inventory
1 Open--jaw and ring wrenches (set) -- Standard
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

055.01 111.01 434.01

Technical details

Term Information
Cylinder head, complete 750 kg
Cylinder head 525 kg

6629 055.02--03 E 07.01 32/40 101/ 04

 1 Hexagon bolt M20x405
2 Hexagon bolt M20x190
16 Cylinder head
17 Charge air pipe section

Figure 1. Cylinder head with attached suspension device

Operating sequence 1 -- Removal of the cylinder head

Starting condition Cooling water in the engine drained to a level below the cylinder heads,
cooling water of injection valves completely drained.

Important! Do not pass cooling water into bilge or waste water.

Pump cooling water into separate container to reuse it (cooling water addi-
tives).

5 Cylinder head bolt

6 Nut
7 O-ring seal
8 Stud
9 Exhaust pipe
10 Sleeve
11 O-ring seal
12 Top land ring
13 Backing ring
14 Sealing ring
15 O-ring seal
16 Cylinder head
17 Charge air pipe section
18 Screw plug

Figure 2. Cylinder head

6629 055.02--03 E 07.01 32/40 102/ 04

 Cocks in the fuel oil pipes closed. Shut-off valve on the compressed air
tank closed, starting air pipes without pressure.
Running gear turned to a position at which piston of the respective cylinder
is at ignition TDC, cylinder head cover removed, cylinder head bolts un-
loaded, push-rods removed.

Steps 1. Remove all pipes and pipe fixtures from the respective cylinder head.
2. Partly remove the covering of the exhaust pipe.
3. Open the clamp on the exhaust pipe connection.
4. Unscrew the screw plug (18), and drain condensed water from the
charge air pipe (17). Screw the screw plug in again (refer to Fig-
ure 2 ).
5. Loosen the pipe couplings on the charge air pipe section (17) and
shift them.
6. Remove the delivery pipe from the injection pipe (see work card
434.01).
434.01
7. Detach the starting air pipe from the starting valve
161.01).
(see work card 161.01
8. Unscrew the nuts (6).
9. Put the support (055.205-1) onto the cylinder head (16), and fasten it
in place by means of hexagon bolts (1 and 2).
10. Attach the rope to the support by means of shackle (002.454), and
suspend it from the lifting tackle.
Important! Make sure to use the correct suspension point (refer to
Figure 1 ).
11. Screw the pilot rod (034.006) into the support.
12. Lift the cylinder head off, guiding it by means of the pilot rod, and put
it down onto a wooden support.
▲ Attention! Do not damage the cylinder head bolts (5) and the
studs (8).
13. Cover all openings on the engine using appropriate means. Close
the exhaust pipe connection by means of the closing cover.
055.03).
14. Clean the cylinder head (see work card 055.03

Operating sequence 2 -- Fitting the cylinder head

Starting condition Cylinder head cleaned, sealing faces between cylinder head and top land
ring as well as between cylinder head and exhaust pipe cleaned. All
covers removed.

11 O-ring seal 20 O-ring seal

13 Backing ring 21 Push-rod
16 Cylinder head 22 Sleeve
19 Sleeve

Figure 3. Connecting sleeves between cylinder head and backing ring

Steps 1. Check the sealing ring (14); replace it it necessary.

6629 055.02--03 E 07.01 32/40 103/ 04

 2. Dismantle the sleeves (10 and 22), remove both O-ring seals (11),
and insert new O-ring seals, which have been coated with acid-free
grease, in the ring grooves, making sure that they are evenly ten-
sioned over the whole circumference, and not distorted. Install the
sleeves (refer to Figures 2 and 3 ).
3. Put the support (055.205-1) onto the cylinder head (16), and fasten it
in place by means of hexagon bolts (1 and 2).
4. Attach the rope to the support by means of shackle (002.454), and
suspend it from the lifting tackle.
5. Screw the pilot rod (034.006) into the support.
6. Insert new O-ring seals (7 and 20), which have been coated with
acid-free grease, into the ring grooves, making sure that the O-ring
seals are evenly tensioned over the whole circumference, and not
distorted.
7. Move the cylinder head over the centre of the cylinder, and lower it,
guiding it by means of the pilot rod.
▲ Attention! Do not damage the studs (8) and cylinder head bolts
(5); pay attention to the position of the sleeves (10, 19, and 22).
8. Screw the nuts (6) onto the cylinder head bolts (5).
9. Slide the pipe couplings over the charge air pipe section (17) and
fasten them in place.
10. Mount the exhaust pipe on the cylinder head and fit the covering.
11. Attach the delivery pipe of the injection pipe (see work cards 221.01
434.01).
and 434.01
12. Fit all pipes and pipe fixtures to cylinder head and starting valve.
13. Tension the cylinder head bolts, applying the specified tensioning
055.01).
pressure (see work card 055.01
14. Check the valve clearance, newly adjusting it if necessary (see work
111.02).
card 111.02
15. Top up the cooling water in the cylinder head and injection valve cool-
ing system, remove air from the cooling water pipes.
16. Open all cocks, which have previously been closed.
Important! In case the cylinder head is untight in spite of correctly
loaded cylinder head bolts, it has to be removed again, and the sealing
ring has to be checked.

6629 055.02--03 E 07.01 32/40 104/ 04

Cylinder head
Cleaning 055.03

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Cylinder heads have to be cleaned from soot and coke deposits at regular
intervals.
This includes:
cleaning of components

Personnel and time required

Numb Qualification Time [h]

1 Assistant 1

Tools/appliances required

Qty Designation No. Availability

1 Degreasing and cold cleaning agent -- Inventory
1 Cleaning trough -- Inventory
1 Wire brush -- Inventory
1 Safety goggles -- Inventory
1 Protective gloves -- Inventory

Related work cards

Work card Work card Work card

000.08 055.02 113.01

Operating sequence -- Cleaning the cylinder head

Starting condition Cylinder head dismounted, rocker arm casing and charge air pipe section
dismantled, inlet and exhaust valves removed.

6629 055.03--02 E 03.02 32/40 101/ 02

Figure 1. Sectional view of a cylinder head dismounted

Steps 1. Check inlet and outlet ducts as well as the combustion chamber side
with regard to deposits, and clean these away, taking care not to
damage the surfaces in the process.
2. Check the cooling spaces for deposits, and remove any deposits
found (see work card 000.08).
000.08
3. Clean the cylinder head top from oil sludge.
4. Install the inlet and exhaust valves (see work card 113.01).
113.01

6629 055.03--02 E 03.02 32/40 102/ 02

Sealing face on cylinder head
and sealing groove in top land ring
Grinding 055.04

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

The sealing face on the cylinder head and the sealing groove in the top
land ring are to be checked every time the cylinder head is removed, and
remachined if necessary.
The work includes:
grinding of the sealing face and the sealing groove.

Tools/appliances required

Quant Denomination No. Availability

1 Grinding tool 050.119 Optional
1 Grinder 050.119--1 Optional
2 Bow 050.119--2 Optional
1 Shackle A0.6 002.452 Standard
1 Eye bolt M12 000.142 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Depth gauge -- Inventory
1 Grinding paste (silicon--free) -- Inventory

Related work cards

Work card Work card Work card

050.01 055.02 055.05

Preliminary remarks

Important! This grinding tool can be used for the cylinder head and
top land ring. The correct side for each case is shown in Figure 1.

After the sealing face or sealing groove has been remachined, the gap (A)
between the cylinder head and top land ring should be not less than 0.5
mm (refer to Figure 2 in the Section ”Operating sequence”).

6629 055.04--01 E 08.97 32/40 101/ 03

 1 Hexagon head bolt 2 Cylinder head B Sealing face
M12x25 3 Top land ring C Sealing groove

Figure 1. Grinding the sealing face on the cylinder head (figure on the left) and the sealing groove in the top land ring (figure on
the right)

Operating sequence 1 -- Grind the sealing face on the cylinder head and/or sealing groove in the top
land ring

Starting condition Cylinder head dismantled and mounted in reversing jig. Top land ring
dismantled, sealing ring taken out.

Steps 1. Attach the bow (050.119-2) to grinding wheel (050.119-1), bearing in

mind whether the sealing face (B) or the sealing groove (C) are to be
ground.
2. Apply grinding paste to grinding wheel.
Tip! Do not apply excessive amount of grinding paste.
3. Place the grinding tool onto the sealing face or into the sealing
groove, refer to Figure 1.
Tip! Possibly use shackle (002.452) to attach grinding tool to rope and
place it on cylinder head or top land ring using the lifting tackle.
4. Exercise a turning, reciprocating motion with the grinding tool and lift
it inbetween so as to permit the grinding paste to redistribute.
Important! Do not grind off more material than required to leave
the sealing face and / or sealing groove bright and free of damage over the
full width; therefore, inspect the sealing face or sealing groove several
times during the grinding process.

6629 055.04--01 E 08.97 32/40 102/ 03

 5. On completion of the grinding, take the grinding tool (050.119) off and
clean the sealing face and/or sealing groove carefully.
6. Determine the gap (A) between the cylinder head (2) and the top land
ring (3) by differential measuring on several points.
Minimum gap with: 0.5 mm

2 Cylinder head
3 Top land ring
4 Sealing ring
5 Cylinder liner
6 Supporting ring

A Gap

Figure 2. Gap between the top land ring and the cylinder liner with the sealing ring
fitted

6629 055.04--01 E 08.97 32/40 103/ 03

.
Cylinder head with turnover stand
Machining 055.05

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

On cylinder heads, various jobs are to be carried out at regular intervals.

For this purpose, the turnover stand is to be used.
The work includes:
clamping of components.

Tools/appliances required

Quant Denomination No. Availability

1 Turnover stand 055.153 Optional
1 Open--jaw and ring spanner (set) -- Standard

1 Frame of turnover stand 6 Turning shaft axle 11 Exhaust valve

2 Adapter plate 7 Arresting lever 12 Inlet valve
3 Turnover gear 8 Cylinder head 13 Receptacle
4 Receiver head 9 Adapter plate 14 Envelope circle (cylinder
5 Fastening bracket 10 Locking bar head with valves)

Figure 1. Cylinder head clamped into the turnover stand

6629 055.05--01 E 07.97 32/40 101/ 02

General

The turnover stand is suitable for:

- thorough cleaning and checking of cylinder heads (cf. work card
055.03),
055.03
- grinding of valve seat faces in the cylinder head,
- checking of valve seats (cf. work card 113.03
113.03),
- measuring of inlet and exhaust valve seat faces,
- removing and installing the valve seat rings in the cylinder head (cf.
work card 113.04).
113.04

Operating sequence 1 -- Clamping of cylinder head

Starting condition Cylinder head suspended on lifing tackle with suspension device.

Steps 1. Fasten adapter plates (2 and 9) to cylinder head (8).

2. By turning hand wheel on turnover gear (3), position receiver head (4)
so that fastening bracket (5) is situated on top (see illustration).
3. Open fastening bracket and locking bar (10).
4. Place cylinder head (see illustration) and clamp it tight, using
fastening bracket. Lock the locking bar.
5. Remove suspension device. With the arresting lever (7) folded up,
the cylinder head may now be moved to any desired position by
turning the hand wheel (arresting is possible in every 45--degree
position).
▲ Attention! When working on the cylinder head, it is absolutely
necessary to engage arresting lever into one of the grooves in the
receiver head (4).
6. The adapter plates may be stored by fastening them to the frame (1).

6629 055.05--01 E 07.97 32/40 102/ 02

Dead centre indicator/
Speed pick-- up

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

6682 071--01 E 04.98 101/ 01

.
Speed pick-- up
Checking, removing and installing 071.01

Purpose of jobs to be done

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

free components from fouling or residues,
ensure/restore operational reliability.

Brief description

Speed pick--ups are to be checked at regular intervals and to be replaced,

if necessary.
The work/steps include:
removal of components,
checking of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Power supply/generation interrupted

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.2

Tools/appliances required

Qty Designation No. Availability

1 Feeler gauge (set) 000.451 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Screw drivers (set) -- Standard

6629 071.01--02 E 03.00 32/40 101/ 03

Operating sequence 1 -- Checking the speed pick-ups

Starting condition Engine shut off.

Steps 1. Check the cables (8) to the speed pick-ups (3).

2. Turn the crankshaft (1) with the flywheel (2) in such a way that the
front side of one tooth coincides with the centre of the speed pick-up.
3. Measure the distance (F) between the front side of the tooth and the
speed pick-up using the feeler gauge (000.451).
Distance (F) = 1.0 ... 3.0 mm.
4. Check the remaining speed pick-ups the same way.
Important! Engines without slow-turn device are equipped with one
speed pick-up less.

2 Flywheel 9 Terminal box A 1SE for engine dependent

3 Speed pick-up 10 Cylinder crankcase control (alarm)
4 Retainer B 2SE for engine dependent
5 Hexagon nut control (safety)
7 Dead centre indicator F Gap between C 3SE for speed governor
8 Cable flywheel and D 4SE for speed governor
speed pick-up E 5SE for slow turn

Figure 1. Speed pick-up with dead centre indicator

Operating sequence 2 -- Removing and installing a speed pick-up

Starting condition Engine shut off and cooled down to room temperature.

Steps 1. Remove the plug (11) of the respective speed pick-up (3).
2. Turn the crankshaft (1) with the flywheel (2) in such a way that the
front side of one tooth coincides with the centre of the speed pick-up.
3. Screw the hexagon nuts (5) out of the respective speed pick-up and
pull the speed pick-up out of the retainer (4).
4. Screw the hexagon nut off the new speed pick-up.

6629 071.01--02 E 03.00 32/40 102/ 03

 5. Install the speed pick-up in the retainer (4) by means of hexagon nuts
(5) - refer to Figure 1 .
6. Insert the feeler gauge (000.451) with distance (F) between the front
side of the tooth and the speed pick-up.
7. Screw the hexagon nuts (5) in alternately until the feeler gauge fits
snugly.

1 Crankshaft
2 Flywheel
3 Speed pick-up
7 Dead centre indicator
8 Cable
9 Terminal box
10 Cylinder crankcase
11 Plug

Figure 2. Speed pick-up with dead centre indicator

8. Tighten the hexagon nut (5), paying attention to the speed pick-up.
Important! After the final tightening of the hexagon nuts (5), the gap
dimension (F) is to be checked once again.
9. Check for proper performance.

6629 071.01--02 E 03.00 32/40 103/ 03

.
Crankcase cover/Saftey valve/
Coverings

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

6682 073--02 E 04.98 101/ 01

.
Safety valve on the crankcase cover
Checking 073.01

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Safety valves on the crankcase covers are to be examined for ease of

motion at regular intervals.
The work includes:
Check of components.

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard

Related work cards

Work card Work card Work card

073.02

Technical details

Term Information
Crankcase cover with safety valve 16.5 kg

Preliminary remarks

Checking all the safety valves mounted on the crankcase for ease of
motion is to ensure that pressure increases/pressure waves occurring, e.g.
after explosions, can be safely controlled.

▲ Attention! When alarm has been signalled or the engine has

been stopped because of excessive bearing temperatures or oil mist
concentration, open the crankcase 10 minutes after at the earliest.
There is the danger of explosions upon access of oxygen because
components that have run hot and the operating media surrounding
them may be at ignition temperature.

6629 073.01--01 E 07.97 32/40 101/ 02

Operating sequence 1 -- Check the safety valve

Steps 1. Unscrew the hexagon nuts (2), remove washers (3) and the
crankcase cover (8).
2. Verify that safety valve (4) is in good condition and moves easily;
073.02) and clean it, if necessary.
disassemble (see work card 073.02
3. Check the valve plate (6), the compression spring (5) and O--ring seal
(7) for damage; disassemble the safety valve if necessary (see work
card 073.02)
073.02 and replace parts.
4. Check the sealing ring (1) for damage and replace if necessary.
5. Mount the crankcase cover and fix it in place by means of hexagon
nuts and washers.

1 Sealing ring
2 Hexagon nut
3 Washer
4 Safety valve
5 Compression spring
6 Spring cup
7 O--ring seal
8 Crankcase cover
9 Crankcase

Figure 1. Safety valve mounted to crankcase cover

6629 073.01--01 E 07.97 32/40 102/ 02

Safety valve on the crankcase cover
Disassembling and assembling 073.02

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Safety valves are to be disassembled if damage on components have

been found during checking.
The work/steps include:
disassembly of components,
assembly of components.

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard
1 Hexagon screw driver (set) -- Standard

Related work cards

Work card Work card Work card

073.01

Technical data

Term Information
Safety valve 6.5 kg

Operating sequence 1 - Disassemble the safety valve

Starting condition Crankcase cover with safety valve removed.

Steps 1. Unscrew the hexagon head bolts (18) and remove safety valve from
the crankcase cover (8).
2. Unscrew the hexagon nuts (15), holding position of countersunk bolts
(14).
3. Remove the cap (11), compression spring (5), flame shields (12),
spring plate (6) and spacer pipe (17), and spring plate (13).
4. Clean all these individual components.
5. Check all parts for damage, and replace if necessary.

6629 073.02--01 E 07.97 32/40 101/ 02

 Important! When replacing the O-ring seal (7), make sure to glue
the new one into the ring groove.

Operating sequence 2 - Assemble the safety valve

Starting condition All the parts have been cleaned, damaged parts replaced.

Steps For assembly of the safety valve, proceed in the reverse order of
disassembly. When fitting hexagon nuts or bolts, new washers should be
used as a matter of principle.

5 Compression spring
6 Upper spring plate
7 O-ring seal
8 Crankcase cover
10 Seal
11 Cap
12 Flame shields
13 Lower spring plate
14 Countersunk bolt
15 Hexagon nut
16 Washer
17 Spacer pipe
18 Hexagon head bolt
19 Washer
20 Sealing plate

Figure 1. Showing safety valve mounted to crankcase cover.

6629 073.02--01 E 07.97 32/40 102/ 02

Camshaft drive

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

6682 100--02 E 04.98 101/ 01

.
Studs for intermediate wheel axles
Checking 100.01

Purpose of jobs to be done

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

ensure operational reliability of bolted connections.

Brief description

Studs for intermediate wheel axles are to be checked at regular intervals

by means of hydraulic tensioning tools.
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Tools/appliances required

Quant Denomination No. Availability

2 Thrust pad 030.243 Standard
2 Tension screw 021.251 Standard
2 Intermediate ring 021.250 Standard
1 High--pressure pump 009.338 Optional
1 Hydraulic hand pump 009.320 Standard
4 High--pressure hose 009.306 Standard
2 Hydraulic tensioning tool 009.097 Standard
2 Hydraulic tensioning tool 009.096 Standard
1 Tommy bar 10 000.263 Standard
1 Open--jaw and ring spanner (set) -- Standard

Related work cards

Work card Work card Work card

000.30 000.32 009.01
009.03

Operating sequence 1 -- Check the fixing bolts

Starting condition Crankshaft outboard bearing removed, covering at coupling end

dismantled, shifted alongside the engine up to the flywheel, supported on
wooden pad (see Figure 2).

6629 100.01--01 E 11.97 32/40 101/ 04

Steps 1. Screw off the hexagon head bolts (4) and remove washers (6).
Figure 1.
2. Take off the lateral shim (9) on axle (1) for double spur gear.
3. Clean the threads of stud bolts (3).
4. Check on tensioning cylinders (009.096 and 009.097) whether
pistons have been fully reset.
5. Screw the puller bolts (021.251) up to contact with tensioning cylinder
(009.096). Figure 2, left.
6. Slip thrust pads (030.243) over nuts (2) and screw tensioning cylinder
(009.096) until seated.
7. Slip intermediate rings (021.250) over puller bolts and screw
tensioning cylinder (009.097) onto puller bolts until it contacts
intermediate rings.
8. Turn the complete tandem tensioning tool back by 230E.
9. Connect four high-pressure hoses (009.306) to tensioning cylinders
and high-pressure pump (009.338) or hydraulic hand pump
(009.320).
10. Start the high-pressure pump or the hydraulic hand pump on (see
009.03) and close the gap produced between the thrust
work card 009.03
pads and axles (1) by the turning back.
11. Pressurise the tensioning cylinder until nuts come loose.
▲ Attention! The pressure is allowed to be max. 7% below and
max. 5% above the tensioning pressure (refer to work cards 000.30
000.33).
and 000.33
Note down the force required for loosening and compare it with the
tensioning pressure.

1 Axle
2 Nut
3 Stud bolt
4 Hexagon head bolt
5 Washer
6 Disc
7 Spur gear (idler)
8 Double spur gear
(idler)
9 Lateral shim

Figure 1. Detail of camshaft drive (side view)

6629 100.01--01 E 11.97 32/40 102/ 04

 12. Adjust the specified tensioning pressure with the high-pressure pump
or operate the hydraulic hand pump until reaching the specified
tensioning pressure, and screw both nuts hand-tight.
13. Release the pressure and remove the hydraulic tandem tensioning
tools.
14. Slip the lateral shim (9) onto the axle (1) for the double spur gear (8).

6629 100.01--01 E 11.97 32/40 103/ 04

 15. Fasten the discs (6) on the axles by means of hexagon head bolts
(4), fitting new washers (5).
16. Mount the covering (11) at the coupling end, and mount the
crankshaft outboard bearing.
009.01).
17. Reset the pistons of tensioning cylinders (see work card 009.01

1 Axle 7 Spur gear (idler) 10 Flywheel

2 Nut 8 Double spur gear 11 Covering
3 Stud bolt (idler) (at coupling end)

Figure 2. Mounting the hydraulic tandem tensioning tools (right) and sectional view of a tandem tensioning tool mounted in
place (left)

6629 100.01--01 E 11.97 32/40 104/ 04

Camshaft drive
Checking 100.02

Purpose of jobs to be done

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

Brief description

The camshaft drive is to be inspected for changes at regular intervals, the

wear pattern is to be assessed so that sources of disturbances are
recognized and, if necessary, remedied in time.
The work includes:
Check of components.

Tools/appliances required

Quant Denomination No. Availability

1 Thickness gauges 0.05--1 000.451 Standard
1 Open--jaw and ring spanner (set) -- Standard

1 Axle 8 Double spur gear (idler) 13 Crankshaft gear wheel

4 Hexagon head bolt 12 Camshaft gear wheel 14 Crankshaft
7 Spur gear (idler) 15 Spray nozzle

Figure 1. Camshaft drive -- at the right viewed from the coupling end

6629 100.02--01 E 10.97 L 32/40 101/ 02

Operating sequence 1 -- Check the camshaft drive

Tip! We recommend having overhaul work on the camshaft drive done

at a service base or by MAN B&W technicians.

Starting condition Casing cover on camshaft drive removed.

Steps 1. Make visual inspection of all gear wheels, examine the wear pattern.
2. Measure the tooth backlash using thickness gauge (000.451), note
down and compare with the specified values. Refer to the operating
manual, Section 2.5.
3. Check spray nozzles (15) for proper performance, clean with
compressed air if necessary.
4. Check the hexagon head bolts (4) for tightness.

6629 100.02--01 E 10.97 L 32/40 102/ 02

Camshaft/Thrust bearing

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

6682 101...--02 E 04.98 101/ 01

.
Injection camshaft
Camshaft section
Removing and installing 101.10

Purpose of jobs to be done

Ensure that the work is carried out correctly,

properly assemble/adjust components.

Brief description

The removal and installation of camshaft sections does not belong to the
work specified in the maintenance schedule. This is only necessary in
case a repair has to be carried out, and requires a considerable degree of
technical expert knowledge.
The work/steps include:
removing components,
installing components,
recording the measuring values.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Personnel and time required

Numb Qualification Time req.

1 Qualified mechanic 5
1 Assistant 5
1 Engineer 1

Tools/appliances required

Qty Designation No. Availability

1 Torque wrench 008.011 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Hexagon screw driver 10 000.298 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Marking pencil -- Inventory

6629 101.10--01 E 11.99 32/40 101/ 04

Related work cards

Work card Work card Work card

000.30 200.03 200.07

Technical details

Term Information
Camshaft section 45 kg

Preliminary remarks

The replacement of camshaft sections is only necessary in case a damage

occurs, and is to be viewed a mere repair work. Prior to the actual
removal of the damaged camshaft section, some measuring values are to
be recorded and/or determined in order to be able to restore the original
condition during the subsequent installation of the new camshaft section.
In case of engines with IMO certification, the plunger lift is to be readjusted
to the value which is specified in the acceptance report and/or in the IMO
certification. In case the specified adjustment range is not observed, the
certificate becomes invalid.

Operating sequence 1 -- Recording of the actual condition and/or determination of the desired condition

- As far as possible, depending on the damage, determine the actual

condition of the plunger lift at the respective cam (see work card
200.07).
200.07
- Determine the actual condition of the plunger lift of the next cam
(viewed from the camshaft drive).
- Compare the determined values with the ones stated in the acceptance
report and/or IMO certification, and enter them in the engine log book.

Operating sequence 2 -- Removal of a camshaft section

Starting condition Fuel injection pump of the respective camshaft section dismantled.
Engine, as far as possible, turned so that the neighbouring pump drive
rollers reach the respective cam base circle.

Steps 1. Screw out the hexagon socket bolt (4) and dismantle the lube oil pipe
(1) to the thrust bearing.
2. Unscrew the hexagon bolts (2) and remove the thrust bearing of the
injection camshaft (3).
3. Mark the installation position of the camshaft section, using the
marker (e.g. at the greatest cam elevation).
4. Put the rope loop around the camshaft section from the outside or
through the bore of the pump drive, and slightly tighten the rope by
means of the lifting tackle.
5. Loosen the screw connection (7, 8) of the camshaft section (11) and
screw off the hexagon nuts (8).
6. Remove the screw connection (9) of the camshaft section (11).
7. Separate the camshaft by displacement in direction of the thrust
bearing (refer to figure 1, at the bottom), taking care that the

6629 101.10--01 E 11.99 32/40 102/ 04

 camshaft section (11), which is to be removed, is completely pulled
out of the centrings of the bearing rings 10).
8. Remove the camshaft section through the opening in the cylinder
crankcase (5).

1 Lube oil pipe 5 Cylinder crankcase 9 Hexagon bolt

2 Hexagon bolt 6 Fuel injection pump 10 Bearing ring
3 Thrust bearing 7 Hexagon bolt 11 Camshaft section
4 Hexagon socket bolt 8 Hexagon nut 12 Rope

Figure 1. Removal of a camshaft section (illustration shows in-line engine)

Operating sequence 3 -- Installation of a camshaft section

Starting condition The roller of the fuel injection pump drive on the camshaft section
concerned has been checked, if necessary, replaced. For installing a
camshaft section, proceed in the reverse order followed for removal,
paying attention to the following items:

Steps 1. Install the camshaft section, making sure that it is positioned

correctly, and screw-connect it with the injection camshaft, hand-tight.
2. Fit the fuel injection pump (see work card 200.07).
200.07
3. Determine the plunger lift of the new camshaft section
200.03).
(see work card 200.03
4. Compare the determined value with the desired value stated in the
acceptance report and/or the IMO certification.
5. In case the actual value is within the permissible adjustment range,
continue with operating sequence 3, item 8. Otherwise, continue with
item 6.
6. Loosen the screw connections of the camshaft and adjust the relative
position of the camshaft section according to the determined value.

6629 101.10--01 E 11.99 32/40 103/ 04

 7. Determine the plunger lift again (see work card 200.07
200.07). Repeat this
process until the plunger lift is within the permissible adjustment
range.
8. Tighten the screw connections of the camshaft, applying MoS2
lubricant and the specified torque (see work card 000.30
000.30).
9. Determine the plunger lift of the next camshaft section (viewed from
the camshaft drive) in the same way and adjust it.
Important! For adjusting the plunger lift, only loosen the screw
connections of the camshaft section which has been replaced.

5 Cylinder crankcase
6 Fuel injection pump
7 Hexagon bolt
8 Hexagon nut
9 Hexagon bolt
11 Camshaft section
13 Starting cam
Figure 2. Installation of a camshaft section

6629 101.10--01 E 11.99 32/40 104/ 04

Valve/injection camshaft
Thrust bearing
Checking 102.01

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

The thrust bearings of the valve and injection camshafts are to be checked
for damage at regular intervals. The end play is to be established. In the
process, changes/sources of disturbances are to be recognised in time
and eliminated, if needed.
The work includes:
checking components.

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Depth gauge -- Inventory
1 Securing compound -- Inventory
(Loctite 243)
1 Grease (acid--free) -- Inventory

Operating sequence -- Checking the thrust bearing

Steps 1. Dismount the lube oil supply pipe (10) leading to the thrust bearing.
2. Remove the sealing cover (11).
3. Remove the bearing cover (12) including butting disc (14) and clean
the contact faces.
4. Measure projection (A) bearing cover - butting disc at several points
and note it down.
5. Clean the contact face on bearing body (5) and thrust bearing disc
(15), measure projection (B) at several points and note down the
value.
6. Remove the thrust bearing disc.
7. Clean the contact face to shaft (2) and butting disc (16), measure
projection (C) at several points, noting down the value.
8. Calculate the axial clearance from the measurements as per points 4,
5 and 7 and compare with the permissible clearance. Refer to
operating manual, Section 2.5.
9. Remove the butting disc.
10. Clean all individual parts and check for damage, replace if necessary.
11. Attach butting disc (16), paying attention to the bore for the spring
cotter (8). Oil the running face.

6629 102.01--01 E 11.97 32/40 101/ 02

 12. Slip the thrust bearing disc (15) onto the shaft (2). Using Loctite 243,
screw the hexagon socket screw (9) in, hand-tight.
13. Slip the butting disc (14) onto bearing cover (12), oil the running face,
install both parts and screw the hexagon socket screw (7) in,
243.14
hand-tight, applying Loctite 243.
14. Put a new O-ring seal (13), which has been smeared with acid-free
grease, into the ring groove, paying attention that it is not distorted.
15. Attach the sealing cover (11).
16. Mount the lube oil supply pipe (10).

1 Injection camshaft
2 Shaft
3 Cylinder crankcase
4 O-ring seal
5 Bearing body
6 Hexagon socket screw
7 Hexagon socket screw
8 Spring cotter
9 Hexagon socket screw
10 Lube oil supply pipe
11 Sealing cover
12 Bearing cover
13 O-ring seal
14 Butting disc
15 thrust bearing disc
16 Butting disc

Figure 1. thrust bearing (side view)

2 Shaft
5 Bearing body
12 Bearing cover
14 Butting disc
15 thrust bearing disc
16 Butting disc

A Projection
B Projection
C Projection

Figure 2. Measuring the projections for establishment of the thrust bearing clearance

6629 102.01--01 E 11.97 32/40 102/ 02

Valve/injection camshaft
Thrust bearing
Checking 102.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

The thrust bearings of the valve and injection camshafts are to be checked
for damage at regular intervals. The axial clearance is to be established.
In the process, changes/sources of disturbances are to be recognized in
time and eliminated, if needed.
The work includes:
Check of components.

Tools/appliances required

Quant Denomination No. Availability

1 Shackle A0.6 002.452 Standard
1 Eye bolt M12 000.142 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Sliding caliper -- Inventory
1 Depth gauge -- Inventory
1 Sealing compound -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.11

Technical data

Term Information
Bearing body 47 kg

Operating sequence 1 -- Check the thrust bearing

Steps 1. Dismantle the lube oil feed pipe (6) to the thrust bearing.

6629 102.02--01 E 11.97 32/40 101/ 03

 2. Remove the cover (9).
3. Remove the butting disk (8).
4. Screw the eye bolt (000.142) into the bearing body (7), attach the
rope to the eye bolt by means of shackle (002.452) and suspend from
lifting tackle.
5. Screw out the hexagon head bolts (5).

1 Valve camshaft
2 Shaft
3 Bearing bush
4 Crankcase
5 Hexagon head bolt
6 Lube oil feed pipe
7 Bearing body
8 Butting disk
9 Cover
10 Hexagon head bolt
11 Hexagon head bolt
12 O--ring seal
13 Oil bore

Figure 1. Thrust bearing for valve camshaft

Steps 6. Jack off the bearing body using two hexagon head bolts M16,
dismantle it and put it down on an appropriate pad.
7. Clean all the individual parts and check them for damage, replace if
necessary.
8. Measure and note down the projection (A) on the butting disk and
dimension (B) on the bearing body. Calculate the axial clearance from
these measurements, and compare it with the admissible clearance.
Refer to operating instruction manual, Section 2.5.
9. Check the bearing bush (3) for damage or dirt scores (refer to work
card 000.11),
000.11 replace if necessary.

7 Bearing body
8 Butting disk

A Projection
B Dimension

Figure 2. Measuring the projections to determine the axial clearance

▲ Attention! Replacement of the bearing bush should only be done

by a service base or by MAN B&W personnel because the bearing
bush has been pressed into the bearing body.

6629 102.02--01 E 11.97 32/40 102/ 03

 10. Screw the eye bolt (000.142) into the bearing body (7), attach rope to
the eye bolt by means of shackle (002.452) and suspend from lifting
tackle.
11. Lubricate a new O--ring seal (12) with acid--free grease and place into
the ring groove, making sure that it is not distorted.
12. Slightly lubricate the running surface of the bearing bush (3) with oil.
13. Carefully install the bearing body, making sure that the oil bore (13) is
at the bottom.
14. Screw the hexagon head bolts (5) down hand--tight.
15. Lubricate the contact face of the butting disk (8) with oil and install
disk.
16. Assemble the lube oil feed pipe (6).
17. Apply sealing compound Hylomar SQ 32/M to the contact face of the
cap (9) and attach the cap to the bearing body.

6629 102.02--01 E 11.97 32/40 103/ 03

.
Valve/injection camshaft
Thrust bearing
Checking 102.03

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

The thrust bearings of the valve and injection camshafts are to be checked
for damage at regular intervals. The end play is to be established. In the
process, changes/sources of disturbances are to be recognised in time
and eliminated, if needed.
The work includes:
checking components.

Tools/appliances required

Quant Denomination No. Availability

1 Shackle A0.6 002.452 Standard
1 Eye bolt M12 000.142 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Sliding caliper -- Inventory
1 Depth gauge -- Inventory
1 Sealing compound -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.11 000.30

Operating sequence 1 - Check the thrust bearing

Steps 1. Dismantle the lube oil feed pipe (6) to the thrust bearing.
2. Remove the cover (9).
3. Remove the friction disc (8).
4. Screw the ring bolt (000.142) into the bearing body (7), attach the
rope to the ring bolt by means of shackle (002.452) and suspend
from lifting tackle.

6629 102.03--01 E 11.97 32/40 101/ 02

 1 Valve camshaft
2 Shaft
4 Crankcase
5 Hexagon head bolt
6 Lube oil feed pipe
7 Bearing body
8 Friction disc
9 Cover
10 Hexagon head bolt
11 Hexagon head bolt
14 Friction disc
15 Retaining ring

Figure 1. Thrust bearing for valve camshaft

5. Screw out the hexagon head bolts (5).
6. Jack off the bearing body using two hexagonal head bolts M 16,
dismantle it and put it down on an appropriate pad.
7. Clean all the individual parts and check them for damage, replace if
necessary.
8. Measure and note down the projection (A) on the friction disc and
dimension (B) on the bearing body. Calculate the axial backlash from
these measurements, and compare it with the admissible backlash.
Refer to operating instruction manual, Section 2.5.

7 Bearing body
8 Friction disc

A Projection
B Dimension

Figure 2. Measuring the projections to determine the axial backlash

9. Screw the ring bolt (000.142) into the bearing body (7), attach rope to
the ring bolt by means of shackle (002.452) and suspend from lifting
tackle.
10. Carefully install the bearing body. During the process watch for
correct fitting position.
11. Screw in the hexagon head bolts (5) down hand-tight.
12. Lubricate the contact face of the friction disc (8) with oil and install
disc.
13. Assemble the lube oil feed pipe (6).
14. Apply sealing compound Hylomar SQ 32/M to the contact face of the
cap (9) and attach the cap to the bearing body.

6629 102.03--01 E 11.97 32/40 102/ 02

Torsional vibration damper

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

6682 101--02 E 04.98 101/ 01

.
Torsional vibration damper of
the injection-- /valve camshaft
Removing and installing 101.03

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Torsional vibration dampers are not to be removed within the scope of

usual maintenance work. This is only necessary in special cases, e.g. for
more extensive work on camshafts.
The work/steps extend to:
removal of components,
installation of components.

Safety requirements

- Engine secured against starting

Personnel and time required

Numb Qualification Time requ

1 Assistant 1
1 Technical assistant 1

Tools/appliances required

Quant Denomination No. Availability

1 Fitting/unfitting tool 101.122 Optional
1 Supporting device 101.122--1 Optional
1 Bar 101.123 Optional
1 Torque wrench 008.011 Standard
1 Shackle A1.0 002.453 Standard
1 Ratchet 001.521 Standard
1 Eye bolt M16 000.143 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Socket wrench (set) -- Standard
4 Hexagon nut M12 -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

6629 101.03--01 E 04.98 L 32/40 101/ 03

Related work cards

Work card Work card Work card

000.30 101.01 101.02

Operating sequence 1 -- Removal of the torsional vibration damper from the camshaft

Starting condition Last camshaft casing cover removed from the free engine end. Camshaft
thrust bearing resp. oil supply for the torsional vibration damper
dismantled.

Steps 1. Slip the supporting device (101.122--1) over studs (2) and screw it
onto the cylinder crankcase by means of hexagon nuts (3).
2. Screw the bar (101.123) into the proper taphole of the damper mass.
3. Screw the hexagon head bolts (4) out, guiding the torsional vibration
damper (5) by means of the bar (101.123).
4. Using the bar, pull the torsional vibration damper along the supporting
device and out of the cylinder crankcase.
5. Screw the bar out and the eye bolt (000.143) into the torsional
vibration damper. Attach the rope to the eye bolt by means of
shackle (002.453) and suspend the rope in the lifting tackle.
6. Using the lifting tackle, place the torsional vibration damper onto the
pad.

1 Cylinder crankcase 3 Hexagon nut M12 5 Torsional vibration damper

2 Stud 4 Hexagon head bolt 6 Rope

Figure 1. Torsional vibration damper with attached fitting/unfitting tool

6629 101.03--01 E 04.98 L 32/40 102/ 03

Operating sequence 2 -- Installation of the torsional vibration damper

For the installation of the torsional vibration damper, proceed in the

reverse order followed for removal, paying attention to the following points:
1. Apply MoS2 lubricant to the threads and contact faces of the hexagon
head bolts (4), screw the bolts in, hand--tight, and tighten them
000.30).
crosswise to the specified torque (see work card 000.30
2. Remove the complete fitting/unfitting tool.

6629 101.03--01 E 04.98 L 32/40 103/ 03

.
Rocker arm/Rocker arm casing

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

6682 111--02 E 04.98 101/ 01

.
Valve clearance
Checking and adjusting 111.02

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

permit/support economic operation,
prevent operating problems/damage.

Brief description

The valve clearance is to be determined and, if necessary, corrected at

regular intervals.
The work includes:
checking/adjusting the valve clearance.

Safety requirements

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5
1 Assistant 0.5

Tools/appliances required

Qty Designation No. Availability

1 Setting tool 113.226 Standard
1 Socket wrench 113.226--1 Standard
1 Socket wrench 113.226--2 Standard
1 Locating device 113.227 Standard
2 Locating screw 113.227--1 Standard
1 Torque wrench 008.011 Standard
3 Setting gauge (exhaust valve) 0.9 113.139 Standard
1 Set of feeler gauges 0.2 000.455 Standard
1 Open--jaw and ring wrenches (set) -- Standard

Related work cards

Work card Work card Work card

000.30 111.03

6629 111.02--02 E 11.01 32/40 101/ 04

Preliminary remarks

Checking and, if necessary, adjusting the valve clearance is to be carried

out whenever new parts are installed or cylinder head and rocker arm
bracket are remounted after carrying out maintenance work. In this con-
nection, it is to be ensured that the setting nuts are tightened to the speci-
000.30).
fied torque (see work card 000.30
In order to rule out mounting or adjusting errors, it is recommended not to
fit the cylinder head together with the rocker arm bracket.

1 Cylinder head cover

2 Rocker arm
(inlet valves)
3 Rocker arm
(exhaust valves)
15 Exhaust valve
16 Cylinder head
19 Inlet valve
39 Sealing cord

Figure 1. Cylinder head with rocker arm support

Operating sequence 1 -- Check the valve clearance

Starting condition The engine is in the cold condition or at operating temperature (however,
30 minutes after engine shut-down at the earliest), i.e. the valves approx.
have the same temperature as the cylinder head. The running gear of the
respective cylinder is in the ignition TDC position (all valves closed). The
cylinder head cover has been removed.
Checking the valve clearance 1. Lift the rocker arm (2, 3) by hand until it rests on the push rods, with-
out any clearance.
2. Measure the valve clearance (C) for both exhaust and inlet valves (15
and 19) between the valve shaft and the calotte (26), using the set-
ting gauge (113.139 for exhaust valve and 000.455 for inlet valve
resp.). For the specified values, refer to the operating instruction
manual, Section 2.5.6.

6629 111.02--02 E 11.01 32/40 102/ 04

 3. If necessary, readjust the valve clearance (see operating sequence
2).
4. Put the cylinder head cover (1) onto the cylinder head (16) and fix it
in place. Pay attention to the sealing cord (39) - refer to Figure 1 .

2 Rocker arm
(inlet valves)
3 Rocker arm
(exhaust valves)
15 Exhaust valve
16 Cylinder head
17 Nut
19 Inlet valve
25 Valve adjuster
26 Calotte

AS Exhaust side
AGS Exhaust counter side

Figure 2. Fitting the setting tool

Operating sequence 2 -- Adjust the valve clearance

Starting condition The engine is in the cold condition or at operating temperature (however,
30 minutes after engine shut-down at the earliest), i.e. the valves approx.
have the same temperature as the cylinder head. The running gear of the
respective cylinder is in the ignition TDC position (all valves closed). Valve
clearance has been checked (valve clearance too large or too small).

6629 111.02--02 E 11.01 32/40 103/ 04

 2 Rocker arm
(inlet valves)
3 Rocker arm
(exhaust valves)
26 Calotte

C Valve clearance

Figure 3. Adjusting the valve clearance and/or tightening the nuts on the setting screws
Adjusting the valve clearance 1. Lift the rocker arm (2, 3) by hand until it rests on the push rods, with-
out any clearance.
2. Screw in the locating screws (113.227-1) so as to keep the rocker
arm in clearance-free position (refer to Figure 2 ).
3. Mount the torque wrench (008.011) on the socket wrench (113.226-2)
- refer to Figure 2 . Loosen the nuts (17) on the valve adjusters (25),
and screw them off; clean the threads and seating faces.
4. Using the socket wrench (113.226-1), slacken the valve adjuster (25).
5. Coat the thread and the seating face of the nut (17) with MoS2
lubricant, and screw the nut on.
6. Slide the feeler gauge (000.455) between valve shaft and calotte (26)
of the inlet valves.
7. Screw the valve adjuster in until the feeler gauge fits without any
clearance.
000.30),
8. Tighten the nut (17) to the specified torque (see work card 000.30
holding the valve adjuster steady (refer to Figure 3 ).
9. Remove the feeler gauge.
10. Using the setting gauge (113.139), adjust the valve clearance on the
exhaust valves in the same way (see items 3 to 9).
11. Place the cylinder head cover (1) on the cylinder head (16) and fix it
in place, paying attention to the sealing cord (39) - refer to Figure 1 .

6629 111.02--02 E 11.01 32/40 104/ 04

Rocker arm bracket with rocker arms
Removing and refitting 111.03

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Rocker arm support with rocker arm are to be dismantled within the scope
of maintenance and repair work.
The work/steps include:
dismounting components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5
1 Assistant 0.5

Tools/appliances required

Qty Designation No. Availability

1 Locating device 113.227 Standard
2 Locating screw 113.227--1 Standard
1 Lifting eye bolt M16 000.143 Standard
1 Shackle A1.0 002.453 Standard
1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Socket wrench insert (set) -- Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lifting tackle with rope -- Inventory

6629 111.03--03 E 11.01 32/40 101/ 04

Related work cards

Work card Work card Work card

000.30 111.02
111.02

Technical details

Term Information
Rocker arm bracket with rocker arms 95 kg

1 Rocker arm bracket

2 Rocker arm
(inlet valves)
3 Rocker arm
(exhaust valves)
4 Hexagon bolt
5 Washer
6 Distance sleeve

Figure 1. Cylinder head with rocker arm support

1 Rocker arm bracket

2 Rocker arm
(inlet valves)
3 Rocker arm
(exhaust valves)

Figure 2. Fitting the locating device

6629 111.03--03 E 11.01 32/40 102/ 04

Operating sequence 1 -- Removing the rocker arm bracket with rocker arm

Starting condition The running gear of the respective cylinder is in the ignition TDC position
(all valves closed). Cylinder head cover has been removed.

Steps 1. Lift the rocker arm (2, 3) by hand until it rests on the push rods, with-
out any clearance.
2. Screw the locating screws (113.227-1) in so as to keep the rocker
arm in a clearance-free position (refer to Figure 2 ).
3. Screw the lifting eye bolt (000.143) into the rocker arm bracket (1).
4. Unscrew three hexagon bolts (4) and take them off, together with the
washers (5) - refer to Figure 3 .
5. Attach the rope to the lifting eye bolt by means of shackle (002.453),
and suspend the rope from the lifting tackle.
6. Carefully lift up the rocker arm bracket (1) with the rocker arm (2, 3),
paying attention to the distance sleeves (6) and the push rods.
7. Lift the rocker arm bracket off completely, and place it on a wooden
support.
8. Take the distance sleeves (6) off (refer to Figure 4 ).

1 Rocker arm bracket

2 Rocker arm
(inlet valves)
3 Rocker arm
(exhaust valves)
4 Hexagon bolt
5 Washer
6 Distance sleeve

Figure 3. Removal of the rocker arm support

Operating sequence 2 -- Fitting the rocker arm bracket with rocker arm

Starting condition Seating faces on the rocker arm bracket, distance sleeves, cylinder head,
valve cones, rocker arms and push rods have been cleaned.

Steps 1. Insert the rocker arm (2, 3) in the rocker arm bracket and keep it in
place by means of locating screws (113.227-1).
2. Screw the lifting eye bolt (000.143) into the rocker arm bracket.
3. Attach the rope to the lifting eye bolt by means of shackle (002.453),
and suspend the rope from the lifting tackle.
4. Lift the rocker arm bracket with the rocker arm and move them over
the centre of the cylinder.

6629 111.03--03 E 11.01 32/40 103/ 04

 5. Insert the distance sleeves (6) in the cylinder head (16) - refer to Fig-
ure 4 ).
6. Carefully lower the rocker arm bracket, taking care that the distance
sleeves engage in the rocker arm bracket. Furthermore, make sure
that the thrust pads of the rocker arms (2, 3) rest on the push-rod
pans correctly (refer to Figure 4 ).
7. Unscrew locating screws (113.227-1) and lifting eye bolt (000.143).
8. Screw in three hexagon bolts (4) with washers (5), and tighten the
000.30) - refer to Fig-
bolts to the specified torque (see work card 000.30
ure 3 ).
Adjustment of the valve 9. Readjust the valve clearance on the exhaust and inlet valves
clearance 111.02).
(see work card 111.02
10. Put the cylinder head cover onto the rocker arm casing, and screw it
in place.

1 Rocker arm bracket

2 Rocker arm
(inlet valves)
3 Rocker arm
(exhaust valves)
6 Distance sleeve
16 Cylinder head

Figure 4. Cylinder head with rocker arm support removed

6629 111.03--03 E 11.01 32/40 104/ 04

Cam follower/Push-- rod

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

6682 112--02 E 04.98 101/ 01

.
Cam follower
Removing and installing/checking 112.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Clearance and components of cam followers are to be checked at regular

intervals.
The work/steps include:
removal of components,
checking of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Thickness gauges 0.05--1 000.451 Standard
1 Screw driver 0.8x5.5 000.391 Standard
2 Tommy bar 8 000.262 Standard
1 Open--jaw and ring spanner (set) -- Standard

Related work cards

Work card Work card Work card

111.03
111.03

Technical details

Term Information
Cam follower 9.5 kg
Push--rod 6.5 kg

Operating sequence - Check the inlet and exhaust valve rocking levers

Starting condition Cam follower of rocking levers at the cam base circle (all valves closed),
rocker arm casing dismounted, cover of the camshaft housing taken off.

6629 112.01--01 E 10.97 L 32/40 101/ 04

 1 Pushrod
2 Thrust pad
3 Rocking lever

Figure 1. Pushrod/rocking lever connection

1 Pushrod
3 Rocking lever
4 Cylinder head
5 Valve camshaft

Figure 2. Pushrod lifted

6629 112.01--01 E 10.97 L 32/40 102/ 04

 3 Rocking lever 10 Bearing bush
5 Valve camshaft 11 Rocking lever axle
6 Crankcase 12 Pillow block
7 Hexagon head bolt 13 Cylindrical pin
8 Wedge-type washer 14 Screw plug
9 Disc 15 Washer
16 Lube oil pipe

Figure 3. Inlet and exhaust valve rocking levers as mounted (viewed from exhaust
gas side)

Steps 1. Turn the pushrod (1) until it can be disengaged from thrust pad (2)
(pushrod with transverse groove, thrust pad with spot-faced shoulder
- see Figure 1).
2. Lift the pushrod, slip the tommy bar (000.262) through the bore in the
pushrod and put the latter down onto the cylinder head (4).
(see Figure 2).
3. Lift off the second pushrod in the same way (points 1 and 2).
4. Measure the axial clearance of rocking levers (3) using caliper gauge
(000.451), note down and compare with specified clearance. Refer
to the operating instruction manual, Section 2.5.
5. Remove discs (9).
6. Measure the radial clearance of rocking levers using the caliper
gauge, note down and compare with specified clearance.
Important! Replacement of bearing bushes (10) should be
entrusted to a service base or to MAN B&W personnel as a matter of
principle because the bearing bushes have been fitted in the rocking levers
by deep-freezing.
7. Disconnect the lube oil pipe (16).
8. Remove the screw plug (14) together with the washer (15) and pull
out the cylindrical pin (13) using the eye bolt (001.407).
9. Remove the rocking lever, slightly shift the rocking lever axle (11) for
this purpose.
10. Measure the axial clearance of follower (17) using the caliper gauge,
note down and compare with the specified clearance.
11. Push in the fixation stud (17) by means of screw driver (000.391) until
the follower bolt (20) can be taken off.
12. Measure the radial clearance of the cam follower using the caliper
gauge, note down and compare with the specified clearance.
13. Clean all parts of the rocking levers and the running surface of the
rocking lever axle and check for damage; purge the oil bores by
means of compressed air.
14. Slightly oil the bore of follower (17) and fit in rocking lever (3).
15. Insert the follower bolt (20) into rocking lever and cam follower (taking
note of the bore hole/fixation stud position), push the fixation stud
(19) in and fully push in the cam follower bolt. Make sure that the

6629 112.01--01 E 10.97 L 32/40 103/ 04

 spring-loaded fixation stud engages in the bore provided in the
rocking lever.
16. Fit the cam follower and bolt in the second rocking lever.
17. Slightly oil the running surface of bearing bushes (10) and slip both
the rocking levers onto the axle (11), each time slightly shifting the
axle.
18. Fit the cylindrical pin (13) to fix the rocking lever axle in position.
Screw down the screw plug (14) with washer (15) hand-tight, and
secure with washer.
19. Mount the discs (9) with hexagon head bolts (7) screwed-in
hand-tight including wedge-type washers (8) onto the rocking lever
axle.
20. Connect the lube oil pipe (16).
21. Slightly oil the thrust pads (2).
22. Lift the pushrod (1), remove the tommy bar (000.262) and place the
pushrod onto the thrust pad, taking note of the transverse groove in
the pushrod and the spot-faced shoulder on the thrust pad.
23. Turn the pushrod by approx. 90E (for position of the marking (M) on
the pushrod, see Figure 5) and connect the pushrod with the thrust
pad (refer to Figure 1).
24. Fit the second pushrod in the same way.
25. On completion of installation, check the rocking levers and pushrods
for ease of motion.
26. Check whether oil is supplied to all the lubricating points.

3 Rocking lever
17 Cam follower
18 Compression spring
19 Fixation stud
20 Cam follower bolt

Figure 4. Rocking lever

1 Pushrod
4 Cylinder head

AS Exhaust side
M Marking on the
pushrod

Figure 5. Position of the markings on the pushrods with the pushrods connected to
the thrust pads (top view)

6629 112.01--01 E 10.97 L 32/40 104/ 04

Push-- rods
Removing and installing 112.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Push--rods are to be disassembled and recorded within the scope of

maintenance and repair work.
The work/steps include:
removal of components,
checking of components,
installation of components.

Related work cards

Work card Work card Work card

111.03
111.03

Technical details

Term Information
Push--rod 6.5 kg

Operating sequence 1 -- Disassemble the pushrods

Starting condition Rocker arm casing dismantled, cover of the camshaft casing taken off.

Steps 1. Turn the pushrod (1) until it can be disengaged from the thrust pad
(2) (pushrod with transverse groove, thrust pad with spot--faced
shoulder -- see Figure 1).
2. Remove the pushrod.
3. Remove second pushrod in the same way.
4. Clean the pushrods and check for damage.

6629 112.02--01 E 07.97 32/40 101/ 03

 1 Pushrod
3 Rocking lever
(Inlet/exhaust valve)
4 Cylinder head
5 Valve camshaft

Figure 1. Pushrod as installed (illustration shows L--type engine)

1 Pushrod
2 Thrust pad
3 Rocking lever
(Inlet/exhaust valve)

Figure 2.

Operating sequence 2 -- Install the pushrods

Starting condition Pushrods cleaned and checked for damage.

Steps 1. Clean the thrust pad (2), then slightly lubricate it with oil.
2. Introduce pushrod (1) into the engine and place onto thrust pad,
taking note of the transverse groove in the pushrod and the
spot--facing on the thrust pad.

6629 112.02--01 E 07.97 32/40 102/ 03

 3. Turn the pushrod by approx. 90ƒ (position of marking (M) on the
pushrod, see Figure 2) and connect the pushrod with the thrust pad
(see Figure 1).
4. Install the second pushrod in the same way.
5. Check the pushrods for ease of motion.

1 Pushrod
4 Cylinder head

AS Exhaust side
M Marking on the
pushrod

Figure 3. Position of the markings on the push rods when the push rods are
connected with the thrust pads (plan view).

6629 112.02--01 E 07.97 32/40 103/ 03

.
Inlet and exhaust valves/Valve seat rings/
Valve guides/Valve rotators

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

6682 113...--02 E 04.98 101/ 01

.
Valve rotator
Checking rotating motion 113.01

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

Valve rotators are to be assessed at regular intervals.

The work includes:
checking components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.1

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Felt--tip pen/Marking pen -- Inventory

Mode of operation

Inlet valve When the valve is opened, the disk spring (4) located in the valve rotator is
flattened out by the increasing force of the valve spring – see Figures 1 and
2. In the process, it applies a load to the bearing balls inserted in the pockets
of the main body (1), forcing them to roll on their sloping raceways, and rolls
on the balls itself. The cover, disk spring, and valve spring, on the other hand,
are engaged frictionally, so that they cannot rotate relative to one another.
The relative rotation between the disk spring/cover and the main body is
transmitted via the main body to the valve. When the valve closes, the load
on the disk spring and thus on the bearing balls is relieved; the latter are then
pushed back into their initial position by the compression springs, without roll-
ing.

Exhaust valve When the valve is opened, it is put into rotation by a propeller sleeve
mounted on the valve stem, as soon as the stream of gas flows past the
propeller sleeve. This rotation is made possible by an axial deep-groove
ball bearing mounted by friction fit on the upper end of the valve.

6629 113.01--02 E 03.00 32/40 101/ 03

Operating sequence 1 -- Checking the valve rotators

Starting condition Engine at a stand-still

Steps 1. Unscrew the hexagon-head screws of the cylinder head cover, and
remove it.
2. Make markings on the valve rotators (15) and the thrust bearings (17)
with a felt-tip pen.
3. Start up the engine, and run it at low revolutions.
4. Observe the valve rotators (15) of the inlet valves to see whether the
main bodies (1) with the valve cones (10) rotate uniformly.

1 Main body
2 Bearing ball
4 Disk spring
5 Cover
6 Circlip
7 Compression spring

Figure 1. Valve rotator of the inlet valve

8 Inlet valve seat ring

9 Cylinder head
10 Inlet valve cone
11 Valve guide
12 Compression spring
13 O-ring seal
14 Compression spring
15 Valve rotator
16 Valve collet
(two-part)
17 Thrust bearing
18 Exhaust valve cone
with propeller sleeve
19 Exhaust valve seat
ring
Figure 2. Inlet and exhaust valves

6629 113.01--02 E 03.00 32/40 102/ 03

 Important! Dirt from residues in the oil (abraded particles, combus-
tion products), particularly in the ball-bearing pockets, can cause malfunc-
tions. The deposits make individual parts sticky and hinder the movement
of the balls. The valve rotator must be removed, disassembled, washed
113.02)
carefully, and lubricated before re-installing it (see Work Card 113.02
5. Observe the thrust bearings (17) of the exhaust valves. One rotation
of the thrust bearing and exhaust valve cone (18) should not take
longer than a minute.
Important! If it takes longer, remove the exhaust valve and clean all
its parts.

▲ Attention! If the bearing balls have indented the raceway, due to

the point load if the inlet or exhaust valve is not turning, the entire
valve rotator or the thrust bearing must be replaced. And if the inlet
or exhaust valve does not turn, check the condition of the valve
113.03).
cone and the valve seat ring (see Work Card 113.03
6. Stop the engine.
7. Place the cylinder head cover on the rocker-arm casing and fasten it.

6629 113.01--02 E 03.00 32/40 103/ 03

.
Inlet and exhaust valve/valve rotator
Removing and installing or rather
disassembling and reassembling 113.02

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Inlet and exhaust valves as well as valve rotators are to be disassembled

at regular intervals and overhauled if necessary.
The work/steps include:
removal of components,
disassembly and assembly,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Valve spring tensioner 113.211 Standard
1 Thrust pad 113.211--1 Standard
1 Bridge 113.211--7 Standard
1 Feeler gauge (set) 000.451 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Special lubricant -- Inventory
(Molykote G Rapid, Molykote G--n)

Related work cards

Work card Work card Work card

000.34 055.02 055.05
113.03 113.04 113.05

6629 113.02--03 E 03.01 32/40 101/ 05

Technical details

Term Information
Inlet valve cone 3.5 kg
Exhaust valve cone 3.5 kg

Operating sequence 1 -- Removing the inlet and exhaust valves

Starting condition Cylinder head has been dismantled and mounted in cylinder-head turnover
stand.

Important! If only the valve rotators or thrust bearings or the com-

pression springs are to be removed, the cylinder head is left mounted, and
the piston is turned to the ignition TDC.

Steps 1. Attach the bridge (113.211-7) to the cylinder head (9) by means of
two hexagon bolts (21) - see Figures 1 and 2 .
2. Slip the thrust pad (113.211-1) over the spindle fitted to the bridge.
Centre the thrust pad over the valve rotator (15) or thrust bearing (17)
- see Figure 2 /I.
3. Screw the hexagon nut (20) onto the spindle.
4. Depress the thrust pad by turning the hexagon nut, thus preloading the
compression springs (12 and 14) sufficiently to allow disassembly of the
two-part valve “cone piece” (collet) (16) - see Figure 2 /II. Hold the
valve cone (10 or 18) against the valve cone cup by hand while depres-
sing the compression springs. Remove the “cone pieces” (collets).
▲ Attention! Unless the valve cone is held in place, it will drop out
of the valve guide when the collet has been removed.
5. Push the valve cone out of the valve guide (11) and set it aside.
6. Back off the hexagon nut to unload the compression springs
(see Figure 2 /III).
7. Back off the hexagon nut completely, remove the thrust pad from the
valve rotator or thrust bearing, turn it and slip it onto the next valve
rotator or thrust bearing.
8. Take off the valve rotator or thrust bearing and the compression
springs.
9. Dismantle the other inlet/exhaust valves in the same way (refer to
items 2 to 8).
Important! Note down the assignment valve cone/valve guide, as
valve cones which have not been overhauled (ground) have to be rein-
stalled into the same valve guide.
10. Remove the O-ring seals (13) from the valve guides.
11. Disassemble the valve rotator (refer to operating sequence 2).
▲ Attention! In case the balls have produced indentations in the
raceway as a result of concentrated load because the inlet or ex-
haust valve stopped rotating, the complete valve rotator or thrust
bearing has to be replaced.
12. Clean all individual parts and check them for damage (for maximum
clearances, please refer to the Operating instruction manual), replace
them if necessary.
13. Clean (e.g. by wet blast cleaning) the fillet of the valve cones and the
transitions above the wing area (exhaust valve) so that they are me-
tallically bright. Carry out a magnetic crack test (see Work Card

6629 113.02--03 E 03.01 32/40 102/ 05

 000.34 In the event that cracks are indicated, an authorised service
000.34).
centre is to be consulted regarding reusability.
14. If required, regrind the valve cone and/or valve seat (see Work Cards
113.04 and 113.05).
113.05
15. Check the condition of the valve guide, remove it if necessary (see
Work Card 055.05).
055.05
16. Slip the valve cone into the valve guide and measure the radial clear-
ance using the thickness gauge (000.451), note down the measured
value and compare it with the specified clearance. Please refer to
the Operating instruction manual, Section 2.5.
17. 113.03).
Check the valve seats (see Work Card 113.03

8 Inlet valve seat ring

9 Cylinder head
10 Inlet valve cone
11 Valve guide
12 Compression spring
13 O-ring seal
14 Compression spring
15 Valve rotator
16 Valve collet
(“cone piece”)
(two-part)
17 Thrust bearing
18 Exhaust valve cone
with propeller sleeve
19 Exhaust valve seat
ring

Figure 1. Inlet and exhaust valve

Operating sequence 2 -- Disassembling and re-assembling the valve rotator

Starting condition Valve rotator removed and set down on support (snap ring located on top).

Steps 1. Remove the snap ring (6) - see Figure 3 .

2. Remove the cover (5) and disk spring (4).
3. Remove all the balls (2) and compression springs (7) from the main
body (1).
4. Clean each individual part in a suitable cleaning agent, and dry it.
5. Check the individual parts for wear and ball indentations; replace
them if necessary.
Important! When parts of the valve rotator are replaced, the item
number of the set of wear parts used must be marked on the main body
(1).
Clean new parts before installing them.

6629 113.02--03 E 03.01 32/40 103/ 05

 6. Insert balls and compression springs in the ball-pocket
raceways located in the main body.
▲ Attention! Make sure that the balls are at the highest point of the
slanting ball-pocket raceways, and thus all in the same direction
(see Figure 3 ).

9 Cylinder head 16 Collet (”cone piece”) 21 Hexagon bolt

10 Inlet valve cone (two-part) 22 Inlet valve cone
12 Compression spring 17 Thrust bearing 23 Exhaust valve cone
14 Compression spring 18 Exhaust valve cone
15 Valve rotator 20 Hexagon nut AS Exhaust side

Figure 2. Inlet and exhaust valve

7. Insert the disk spring, put on the cover, and install the snap ring.
8. Immerse the valve rotator in clean lube oil, and remove it again
shortly before installing.
▲ Attention! Never pack the valve rotator with grease!

6629 113.02--03 E 03.01 32/40 104/ 05

Storage Parts kept in stock must be well packaged, and protected against dust,
water, humidity, and aggressive media. Dust makes the parts stick, hinder-
ing or preventing rotation when they are put into use.

1 Main body
2 Ball
4 Disk spring
5 Cover
6 Snap ring
7 Compression spring

Figure 3. Valve rotator of the inlet valve

Operating sequence 3 -- Installing the inlet and exhaust valves

Starting condition All individual parts cleaned, cylinder head mounted in cylinder-head turn-
over stand. Bridge mounted on cylinder head.

Important! If only the valve rotators or thrust bearings or the com-

pression springs have been removed, the cylinder head is mounted, and
the piston is positioned in the ignition TDC.

Steps 1. Clean the boreholes in the valve guide (11) and the valve seat
ring (8 or 19).
2. Insert a new O-ring seal (13) in the ring groove; be careful not to twist
it.
3. Fit the compression springs (12 and 14) into the cylinder head (9),
and place the valve rotator (15) or thrust bearing (17) on the com-
pression springs.
4. Slip the thrust pad (113.211-1) over the spindle fitted to the bridge
(113.211-7). Centre thrust pad over the valve rotator or thrust bearing
(see Figure 2 /III).
5. Screw the hexagon nut (20) onto the spindle.
6. Apply Molykote ”G-n” to the stem of the valve cone (10 or 18), and
slide it into the valve guide. If the engine is to be started up immedi-
ately, the valve stem can be coated with clean engine oil instead.
Tip! While installing the “cone piece” (collet), hold the valve cone
against the valve cone cup by hand.
7. Depress the thrust pad by turning the hexagon nut, thus preloading
the compression springs sufficiently to allow installation of the two-
part valve “cone piece” (collet) (16) - see Figure 2 /II. Insert the
“cone pieces” (collets).
▲ Attention! Before unloading the compression springs, check that
the two-part collet is inserted properly, and that the gap between the
two parts is uniform.
8. Back off the hexagon nut to unload the valve-spring tensioner.
9. Back off the hexagon nut completely, remove the thrust pad from the
valve rotator or thrust bearing, and swivel it aside.
10. Install the other inlet/exhaust valves in the same way
(see items 1 to 9).
11. Remove the valve-spring tensioner.

6629 113.02--03 E 03.01 32/40 105/ 05

.
Inlet and exhaust valves
Valve seats
Checking 113.03

Purpose of jobs to be done

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

check components for condition/wear,
assess the contact pattern/wear.

Brief description

Inlet and exhaust valve seats are to be checked and, if necessary,

overhauled/replaced at regular intervals.
The work/steps include:
carrying out an ink contact (”touching”) test,
assessing contact pattern/wear condition.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.2

Tools/appliances required

Qty Designation No. Availability

1 Touching up device 113.224 Standard
1 Touching--test ink -- Inventory
1 Grinding paste (silicon--free) -- Inventory

Related work cards

Work card Work card Work card

113.02 113.06 113.08

Technical details

Term Information
Inlet valve cone 3.5 kg
Exhaust valve cone 3.5 kg

6682 113.03--03 E 05.01 32/40 101/ 04

Preliminary remarks

Exhaust and inlet valves with a poor contact pattern do not have a long life
expectancy. They have to be overhauled or replaced.
The intervals for overhaul as entered in the maintenance schedule are
guide values and depend on the operating mode and the engine condition,
and the quality of the fuel used. The most suitable intervals for overhaul
have to be chosen, making due allowance for the specified checks.
Due to the frequent temperature changes, the material of the valve cone is
subject to fatigue. The inlet and exhaust valve cones have to be replaced
when the operating times stated in the maintenance schedule have been
reached, even if the admissible maximum remachining limits have not yet
been reached.

▲ Attention! Use beyond this limit involves an unpredictable risk

for the engine.
The valve seat angle of the valve cone is 120ƒ , with a positive tolerance.
The valve seat angle in the cylinder head has a negative tolerance so that
the valve cone seating face is in contact with the full seating face of the
valve seat ring, or a small differential angle exists. This ensures that in
operation the sealing zone for the hot gases is on the outer margin of the
valve seat area.
The contact pattern is checked by means of a touching test.

▲ Attention! With valve seat grinders that have long been in use,
tolerances resulting from wear may influence the valve seat angle so
that an incorrect contact pattern is produced. We recommend check-
ing by means of a touching test made with a new, original MAN B&W
valve cone. If deviations are found, the valve seat grinder has to be
readjusted or overhauled.

8 Valve seat ring

9 Cylinder head
10 Valve cone

§ Valve seating angle on

the valve cone
(120ƒ +10’)
¨ Valve seating angle on
the valve seat ring
(120ƒ 10’)
­ Differential angle
(0’ to 20’)

Figure 1. Valve cone and valve seat ring (illustration shows inlet valve)

6682 113.03--03 E 05.01 32/40 102/ 04

Operating sequence 1 -- Touching test

Starting condition Cylinder head mounted in the cylinder head turnover stand, inlet/exhaust
valves dismantled.

Steps 1. Carefully clean the valve seat surfaces.

▲ Attention! Do not damage the valve cone by using a wrong
cleaning tool (such as a slag hammer).
2. Fasten the flat magnet of the touch-up device (113.224) centrally to
the valve cone (10) - refer to Figure 1 .
3. Apply a uniform film of touching-test ink, as thin as possible, to the
valve seat of the valve cone.
4. Slide the valve cone into its valve guide and turn it by one half revolu-
tion in vertical position and under pressure, using the touching-up
device.
5. Take the valve cone out. If the differential angle is correct and/or re-
machining has been carried out properly, there must be a continuous
bearing zone at the outer margin of the valve seat.

Operating sequence 2 -- Assessing valve seat surfaces

Starting condition Cylinder head mounted in the cylinder head turnover stand, inlet/exhaust
valves dismantled.

Figure 2. Illustrating Diagnosis 1

Diagnosis 1 Valve seat surfaces of valve cone and valve seat ring are clean, showing
slight varnishing or only minor pitting. Uniform contact pattern all around
(refer to Figure 2 ).

Action Apply silicon-free grinding paste to the valve seat surface of valve cone
and valve seat ring (observe instructions of the supplier!) and clean by
hand using the touching-up device (113.224) until varnishing has been re-
moved. After cleaning, make a touching test (see operating sequence 1).

Important! Use as little grinding paste as possible for cleaning, and

carefully wash the valve cone and valve seat ring afterwards. Residues of
grinding paste promote wear.

6682 113.03--03 E 05.01 32/40 103/ 04

 Minor pitting left after removal of varnishing can be tolerated, it has but
little effect on the service life.

Figure 3. Illustrating Diagnosis 2

Diagnosis 2 The valve seat surface of valve cone or valve seat shows heavy deposits,
rather deep corrosion pitting and/or distinct pounding marks. There is wear
on the valve cone or valve seat ring. Refer to Figure 3 .

Action Remachine the valve cone and valve seat ring using the valve cone/valve
seat grinder until the seat surfaces are clean or the appearance of the
contact faces is as new (see work cards 113.06 and 113.08).
113.08 After clean-
ing, make a touching test (refer to operating sequence 1).

Important! Keep grinding treatment to a minimum and subse-

quently wash the valve cone and valve seat ring carefully. Grinding resi-
dues promote wear.
Minor pitting left after grinding can be tolerated, it has but little effect on
the service life.

Diagnosis 3 Valve cone showing incipient blow-by or stress cracking.

Action The valve cones are to be replaced.

6682 113.03--03 E 05.01 32/40 104/ 04

Valve seat rings
Removing and installing 113.04

Purpose of jobs to be done

Impart the required knowledge,

ensure correct execution of work.
Carry out the work in time according to the maintenance schedule,
enable/support economic operation,
prevent operating problems/damage.

Brief description

Removal and installation of valve seat rings are not part of the work
specified in the maintenance schedule.
The work/steps consist of:
removal of components,
installation of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1
1 Assistant 1

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 113.219 Standard
1 Thrust pad 113.220 Standard
1 Guide piece 113.221 Standard
1 Clamping piece 113.222 Standard
1 Extractor 113.218 Standard
1 Extractor 002.512 Standard
1 Nut 002.512--1 Standard
1 Spindle head 002.512--4 Standard
1 Crown 002.512--5 Standard
1 Spindle 002.512--8 Standard
3 Shell 002.512--9 Standard
1 Expanding solid 002.512--10 Standard
1 Counterbrace 002.524 Standard
1 Cross tie 002.524--4 Standard
2 Adjusting nut 002.524--5 Standard

6629 113.04--04 E 04.01 32/40 101/ 06

 Qty Designation No. Availability
2 Bolt 002.524--7 Standard
1 Spindle 002.524--8 Standard
2 Angle 002.524--9 Standard
1 Feeler gauge (set) 000.451 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Welding apparatus (autogenous) -- Inventory
1 Micrometer (inside) -- Inventory
1 Sliding caliper -- Inventory
1 Lubricating oil, clean -- Inventory
1 Securing compound Loctite 640 -- Inventory

Related work cards

Work card Work card Work card

113.02 113.03 113.06

1 Welding torch 3 Inlet valve seat ring A Points of heating

2 Cylinder head 7 Exhaust valve seat ring AS Exhaust side

Figure 1. Heating the valve seat rings

Preliminary remarks

Valve seat rings have to be disassembled and replaced

- if they have corrosion or pounding marks that cannot be machined
away by grinding,
- if material has broken off locally or in case of blow-by or stress crack-
ing, and
- if the limit for remachining (cf. work card 113.06
113.06) has been reached.

6629 113.04--04 E 04.01 32/40 102/ 06

 Removing valve seat rings is not possible without preceding preheating
and cooling down.

2 Cylinder head 7 Exhaust valve seat ring D Gap between cylinder

3 Inlet valve seat ring 6 Hexagon nut M16 head and valve seat ring
AGS Exhaust counter side

Figure 2. Removal of the valve seat rings (illustration shows removal of an inlet valve seat ring)

Operating sequence 1 -- Removal of the valve seat rings

Starting condition Cylinder head removed, carefully cleaned from residues of oil and fuel,
and mounted in cylinder head turnover stand (combustion space side up).
The corresponding inlet or exhaust valve dismantled.

Steps 1. Use the welding torch (1) to heat the valve seat ring (3 or 7) at the
valve seat, at four points spaced approx. 90• around the circumfer-
ence until the material starts melting (refer to Figure 1 ).
2. Let the cylinder head (2) with valve seat ring cool down.
▲ Attention! The tangential stress decays in the zone of heating
because the yield point is exceeded.

6629 113.04--04 E 04.01 32/40 103/ 06

 3. Slacken the expanding solid (002.512-10) to such an extent that the
extractor (002.512) can be inserted into the valve seat ring (refer to
Figure 2 /I).
4. Place the complete extractor (113.218) over the valve seat ring.
5. Align the bolts (002.524-7) by loosening the hexagon nuts (6) so that
the bolts snugly rest on the cylinder head. Afterwards retighten the
hexagon nuts again.
6. Position the shells (002.512-90) in front of gap (D), between valve
seat ring and cylinder head (2), by turning the spindle (002.524-8) -
refer to Figure 2 /I or Detail X.
7. Hold the crown (002.512-5) and force the extractor (002.512) apart
as far as possible by turning the spindle (002.524-8). In this connec-
tion, take care that the shells engage in gap (D), between valve seat
ring and cylinder head (see Figure 2 /II or Detail Y).
8. By evenly turning the adjusting nut (002.524-5), pull the valve seat
ring out (refer to Figure 2 /III).
Important! Take care that the valve seat ring is pulled out evenly,
i.e. that it is not tilted.
9. Inspect the locating bore in the cylinder head for damage, check di-
mension (B) (118.022 mm being the admissible maximum), measure
and note down dimension (E) - refer to Figure 3 ).
▲ Attention! If dimension (B) is exceeded, oversize valve seat rings
should be obtained from MAN B&W Diesel AG. Remachining of the
locating bore is required for this purpose.

Operating sequence 2 -- Installation of the valve seat ring

Starting condition Cylinder head mounted in cylinder head turnover stand (combustion space
side up), locating bore in the cylinder head cleaned and measured.

2 Cylinder head

B max. admissible di-

mension of the locating
bore
E Distance between the
two faces
Figure 3. Locating bore for the valve seat ring in the cylinder head

Steps 1. Measure the distance from the bottom edge to the seating face on
the new valve seat ring, and compare the result with dimension (E).
Dimension (E) must be at least 0.2 mm larger.
2. Insert a new O-ring seal (5) into the ring groove on the exhaust valve
seat ring (7), taking care that it is under even tension over the entire
circumference, and that it is not twisted. The inlet valve seat ring
does not have an O-ring seal (refer to Figure 4 ).
3. Slide the guide piece (113.221) into the valve guide (8), mount the
clamping piece (113.222) and screw the hexagon nut (6) on all the
way, by hand (not using open-jaw and ring wrenches).

6629 113.04--04 E 04.01 32/40 104/ 06

 2 Cylinder head 5 O-ring seal
3 Inlet valve seat ring 7 Exhaust valve seat ring

Figure 4. Cylinder head with inlet and exhaust valve seat ring

2 Cylinder head 6 Hexagon nut M20 C Contact face cylinder

3 Inlet valve seat ring 8 Valve guide head
D Gap between cylinder
head and valve seat ring

Figure 5. Installation of the valve seat ring (illustration shows installation of an inlet valve seat ring)

6629 113.04--04 E 04.01 32/40 105/ 06

 4. Coat the contact face (C) in the cylinder head (2) with Loctite 640,
and, in addition, treat the zone of the O-ring seal (5) with clean min-
eral oil.
5. Place the thrust pad (113.220) on the valve seat ring, slip both over
the guide piece together, and centre them in the locating bore of the
cylinder head by hand (refer to Figure 5 /I).
6. Screw the second hexagon nut (6) all the way onto the guide piece.
7. By turning the hexagon nut, draw the valve seat ring in all the way,
down to contact.
Important! Take care that the valve seat ring is pressed in evenly,
i.e. that it is not tilted.
8. Remove the tool.
9. Check the gap (D) at several points for even width, using the feeler
gauge (000.451).
▲ Attention! The gap must not be narrower than 0.2 mm!
10. Grind the valve seat ring using the valve seat grinder (cf. work card
113.06), and carry out a touching test with a new valve cone (cf. work
113.06
113.03).
card 113.03
11. Fit the inlet or exhaust valve with the new or reground valve cone
113.02).
(cf. work card 113.02

6629 113.04--04 E 04.01 32/40 106/ 06

Valve guide in the cylinder head
Removing and installing 113.05

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Removal and installation of valve guides is not part of the work specified in
the maintenance schedule. This is only necessary if the valve guides are
damaged/worn to such an extent that sealing effect and reliable guiding
are no longer ensured.
The work/steps consist of:
removal of components,
installation of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1
1 Assistant 1

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 113.219 Standard
1 Thrust pad 113.220 Standard
1 Guide piece 113.221 Standard
1 Clamping piece 113.223 Standard
1 Open--jaw and ring wrenches (set) -- Standard

Related work cards

Work card Work card Work card

113.02 113.04

6629 113.05--03 E 04.01 32/40 101/ 03

Operating sequence 1 -- Removal of a valve guide

Starting condition Cylinder head removed and mounted in the cylinder head turnover stand.
Corresponding inlet or exhaust valve dismantled.

Steps 1. Insert the guide piece (113.221) into the valve guide (8), and hold it.
2. Slip the clamping piece (113.223) over the guide piece, and screw on
the hexagon nut (6) - refer to Figure 1 .
3. By turning the hexagon nut, pull the valve guide out of the cylinder
head (2).
4. Clean the locating bore in the cylinder head.

2 Cylinder head
6 Hexagon nut M20
8 Valve guide

Figure 1. Removal of the valve guide

Operating sequence 2 -- Installation of a valve guide

Starting condition Cylinder head mounted in the cylinder head turnover stand (combustion
space side up). Locating bore in the cylinder head cleaned.

Steps 1. Slip the valve guide (8) onto the guide piece (113.221), and attach it
by means of hexagon nut (6) - refer to Figure 2 .
2. Insert the guide piece together with the valve guide into the cylinder
head (2) from below and hold them.
3. Slip the thrust pad (113.220) over the guide piece and place them on
the valve seat ring.
4. Screw on the second hexagon nut (6).
5. By turning the hexagon nut, draw the valve guide into the locating
bore all the way, down to contact.
Important! Take care that the valve guide is drawn in evenly, without
tilting.
6. Remove the complete tool.

6629 113.05--03 E 04.01 32/40 102/ 03

 2 Cylinder head
6 Hexagon nut M20
7 Exhaust valve seat
ring
8 Valve guide

Figure 2. Installation of the valve guide (illustration shows valve guide on the exhaust valve)

6629 113.05--03 E 04.01 32/40 103/ 03

.
Valve plate
Depth of burning marks and corrosion
Checking 113.09

Purpose of jobs to be done

Counteracting corrosion attacks,

keeping the state within the permissible range.

Brief description

When regrinding the valve seat surface, the permissible valve plate
thickness is to be determined.
The work /steps include:
Measure components and
assess wear pattern/condition.

Tools/appliances required

Qty Designation No. Availability

1 Feeler gauge (set) 000.451 Standard
1 Sliding caliper -- Inventory
1 Felt--tip pen/Marking pen -- Inventory
1 Ruler (steel) -- Inventory

Related work cards

Work card Work card Work card

113.03 113.05 113.06

Operating sequence 1 -- Checking the valve plate thickness

Steps 1. Clean valve cone and remove any adhering carbon.

2. Check plate thickness in the as-new condition (HN) at measuring
point C on an identical new valve and note the dimension measured.
3. Using a felt-tip pen, mark one or, depending on the condition of the
valve to be checked, several measuring points C distributed over the
circumference.
4. Using a sliding caliper, check plate thickness at point C and note the
dimension measured.
Dimension A = difference between HN and the dimension measured
must not be larger than 10% of HN (as-new condition) at any point.
Important! If the seat surface of a used valve cone must be
reground, the amount of material expected to be removed by regrinding
must be taken into account in the evaluation of the determined wear

6682 113.09--01 E 05.00 General 101/ 03

 rate A. (The plate thickness will be further reduced by removal of material
from the seat surface S).

5. Laying a ruler on the plate bottom, check wear rate (B) by means of a
depth gauge or feeler gauge approximately in the plate centre, and
note the wear rate measured. Dimension B must not exceed 3.0 mm
at the lowest point.
Important! The valve plate thickness may be reduced to
inadmissible values by regrinding of the valve seat surface (S) and
possible hot corrosion on the plate bottom.

1 Valve plate in as-new

condition
2 Valve plate with
maximum admissible
wear

A Wear rate on plate

edge at point C
B Wear rate in plate
centre
C Measuring point at a
distance of 1/6 of the
outer plate diameter
from the plate edge
D Outer diameter of valve
plate
E Contact blades of the
sliding caliper
HN Plate thickness in the
as-new condition at
point C
S Seating

Figure 1. Determination of wear rate A on valve plate

Operating sequence 2 -- Checking outer diameter (D) of valve plate for corrosion marks

Important! Circumferential corrosion marks of minor depth may

occur at the outer diameter (D) of the valve plate in the transition area
from standard material of valve plate to armour-plating. The transition
area is to be checked for incipient cracks. In case of fissures being found,
the rim (outer diameter is to be reground until all fissures are removed.
However, given machining limits have to be observed.

Steps 1. Clean valve cone. When doing so, do not damage surface by
application of unsuitable cleaning tool (e.g. pick hammer).
2. Check transition area standard material/armour-plating by means of
dye penetration test (Met-L-Check) for fissures (see work card
000.34).
000.34
3. In case of fissures found, valve plate rim (outer diameter) must be
reground until all fissures are removed. Grinding is to be done
without any coolant being used. The following machining limits have
to be observed (refer to Table 1).

6682 113.09--01 E 05.00 General 102/ 03

 Permissible remachining with
Valve plate outer diameter reference to diameter compared
with as-new condition
up to 100 mm 0.2 mm
over 100 mm 0.5 mm
Table 1. Limiting values for reconditioning of valve plate outer diameter

6682 113.09--01 E 05.00 General 103/ 03

.
Operating device

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

6682 125--02 E 04.98 101/ 01

.
4/2-- way valve
Checking, overhauling 125.01

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 4/2--way valve 125.98.237
125.98

4/2-way valve M237

Operating sequence 1 -- Disassembly of the 4/2-way valve

Starting condition Compressed air and control air system resp. without pressure. Valve
cleaned on the outside.

6682 125.01--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check the wear parts for signs of wear and/or hardening (in case of
sealing rings), replace parts as necessary.
5. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 4/2-way valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and in the compressed air/control air system resp.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

Figure 1. 4/2-way valve M237

Mode of operation

Connection TA A P B TB
Control connection X pressurised connected connected closed
Control connection Y pressurised closed connected connected

6682 125.01--01 E 04.98 General 102/ 02

Three-- way valve
Checking, overhauling 125.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Three--way valve 125.98.306
125.98
1 Set of wear parts 125.99.306
125.99

Three-way valve M306

Operating sequence 1 -- Disassembly of the three-way valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.02--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw off the roller lever (11), screw out the valve guide (12) together
with valve tappet (13) and spring.
4. Disassemble the valve further, and thoroughly clean all individual
parts.
5. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the three-way valve M306, a set of wear parts can
be obtained from MAN B&W Diesel AG.
6. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the three-way valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points.

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particules may cause disturbances in
the valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Roller lever
12 Valve guide
13 Valve tappet
14 Valve seat

V Wear parts

Figure 1. Sectional view of the three-way valve M306

Operating principle

Connection 1 2 4
Position I closed connected
Position II connected closed

6682 125.02--01 E 04.98 General 102/ 02

3/2-- way solenoid valve
Checking, overhauling 125.03

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 3/2--way solenoid valve 125.98.307
125.98
1 Set of wear parts 125.99.307
125.99

3/2-way solenoid valve M307

Operating sequence 1 -- Disassembly of the 3/2-way solenoid valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.03--01 E 04.98 General 101/ 03

Steps 1. Loosen pipe connections and/or connecting cables (mark them, if
necessary), remove fixing bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the 3/2-way solenoid valve M307, a set of wear
parts can be obtained from MAN B&W Diesel AG.
5. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 3/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.
▲ Attention! During assembly, pay attention to the installation
position of the seal (12). By dislocation of this seal, the valve
function can be converted.

11 Solenoid part
12 Seal
13 Emergency manual
control knob

Figure 1. Schematic representation of the 3/2-way solenoid valve M307

6682 125.03--01 E 04.98 General 102/ 03

Operating principle

Valve design Connection R1/2 A P1/2

M307/1 Solenoid de-excited connected closed
((open circuit)
i it) Solenoid excited closed connected
M307/2 Solenoid de-excited closed connected
((closed
l d circuit)
i it) Solenoid excited connected closed

6682 125.03--01 E 04.98 General 103/ 03

.
Three-- way valve
Checking, overhauling 125.04

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Hook spanner -- Inventory
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Three--way valve 125.98.317
125.98
1 Set of wear parts 125.99.317
125.99

Three-way valve M317

Operating sequence 1 -- Disassembly of the three-way valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.04--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the hexagon socket bolts (11) and take off the upper part
of the casing (12).
4. Using the hook spanner, turn out the valve guide (15) together with
piston (13) and valve tappet (14).
5. Take out the valve seat (16) and remove the valve (17).
6. Disassemble the valve further, thoroughly clean all individual parts
and discharge the compressed air.
7. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the three-way valve M317, a set of wear parts can
be obtained from MAN B&W Diesel AG.
8. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the three-way valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Hexagon socket bolt

12 Casing -- upper part
13 Piston
14 Valve tappet
15 Valve guide
16 Valve seat
17 Valve
18 Casing -- lower part

V Wear parts

Figure 1. Sectional view of the three-way valve M317

Operating principle

Connection 1 2 4
5 pressurised connected closed
5 pressureless closed connected

6682 125.04--01 E 04.98 General 102/ 02

3/2-- way solenoid valve
Checking, overhauling 125.05

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 3/2--way valve 125.98.329
125.98
1 Set of wear parts 125.99.329
125.99

3/2-way solenoid valve M329

Operating sequence 1 -- Disassembly of the 3/2-way solenoid valve

Starting condition Compressed air and control air system resp. without pressure. Valve
cleaned on the outside.

6682 125.05--01 E 07.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out hexagon bolts (11) and hexagon socket bolts (12).
4. Remove connecting piece (13) with emergency switch (14) and un-
screw hexagon socket bolt (12).
5. Disassembly the valve further and thoroughly clean all individual
parts.
6. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the 3/2-way valve solenoid valve M329, a set of
wear parts can be obtained from MAN B&W Diesel AG.
7. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 3/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and in the compressed air/control air system resp.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Hexagon bolt
12 Hexagon socket bolt
13 Connecting piece
14 Emergency switch
15 Valve casing

V Wear parts

Figure 1. Sectional view of the 3/2-way solenoid valve M329

Mode of operation

Depending on the arrangement of the pins in the valve casing, the

functions illustrated in Figure 1 can be reached.

6682 125.05--01 E 07.98 General 102/ 02

3/2-- way solenoid valve
Checking, overhauling 125.06

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 3/2--way solenoid valve 125.98.359
125.98
1 Set of wear parts 125.99.359
125.99

3/2-way solenoid valve M359

Operating sequence 1 -- Disassembly of the 3/2-way solenoid valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.06--01 E 04.98 General 101/ 03

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw off hexagon nuts (10), hexagon nut (11) and hexagon bolts
(12) and disassemble the valve.
4. Thoroughly clean all individual parts.
5. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the 3/2-way solenoid valve M359, a set of wear
parts can be obtained from MAN B&W Diesel AG.
6. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 3/2-way solenoid valve

For assemby, proceed in the reverse order followed for disassembly,

paying attention to the following points.

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

10 Hexagon nut
11 Hexagon nut
12 Hexagon bolt

V Wear parts

Figure 1. Sectional view of the 3/2-way solenoid valve M359

6682 125.06--01 E 04.98 General 102/ 03

Operating principle

Connection C A B
Solenoid energised closed connected
Solenoid de-energised connected closed

6682 125.06--01 E 04.98 General 103/ 03

.
3/2-- way solenoid valve
Checking, overhauling 125.07

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Inventory
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 3/2--way solenoid valve 125.98.371
125.98
1 Set of wear parts 125.99.371
125.99

3/2-way solenoid valve M371

Operating sequence 1 -- Disassembly of the 3/2-way solenoid valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.07--01 E 04.98 General 101/ 03

Steps 1. Loosen pipe connections and/or connecting cables (mark them, if
necessary), remove fixing bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the socket (12).
4. Disassemble the valve further and thoroughly clean all individual
parts.
5. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the 3/2-way solenoid valve M371, a set of wear
parts can be obtained from MAN B&W Diesel AG.
6. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 3/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause distrubances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Valve casing
12 Socket

V Wear parts

Figure 1. Sectional view of the 3/2-way solenoid valve M371

6682 125.07--01 E 04.98 General 102/ 03

Operating principle

Connection 1 2 3
Solenoid energised closed connected
Solenoid de-energised connected closed

6682 125.07--01 E 04.98 General 103/ 03

.
5/2-- way solenoid valve
Checking, overhauling 125.08

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Qty Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Qty Denomination No.

1 5/2--way solenoid valve 125.98.367
125.98

5/2-way solenoid valve M367

Operating sequence 1 -- Disassembly of the 5/2-way solenoid valve

Starting condition Compressed air and/or control air system without pressure. Governor
cleaned on the outside.

6682 125.08--02 E 03.99 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check the wear parts for signs of wear and/or hardening (in case of
sealing rings), replace parts as necessary.
5. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 5/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and in the compressed air/control air system resp.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

Figure 1. 5/2-way solenoid valve

Mode of operation

Connection 5 4 1 2 3
Solenoid de-energised connected connected closed
Solenoid energised closed connected connected

6682 125.08--02 E 03.99 General 102/ 02

Pressure reducing valve
Checking, overhauling 125.09

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Pressure reducing valve with manometer 125.98.409
125.98
1 Set of wear parts 125.99.409
125.99

Pressure reducing valve M409

Operating sequence 1 -- Disassembly of the pressure reducing valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.09--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the cylindrical screws (11) and knurled screw (14).
4. Separate the upper part of the casing (12) from the lower part (13)
and remove the wear parts (V).
5. Disassemble the valve further and thoroughly clean all individual
parts.
6. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the pressure reducing valve M409, a set of wear
parts can be obtained from MAN B&W Diesel AG.
7. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the pressure reducing valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Cylindrical screw
12 Casing -- upper part
13 Casing -- lower part
14 Knurled screw

V Wear parts

Figure 1. Sectional view of the pressure reducing valve M409

6682 125.09--01 E 04.98 General 102/ 02

Compressed air filter
Checking, overhauling 125.10

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Compressed air filter 125.98.462
125.98
1 Filter insert 125.99.462
125.99

Compressed air filter M462

Operating sequence 1 -- Disassembly of the compressed air filter

Starting condition Compressed air and/or control air system without pressure. Filter cleaned
on the outside.

6682 125.10--01 E 04.98 General 101/ 02

Steps 1. Loosen the pipe connections (mark them, if necessary), remove fixing
bolts and filter.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. First of all, drain the compressed air filter via the hexagon bolt (13).
4. Screw off the hexagon nut (11) and take off the clamp.
5. Disassemble the filter and thoroughly clean all individual parts.
6. Clean the filter insert (12) according to manufacturer’s specification
or, if necessary, replace it by a new one.
Tip! The filter insert for the compressed air filter M462 can be obtained
from MAN B&W Diesel AG.

Operating sequence 2 -- Assembly of the compressed air filter

For assembly, proceed in the reverse order followed for removal, paying
attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.

11 Hexagon nut
12 Filter insert
13 Hexagon bolt

Figure 1. Sectional view of the compressed air filter M462

6682 125.10--01 E 04.98 General 102/ 02

Pressure regulator
Checking, overhauling 125.11

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 1

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Pressure regulator 125.98.470
125.98

Pressure regulator M470

Operating sequence 1 -- Disassembly of the pressure regulator

Starting condition Compressed air and/or control air system without pressure. Regulator
cleaned on the outside.

6682 125.11--01 E 04.98 General 101/ 03

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the hexagon socket bolts (11) and carefully take off the
pilot governor (A).
4. Screw the hexagon socket bolts (13) out and separate the upper part
of the casing (14) from the lower part (15).
5. Disassemble the valve further and thoroughly clean all individual
parts.
6. Check wear parts (V) for signs of wear and/or hardening (in case of
sealing rings), replace parts as necessary.
7. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the pressure regulator

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

6682 125.11--01 E 04.98 General 102/ 03

 11 Hexagon socket bolt 14 Casing -- upper part A Pilot governor
12 Stop knob 15 Casing -- lower part B Main governor
13 Hexagon socket bolt V Wear parts

Figure 1. Sectional view of the pressure regulator M470

6682 125.11--01 E 04.98 General 103/ 03

.
Limit switch
Checking, overhauling 125.12

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Electric/electronic control and/or switch elements are to be checked and, if

necessary, overhauled at regular intervals.
The work/steps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard

Spare parts required

Quant Denomination No.

1 Limit switch 125.98.745
125.98
1 Set of wear parts 125.99.745
125.99

Limit switch M745

Operating sequence 1 -- Disassembly of the limit switch

Starting condition No voltage is applied to the limit switch.

Steps 1. Loosen the connecting cables (mark them, if necessary), remove

fixing bolts and switch.

6682 125.12--01 E 04.98 General 101/ 02

 2. Remove the roller lever(1), screw out the cylindrical screws (2) and
take off the push-button.
3. Screw out the cylindrical screws (3) and take off the cover (4).
4. Disassemble the limit switch further and thoroughly clean all
individual parts.
5. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the limit switch

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work.

1 Roller lever
2 Cylindrical screw
3 Cylindrical screw
4 Cover

Figure 1. Illustration of the limit switch M745

6682 125.12--01 E 04.98 General 102/ 02

Pressure regulator
Checking, overhauling 125.13

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 1

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Pressure regulator 125.98.618
125.98

Pressure regulator M618

Operating sequence 1 -- Disassembly of the pressure regulator

Starting condition Compressed air and/or control air system without pressure. Regulator
cleaned on the outside.

6682 125.13--01 E 04.98 General 101/ 03

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the hexagon nuts (11) and take off pilot governor (A) and
3/2-way valve (B).
4. Screw out the hexagon socket bolts (13) and separate the upper part
of the casing (14) from the lower part (15).
5. Disassemble the valve further and thoroughly clean all individual
parts.
6. Check wear parts (V) for signs of wear and/or hardening (in case of
sealing rings), replace parts as necessary.
7. Before assembly, check all moving parts for smooth movement.

11 Hexagon nut 14 Casing -- upper part A Pilot governor

12 Stop knob 15 Casing -- lower part B 3/2-way valve
13 Hexagon socket bolt 16 Pressure gauge C Main governor
V Wear parts

Figure 1. Sectional view of the pressure regulator M618

6682 125.13--01 E 04.98 General 102/ 03

Operating sequence 2 -- Assembly of the pressure regulator

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

6682 125.13--01 E 04.98 General 103/ 03

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

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

6682 160...--02 E 04.98 101/ 01

.
Starting air pilot valve
Disassembling and assembling 160.01

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Starting air pilot valves are to be disassembled and overhauled at regular

intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Tools/appliances required

Qty Designation No. Availability

1 Thickness gauges 0.05--1 000.451 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Depth gauge -- Inventory

Technical details

Term Information
Starting air pilot valve 8.5 kg

Operating sequence 1 -- Dismantling and disassembling the starting air pilot valve

Important! When opening the starting air system make sure that
no dirt can enter the valves and pipes. Open pipe ends have to be
blanked off with plastic caps or adhesive tape. The work place at which
starting air pilot valves are disassembled must be clean; use fat solvents
and compressed air for cleaning.
For reassembly, make sure that the work place is meticulously clean. Dirt
particles may cause malfunctions in the starting air system.

Steps 1. Screw the air supply pipe (2) and the control air pipe (4) off the cas-
ing (9). Figure 1.
2. Dismantle and disassemble the complete starting air pilot valve, clean
all the parts, purge the control air holes, check the sliding faces and
the set of seals (6) for wear, replace if necessary.

6629 160.01--02 E 12.00 32/40 101/ 02

 1 Spacer disc 6 Set of seals 12 Pressure tube
2 Air supply pipe 7 O-ring seal 13 Starting cam
3 Hexagon bolt 8 PTFE ring
4 Control air pipe 9 Casing A Gap size
5 Control piston 11 Cylinder crankcase B Gap as new, 2 “ 0.6 mm

Figure 1. Starting air pilot valve - Left: arrangement/Right: control piston. Figure shows clockwise rotating engine

Operating sequence 2 -- Fitting the set of seals

Steps 1. Insert the O-ring seal (7) into the groove.

2. Heat the PTFE ring (8) in oil to 80•C-100•C.
3. Pull the PTFE ring over the control piston (5) into the groove.
4. Reshape the stretched PTFE ring by introducing the control piston (5)
into the oiled casing (9).

Operating sequence 3 -- Assembling and mounting the starting air pilot valve

Starting condition Verify that all the parts are clean, and reassemble and mount them in reverse
order. Pay special attention to the following points:

Steps 1. Check the control piston (5) for ease of movement.

2. After screwing down the two hexagon bolts (3), check the gap size
(A) - see the Operating Instructions, Section 2.5; if necessary, dis-
mantle the starting air pilot valve again and correct the gap size (B)
by removing foils from the spacer disc (1).
3. After connecting the air pipes (2 and 4), check them for leakages and
proper functioning.

6629 160.01--02 E 12.00 32/40 102/ 02

Starting valve
Checking, removing and installing 161.01

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Starting valves are to be checked and, if necessary, overhauled at regular

intervals.
The work/steps include:
checking for tightness,
removal of components,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Fitting/unfitting tool 161.018 Standard
1 Thrust pad 161.018--1 Standard
1 Spindle 161.018--5 Standard
1 Cleaning tool 055.149 Standard
1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Shackle A0.6 002.452 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Ring nut M12 000.182 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.30 161.03

6629 161.01--01 E 07.97 32/40 101/ 04

Technical details

Term Information
Starting valve 6.5 kg
Thrust flange 5.5 kg

Operating sequence 1 -- Checking the tightness

▲ Attention! Should the starting air pipe become hot in operation,

the engine should be shut down immediately if possible, and the
defective starting air valve should be replaced. Prior to working on
the starting air valve, depressurise all the air- carrying pipes. Close
the shut- off valve on the compressed air container.

1 Cylinder head
2 Thrust flange
3 O--ring seal
4 O--ring seal
5 Starting valve
6 Stud bolt
7 Hexagon nut
8 Control air pipe

Figure 1. Starting valve in the cylinder head

Steps 1. Remove the pipe section between the main starting valve and the
manifold to the starting air pilot valves, and block the open ends by
means of the union nut and screw plugs. In that way, it is precluded
that control air can be admitted to any of the starting valves.
2. Open the indicator valve on the cylinder head.
3. Turn the piston into ignition TDC position (inlet and exhaust valves
closed).
4. Admit air to the starting air pipes. Starting valves that are not tight
can be recognised by air issuing at the indicator valve.
Important! Leaking starting air valves should be overhauled
immediately, if possible; otherwise, destruction of the valve seat will
proceed further.

6629 161.01--01 E 07.97 32/40 102/ 04

Operating sequence 2 -- Removing the starting valve

Steps 1. Screw the control air pipe (8) off the thrust flange (2).
2. Screw off two hexagon nuts (7) and remove the thrust flange.
3. Screw the spindle (161.018--5) onto the starting valve (5) until seated.
4. Put the thrust pad (161.018--1) over the spindle and onto the cylinder
head (1), screw on the collar nut (10).
5. Loosen the starting valve by turning the collar nut, and carefully lift
the starting valve out.
6. Screw the ring nut (000.182) onto the spindle, suspend from the
lifting tackle by means of shackle (002.452) and rope, and remove
from the cylinder head.
7. Clean the starting valve bore in the cylinder head using the cleaning
tool (055.149). Be careful that no foreign objects can fall into the
combustion space.
8. Check the valve seat surface in the cylinder head and regrind it if
161.03).
necessary (see work card 161.03
9. Cover the bore in the cylinder head.
10. Put the starting valve down onto the work bench and remove the tool.
11. 161.02).
Disassemble the starting valve and clean it (see work card 161.02

1 Cylinder head
5 Starting valve
9 Neighbouring cylinder
head
10 Collar nut M 20

Figure 2. Removing/installing the starting valve

Operating sequence 3 -- Installing the starting valve

Starting condition Starting valve cleaned and checked, damaged components replaced.
For installation, proceed in the reverse order of removal, taking note of the
following:
1. Treat new O--ring seals (3 and 4) with acid--free grease and fit in ring
groove, taking care that they are evenly tensioned around the
circumference, and not twisted.
2. Fit the starting valve (5) by means of spindle (161.018--5) and ring
nut (000.182).
3. Apply MoS2 lubricant to the threads and contact face of the hexagon
nuts (7), screw them in place and alternately tighten them to the
000.30).
specified torque (see work card 000.30
▲ Attention! If the starting valve is installed with the cylinder head
at operating temperature, provisionally screw the two hexagon nuts

6629 161.01--01 E 07.97 32/40 103/ 04

 (7) hand- tight and tighten them to the specified torque after
temperature equalisation.
4. Upon installation, check the starting valve for tightness (see operating
sequence 1).

6629 161.01--01 E 07.97 32/40 104/ 04

Starting valve
Disassembling and assembling 161.02

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Starting valves are to be checked at regular intervals and overhauled if

necessary.
The work/steps include:
disassembly of components,
replacement of sealing rings/sealing elements,
assembly of components.

Tools/appliances required

Quant Denomination No. Availability

1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Socket wrench insert 19x12.5L 001.767 Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Grinding paste (silicon--free) -- Inventory
1 Touch--up paste -- Inventory

Related work cards

Work card Work card Work card

000.30

Operating sequence 1 - Disassembling the starting air valve

Starting condition Starting air valve dismantled and put down on work bench.

Steps 1. Mount the starting air valve in the vice, with two faces of the valve
cone (21).
2. Screw off the hexagon nut (11), whereby the compression spring (19)
is unloaded.
3. Take the piston (15) off the valve cone. Then take off the casing (20)
with the compression spring.
4. Take the sealing sets (12 and 16) off the piston.
5. Clean all the parts, check them for wear and damage.
6. Check the valve seats by touching tests.

6629 161.02--01 E 05.98 32/40 101/ 03

 7. If grinding in becomes necessary, cautiously mount the casing in the
vice, taking care not to damage sealing faces. Fit the valve cone with
piston but without compression spring and sealings in the casing.
Apply fine grinding paste to the valve seat and rotate the valve cone
to and fro. Lift the valve cone occasionally so that the grinding paste
distributes again. After grinding in, clean the valve cone, the casing
and the piston.
Important! Remove as little material as possible and do not grind
longer than necessary to obtain a uniform, pale-grey annular face (check
by applying touch-up ink).

1 Hexagon nut
12 Packing consisting
of:
13 O-ring seal
14 PTFE ring
15 Piston
16 Packing consisting
of:
17 O-ring seal
18 PTFE ring
19 Compression spring
20 Casing
21 Valve cone

Figure 1. Sectional view of the starting valve (left)/disassembled piston with sealings (right)

Operating sequence 2 - Fit the packings (12 and 16)

Steps 1. Insert the O-ring seal (13 or 17) into the groove.
2. Heat the PTFE ring (14 or 18) in oil to 80 - 100 EC.
3. Pull the PTFE ring over the piston (15) into the groove.
4. Restore the original shape of the elongated PTFE ring by fitting the
piston in the oiled casing (20).

6629 161.02--01 E 05.98 32/40 102/ 03

Operating sequence 3 - Assemble the starting air valve

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

Steps For assembly of the starting air valve, proceed in the reverse order of
disassembly, taking note of the following:

Apply MoS2 lubricant to the threads and contact face of the hexagon nut
(11), screw in place and tighten to the specified torque (see work card
000.30).
000.30

6629 161.02--01 E 05.98 32/40 103/ 03

.
Starting valve
Seat in the cylinder head
Grinding 161.03

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Starting valves are to be checked at regular intervals and overhauled if

necessary.
The work concerns:
establishment of a correct contact pattern.

Personnel and time required

Numb Qualification Time req.

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Grinding tool 055.197 Standard
1 Spindle 055.197--1 Standard
1 Guide bush 055.197--3 Standard
1 Guide bush 055.197--5 Standard
1 Grinding wheel 055.197--9 Standard
1 Small grinding plates (set) 055.197--13 Standard
1 Pliers for retaining rings 055.197--19 Standard
1 Quick--acting cleanser Loctite 7061 055.197--21 Standard
1 Tap wrench 055.197--23 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Depth gauge -- Inventory
1 Torch -- Inventory

Related work cards

Work card Work card Work card

161.01

6629 161.03--02 E 09.99 32/40 101/ 03

Operating sequence 1 -- Grinding the starting valve seat

1 Cylinder head

A Maximum permissible
dimension

Figure 1. Foreshortened representation of the maximum permissible dimension

for grinding the starting valve seat

Starting condition Starting valve removed.

Steps 1. Slip the grinding wheel (055.197-9) onto the spindle (055.197-1) and
fasten it by means of the hexagon nut (22) - refer to Figure 3.
2. Pull worn small grinding plates (055.197-13) from the grinding wheel
and remove possible remnants of adhesive material using
quick-acting cleanser (055.197-21).
3. Paste new small grinding plates onto the grinding wheel - refer to
Figure 2.
4. Introduce the grinding tool into the cylinder head (1), paying attention
to the guide bush (055.197-5).
5. Slip on the guide bush (055.197-3) with an outer diameter of 70 mm
and use it to guide the grinding tool in the starting valve bore.
6. Move the grinding tool to and fro, turning it in the process, lift it now
and then and blow off the grinding dust by means of compressed air.
Tip! Only grind off as much material as necessary to obtain a valve
seat which is polished over the whole width and free from damage.
Therefore, frequently check the valve seat during the grinding process.
Maximum permissible dimension A: 388.5 mm. In case a measured
distance is larger than the permissible dimension, the cylinder head has to
be replaced.
7. After the grinding process has been finished, take the grinding tool
(055.197) out and thoroughly clean the valve seat by means of the
cleaning tool (055.149) - refer to Figure 3.

6629 161.03--02 E 09.99 32/40 102/ 03

 Figure 2. Pasting on the small grinding plates

Figure 3. Grinding (on the left) and cleaning (on the right) the starting valve seat in the cylinder head

6629 161.03--02 E 09.99 32/40 103/ 03

.
Main starting valve
Disassembling and assembling 162.01

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

The main starting valve is to be checked, cleaned and, if necessary,

overhauled at regular intervals.
The work/steps include:
removal of components,
disassembly and assembly,
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Tools, basic scope 000.002 Standard
1 Grinding paste (silicon--free) -- Inventory
1 Threaded rod -- Standard

Technical details

Term Information
Main starting valve 26.2 kg

Operating sequence 1 -- Dismantle and disassemble

Starting condition Engine stopped, no starting attempt necessary. Compressed air vessel
shut off, relieve valves in the compressed air pipes open.

Important! When opening the starting air and control air system,
take care that no dirt can enter the valves and pipes. Open pipe ends are
to be blocked by plastic caps or adhesive tape. Choose a clean work place
for disassembling the main starting valve and the pilot valves, use
fat--dissolving agents and compressed air for cleaning.
Assembly should be done with utmost care and cleanliness. Even
microscopically small dirt particles may cause malfunctions.

Steps 1. Undo pipe connections, remove hexagon head bolts (1) and
dismantle the valve, taking care of sealing rings (2).
2. Block open pipe ends to prevent dirt from entering.

6629 162.01--01 E 07.97 32/40, 40/45, 40/54 101/ 02

 3. Loosen and remove the hexagon head bolts (3), mark the position of
the casing (4) relative to the valve seat (14).
4. Separate the casing from the valve seat. Remove all the individual
parts (5 -- 7), clean them and apply compressed blast air and check
their condition, replace them if necessary.
5. Loosen the cap (8) and remove it, take out the venting valve and
disassemble it into parts (9 --13).
6. Clean all the parts, apply compressed blast air and check their
condition, replace them if necessary.
7. If necessary, grind the valve piston (5) and/or the venting cone (9)
into the valve seat (14 or 10 respectively), using fine--grained grinding
paste.
Important! In grinding in, remove little material and do not grind
longer than necessary to obtain a pale--grey, annular face without defects.
The sealing efficiency can be checked by means of fuel oil or touching ink.
A threaded rod M10 is to be screwed into the valve piston (5) for the
grinding--in operation.

1 Hexagon head bolt

2 Sealing ring
3 Hexagon head bolt
4 Casing
5 Valve piston
6 Sealing ring, consisting
of:
O ring and PTFE ring
7 Compression spring
8 Cap
9 Venting cone
10 Valve seat
11 Nut
12 Piston
13 Sealing ring, consisting
of:
O ring and PTFE ring
14 Valve seat
15 Safety valve

Figure 1. Main starting valve

Operating sequence 2 -- Assemble

For assembly, proceed in the reverse order of disassembly. Particular

attention should be paid to the ease of movement of the moving parts and
to the sealing effect of joints. A performance check is to be made after
installation. If the tightness of the casings is to be checked, the moving,
internal parts are not installed initially. A test pressure of max. 45 bar is to
be used for checking.
For fitting new sealing rings (6 and/or 13), proceed as follows:

Steps 1. Insert an O ring into the groove.

2. Heat the PTFE ring in oil to 80 -- 100 EC.
3. Pull the PTFE ring over the groove edge and into the groove.
4. Restore the original state of the PTFE ring by introducing the valve
piston (5) or the venting cone (9) into the oiled casing (4) or valve
seat (10).

6629 162.01--01 E 07.97 32/40, 40/45, 40/54 102/ 02

Fuel injection pump/Control linkage

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

6682 200...--02 E 04.98 101/ 01

.
Fuel injection pump
Checking 200.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Fuel injection pumps are to be checked at regular intervals.

The work includes:
checking components.

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard
1 Hexagon screw driver (set) -- Standard

Preliminary remarks

Wear of the pump elements primarily depends on the abrasive or corrosive

constituents of the fuel. Correct prehaeating, separation and filtration,
timely maintenance and replacement of wear parts (baffle screws)
contribute to extended service lives, even under unfavourable basic
conditions.

Operating sequence 1 -- Check a fuel injection pump

Starting condition Cover of the injection camshaft housing and the covering at the exhaust
counterside removed.

Steps 1. Check the condition (lubrication) of the injection cams (33), the
followers (32) and the tappet guides.
2. Remove the hexagon head bolt (22) between the fuel rack (25) and
the articulated head (24), and check the fuel rack and sleeve (26) for
ease of motion.
Tip! Movability of sluggish or stuck sleeves can be restored by means
of Diesel fuel oil.
3. Screw the hexagon head bolt (22) in place again and fix it by means
of hexagon nut (23).
4. Block the fuel pipes (fuel oil system without pressure).
5. Screw out both baffle screws (17) of each injection pump (16) and
check them for wear; replace them if necessary.

6629 200.01--01 E 07.97 32/40 101/ 02

 6. Screw the baffle screws (17) complete with new sealing rings (18)
into the injection pump (16), hand-tight.
7. Open the fuel oil pipes.
8. Check the leaked fuel discharge from time to time. In case of
excessive leakage losses, disassemble the respective pump element
(27). If the sealing rings (19) and the O-ring seal (20 and 21) are in
order, the pump element has to be replaces.

16 Injection pump
17 Baffle screw
18 Sealing ring
19 Sealing ring
20 O-ring seal
21 O-ring seal
22 Hexagon head bolt
23 Hexagon nut
24 Articulated head
25 Fuel rack
26 Regulating sleeve
27 Pump element
28 Monobloc cylinder
29 Pump plunger
30 Crankcase
31 Tappet
32 Follower
33 Injection cam

Figure 1. Fuel injection pump

▲ Attention! A pump element consists of the pump pluger (29) and

the monobloc cylinder (28). The pump plunger and monobloc
cylinder can only be replaced together because they fit together.
When installing new pump elements, it is also recommended to fit
new sealing rings (19) and O-ring seals (20 and 21).

6629 200.01--01 E 07.97 32/40 102/ 02

Fuel injection pump
Shutting off 200.02

Purpose of jobs to be done

Ensure correct execution of work,

enable emergency operation.

Brief description

Injection pumps are to be shut off every time single running gears have to
be put out of operation.
The work includes:
putting out of operation components

Tools/appliances required

Quant Denomination No. Availability

1 Clamp 200.078 Standard
1 Hexagon screw driver (set) -- Standard

Preliminary remarks

In case of failures in the injection system, on the cylinder head, on the

valve timing gear or with the piston/connecting rod removed, it is possible
or necessary to shut off the injection pump involved, as a prerequisite for
emergency operation (refer to the operating instruction manual, Section
3.6).
For shut-down, the fuel rack of the injection pump involved is blocked at
the “Zero admission” position.

▲ Attention! Fuel admission to the injection pump must not be

shut off (lubrication of the pump plunger).
Fuel admission to the other injection pumps is made possible by tilting the
knuckle lever fitted on the injection pump that is shut off.

Operating sequence 1 - Shutting off a fuel injection pump

Starting condition Covering of the corresponding cylinder on the exhaust counter side
removed, damaged parts removed and/or the necessary measures for
emergency operation taken (refer to the operating instruction manual,
Section 3.6).

Steps 1. Verify that the fuel rack (25) is at “Zero admission” position (with
engine shut down), or pull the fuel rack against the force of the
knuckle lever spring into “Zero admission” position and hold in that
position (with the engine running).

6629 200.02--01 E 07.97 32/40 101/ 02

 2. Put the two-part clamp (200.078) onto the fuel rack, loosely screw in
the hexagon socket screw. (35).
3. Push the clamp forward until it contacts the casing (34), and tighten
the hexagon socket screws hand-tight.

25 Fuel rack
34 Casing
35 Hexagon socket screw

Figure 1. Fuel injection pump with fuel rack blocked

6629 200.02--01 E 07.97 32/40 102/ 02

Fuel injection pump
Removing and installing 200.03

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Fuel injection pumps are to be dismantled within the scope of maintenance

and repair work.
The work/steps extend to:
removal of components,
installation of components.

Tools/appliances required

Qty Denomination No. Availability

1 Fitting/unfitting tool 200.079 Standard
1 Lever 200.079--1 Standard
1 Support 200.079--6 Standard
1 Bolt 200.079--7 Standard
1 Spring plug 200.079--8 Standard
1 Ring extension, A/F 24 200.073 Standard
1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Shackle A0.6 002.452 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Angular screw driver 000.445 Standard
1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.30 200.05 434.01

6629 200.03--01 E 11.98 32/40 101/ 05

Technical details

Term Information
Fuel injection pump 36.5 kg

Operating sequence 1 - Dismantle a fuel injection pump

Starting condition Covering on the exhaust gas counterside removed, fuel injection pipe
dismounted.

Steps 1. Turn the engine so that the follower of the injection pump (16) is at
cam base circle position (spring largely unloaded).
2. Close all the necessary shut-off valves (such as for the fuel oil pipes,
air ducts etc.).
3. Disconnect the air duct, leaked fuel oil pipe, lube oil pipe and sealing
oil pipe (if fitted) from the injection pump
4. Unscrew the hexagon socket bolts (41) with the hexagon screw driver
(000.445) and take off the flanges (40) of the fuel admission pipe (38)
and fuel oil discharge pipe (42).
5. Unscrew the hexagon head bolt (22) between the control rod (25) and
the articulated head (24).

16 Injection pump
22 Hexagon head bolt
23 Hexagon nut
24 Articulated head
25 Control rod
36 Buckling lever
37 Control linkage
38 Fuel admisson pipe
39 O-ring seal
40 Flange
41 Hexagon socket bolt
42 Fuel oil discharge pipe

Figure 1. Fuel injection pump as mounted

▲ Attention! The correct length of the articulated head between the

buckling lever and the control rod has been adjusted and secured by
the manufacturer. It is expressly pointed out that the articulated
head must not be disassembled and/or changing the length as
adjusted is only allowed for zero position balancing between the
injection pump and the governor.
6. As a protective precaution for the control rod, push it completely in
(full load position).
7. Screw off the hexagon nuts (45) with ring extension (200.073).
8. Screw the support (200.079-6) onto the injection pump.
Important! On engines with attached gallery, removal and
installation by means of lever (200.079-1) may create problems. In this

6629 200.03--01 E 11.98 32/40 102/ 05

 case, the work is to be continued with step 14. If so, steps 9 to 13 are not
to be carried out.
9. Insert the lever (200.079-1) into the support and connect it with the
bolt (200.079-7). Secure the bolt by means of the spring plug
(200.079-8).
10. Attach the rope (44) to the lever by means of shackle (002.452) and
suspend it from the lifting tackle.
11. Lift rope until the lever approximately has the position as shown in
Figure 2/I.
12. Depress the lever to lift the injection pump far enough to come clear
of the bore (see Figure 2/II).
13. Keep the injection pump in this position and remove it sideward.
▲ Attention! During removal, take care that the studs are not
damaged and that the injection pump does not hit any other
parts/does not get caught whereby damage may be caused.
14. Remove the charge-air pipe section (43) situated above and attach
rope together with shackle (002.452) directly to support (200.079-6)
by means of bolt (200.079-7) and spring plug (200.079-8).
15. Cautiously remove injection pump (16) in upward direction, using
lifting tackle.
16. Cover the resultant opening in the crankcase (30).
17. Put the injection pump down on a clean place.
18. Completely remove the tool.
19. Clean the injection pump on the outside.

16 Injection pump 33 Injection cam 45 Hexagon nut

24 Articulated head 36 Buckling lever 46 Stud
25 Control rod 43 Charge-air pipe 47 O-ring seal
30 Crankcase 44 Rope

Figure 2. Removing a fuel injection pump (illustration shows in-line engine)

6629 200.03--01 E 11.98 32/40 103/ 05

Operating sequence 2 - Install a fuel injection pump

Starting condition Injection pump cleaned and checked, control rod completely pushed in as
a precautionary measure of protection (full load position).

Steps 1. Clean the contact faces on the injection pump (16) and the crankcase
(30).
2. Treat new O-ring seals (39) with acid-free grease and fit them in the
ring grooves on the fuel oil admission pipe (38) and fuel oil discharge
pipe (42), making sure not to twist them.
3. Screw the support (200.079-6) onto the injection pump.
Important! Depending on the procedure followed for removal, the
steps 4 to 9 or 10 to 13 are to be carried out for installation.
4. Insert the lever (200.079-1) into the support and connect by means of
bolt (200.079-7). Secure the bolt by means of spring plug
(200.079-8).
5. Attach the rope (44) to the lever by means of a shackle (002.452)
and suspend from lifting tackle. Lift the injection pump.
6. Treat a new O-ring seal (47) with acid-free grease and fit it in the ring
groove, taking care that it is evenly tensioned over the whole
circumference and not twisted.
7. Press the lever down to lift the injection pump.
8. Push the injection pump under the charge-air pipe (43) and over the
bore.
9. Release the pressure exerted on the lever, lowering the injection
pump into the bore.
▲ Attention! Take care that the injection pump does not hit any
other parts/does not get caught during installation whereby damage
may be caused.
10. Attach rope together with shackle (002.452) directly to the support
(200.079-6) by means of bolt (200.079-7) and spring plug
(200.079-8).
11. Lift the injection pump.
12. Treat new O-ring seal (47) with acid-free grease and fit it in the ring
groove, taking care that it is evenly tensioned over the whole
circumference and not twisted.
13. Position the injection pump (16) above the bore and carefully lower it
into the bore by means of the lifting tackle.
▲ Attention! In introducing the injection pump, take care that studs
do not suffer damage.
14. Completely remove the tool.
15. Treat new O-ring seals (39) with acid-free grease and fit them in the
ring grooves on the flange (40), taking care that they are not twisted.
16. Push the flange between the injection pump and fuel admission pipe
and fuel oil discharge pipe, respectively and loosely screw home the
hexagon socket bolts (41) with the hexagon screw driver (000.445)
until seated so as to permit the injection pump to align.
17. Treat the thread and contact face of the hexagon nut (45) with MoS2
lubricant, screw it hand-tight onto the studs (46) (do not tighten
them).
18. Turn the engine (follower of the injection pump aligns on cam).
19. Tighten hexagon nut (45) with ring extension (200.073). During this
process, watch for specified torque (refer to work card 000.30).
000.30 For
order of tightening see Figure 3.

6629 200.03--01 E 11.98 32/40 104/ 05

 1-4 Order of tightening
16 Injection pump
45 Hexagon nut
46 Stud

AGS Exhaust gas

counterside

Figure 3. Order of tightening

20. Tighten the hexagon socket bolts (41).
21. Connect the air pipe, the leaked fuel oil pipe, the lube oil pipe and the
sealing oil pipe (if applicable) to the injection pump.
22. Mount the fuel injection pipe (see work card 434.01).
434.01
23. Measure start and end of delivery on a new or overhauled injection
pump (see work card 200.05).
200.05 Compare the results with those of the
other injection pumps (see the logs).
24. Attach the articulated head (24) to the control rod (25).
▲ Attention! The correct length of the articulated head between
buckling lever and control rod was adjusted and secured by the
supplier. It is expressly pointed out that changing the length of the
articulated head as adjusted is only allowed for zero position
balancing between the injection pump and the governor.
25. Open all the shut-off valves that had been closed in operating
sequence 1.
26. Verify that the control rod is in the “Zero admission” end position
when the complete control linkage is at “Zero admission” (compare
control rod position with that on the other injection pumps).
27. After putting into operation, determine the ignition pressure by taking
indicator diagrams.
Important! A precise setting is very essential for output,
combustion and for an undisturbed operation of the engine.
In the case of excessive ignition pressure deviations, readjustment of the
start of delivery is the only remedy. For this purpose, the thrust plate (59)
in the injection pump is to be replaced. MAN B&W has several thrust
plates of varying thicknesses available (10.6/10.8/11.2/11.4 mm).

6629 200.03--01 E 11.98 32/40 105/ 05

.
Fuel injection pump
Disassembling and assembling 200.04

Purpose of jobs to be done

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

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

Fuel injection pumps are to be dismantled within the scope of maintenance

and repair work.
The work/steps include:
disassembly of components,
replacement of sealing rings/sealing elements,
assembly of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 4
1 Assistant 4

Tools/appliances required

Qty Designation No. Availability

1 Removing tool 200.109 Standard
1 Pressure plate 200.109--1 Standard
1 Support ring 200.109--2 Standard
1 Fitting/unfitting tool 200.074 Standard
1 Bridge 200.074--1 Standard
1 Thrust pad with spindle 200.074--6 Standard
1 Hexagon screw driver 6L 200.095 Standard
1 Hexagon screw driver 6K 200.096 Standard
1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Cross handle 001.891 Standard
1 Screw driver insert 12x12.5 001.857 Standard
1 Screw driver insert 20x12.5 001.856 Standard
1 Eye bolt 001.404 Standard
1 Ring spanner 19x22 000.224 Standard
1 Feeler gauge (set) 000.451 Standard

6629 200.04--04 E 10.01 32/40 101/ 07

 Qty Designation No. Availability
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Securing compound -- Inventory
(Loctite 243)
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.30 200.03 200.06

Operating sequence 1 -- Disassembly of a fuel injection pump

Important! The assembly of injection pumps should be done with

utmost care because an unobjectionable performance and sealing effect
can only be achieved with its individulal components being intact and
clean. In particular, this applies to the monoblock cylinder and the pump
plunger.

Starting condition Injection pump detached and cleaned on the exterior.

Steps 1. Screw out the hexagon socket bolts (48), take off the valve support
(52) and put it down onto a clean support (refer to Figure 1 ).
2. Screw the spindle (74) back, place the bridge (200.074-1) diagonally
onto the casing (34) and attach it by means of hexagon nuts (75) -
refer to Figure 2 /I.
3. Turn the spindle until the thrust pad (200.074-6) contacts the tappet
(31) - refer to Figure 2 /II.
4. Turn the spindle to depress the tappet far enough to unload the screw
plug (57) so that the latter can be removed by means of the eye
bolt (001.404) - refer to Figure 2 /III.
5. Turn the spindle back to untension the compression spring (refer to
Figure 2 /IV).
6. Remove the complete tool.
7. Disassemble the tappet together with the pump plunger (29) and put
them down onto a clean support.
▲ Attention! Do not touch the pump plunger with your bare hands.
Protect the control edges on the pump plunger from damage.
8. Measure the clearance (A) of the pump plunger between the pres-
sure plate (59) and the piston spring plate (63), note down the value
and compare it with the specified clearance.
9. Screw off the hexagon socket bolts (62), and take off the tappet.
10. Take the pressure plate out, and pull the piston spring plate off the
pump plunger.
11. Take the compression spring out of the casing, disassemble the
spring plate (55) and the regulating sleeve (26).
12. Remove the locking wires (76), and screw out both baffle screws
(17).
13. Unscrew the hexagon socket bolts (49), and take the thrust ring (50)
off.
14. Place the support ring (200.109-2) on the casing (34).

6629 200.04--04 E 10.01 32/40 102/ 07

 15. Put the pressure plate (200.109-1) onto the monoblock cylinder (28)
and fix it in place by means of hexagon bolts (84) - refer to Fig-
ure 3 .

17 Baffle screw 49 Hexagon socket bolt 63 Piston spring plate

18 Sealing ring 50 Thrust ring 65 Parallel pin
19 Variseal sealing ring 51 Parallel pin 66 Distance sleeve
20 O-ring seal 52 Valve support 67 Compression spring
22 Variseal sealing ring 53 Compression spring 68 Spring plate
25 Control rod 54 Pressure valve 69 Ball
26 Regulating sleeve 55 Spring plate 70 Plunger packing
27 Pump element 56 Compression spring 71 Cylinder
28 Monoblock cylinder 57 Screw plug 72 Sealing ring
29 Pump plunger 58 Sealing ring 73 Parallel pin
31 Tappet 59 Pressure plate 76 Locking wire
32 Roller 60 Set screw A Clearance
34 Casing 61 Roller pin M Marking
48 Hexagon socket bolt 62 Hexagon socket bolt control rod/
regulating sleeve

Figure 1. Fuel injection pump

16. Screw three hexagon bolts (83) into the pressure plate, and screw
them down until they contact the support ring.

6629 200.04--04 E 10.01 32/40 103/ 07

 17. Pull the monoblock cylinder (28) out of the casing (34) and put it
down onto a clean support.
Important! Take care to avoid tilting of the monoblock cylinder as it
is being pulled out.

31 Tappet 57 Screw plug 75 Hexagon nut M16

34 Casing 58 Sealing ring
56 Compression spring 74 Spindle

Figure 2. Untensioning/tensioning of the compression spring in the fuel injection pump

6629 200.04--04 E 10.01 32/40 104/ 07

 18. Screw the cylinder (71) off, and dismantle the control rod (25).
19. Measure the axial and radial clearance of the roller (32), note down
the values and compare them with the specified clearances.
Important! The replacement of roller should be entrusted to a
service base or MAN B&W personnel as a matter of principle because the
roller pin has been fitted in the tappet by deep-freezing.
20. Check the complete valve support for tightness, and verify that all the
parts move easily; disassemble the valve support, if necessary.
21. Clean all the parts with clean Diesel fuel, and check them for wear
and/or damage.
Important! A pump element consists of the pump plunger and
monoblock cylinder. Pump plunger and monoblock cylinder can only be
replaced together because both parts are fitted together.

20 O-ring seal 83 Hexagon bolt M12x170 84 Hexagon bolt M12x40

28 Monoblock cylinder
34 Casing

Figure 3. Removal of the monoblock cylinder

Operating sequence 2 - Assembly of a fuel injection pump

Starting condition All the parts cleaned and checked for damage, and replaced if necessary.
Tappet and valve support assembled.

Steps 1. Prior to assembly, slightly oil all the parts with thin-bodied mineral oil.
Important! Metallic sealing and contact faces must be absolutely
dry when assembled.
2. Fit a new plunger packing (70) in the ring groove.
3. Install the control rod (25) in the casing (34).
4. Coat the thread of the cylinder (71) over a length of 6 mm with Loctite
243 securing compound, and screw it into the casing with a new seal
(72) fitted.
5. Treat new O-ring seals (20) with acid-free grease, and insert them
into the ring groove, making sure that the O-ring seals are evenly ten-
sioned over the whole circumference, and not twisted.
6. Insert new Variseal sealing rings (19 and 22) into casing (34) and/or
monoblock cylinder (28).

6629 200.04--04 E 10.01 32/40 105/ 07

 7. Introduce the monoblock cylinder (28) into the casing (34), taking
note of the position of the parallel pin (65).
8. Press the monoblock cylinder into the casing, making sure that paral-
lel pin (65) is located between parallel pins (73) - refer to Figure 1 .
Important! When forcing the monoblock cylinder into the casing,
prevent it from tilting.
9. Slip the thrust ring (50) onto the monoblock cylinder.
10. Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket bolts (49), screw the bolts into the casing, hand-tight, and
000.30). For
tighten them to the specified torque (see work card 000.30
order of tightening, refer to Figure 4 .
11. Place the valve support (52) onto the monoblock cylinder, taking note
of the position of bore hole/parallel pin (51).
12. Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket bolts (48), screw the bolts in, hand-tight, and tighten them to
000.30). For order
the specified torque in three stages (see work card 000.30
of tightening, refer to Figure 4 .
13. Fit the regulating sleeve (26) so that the markings (M) on the control
rod and regulating sleeve coincide.
14. Install the spring plate through the regulating sleeve into the casing
Important! Prior to installing the spring plate, verify again that the
markings of regulating sleeve and control rod coincide.
15. Fit the compression spring (56) in the casing.
16. Put the piston spring plate (63) onto the pump plunger (29), insert the
pressure plate (59) in the piston spring plate.
▲ Attention! Do not touch the pump plunger with your bare hands,
protect the control edges on the pump plunger from damage.
17. Slip the tappet (31) over the piston spring plate and fasten it by
means of four hexagon socket bolts (62).
18. Measure the clearance (A) of the pump plunger between pressure
plate and piston spring plate, note down the value and compare it
with the specified clearance.
19. Carefully push the pump plunger and tappet into the monoblock cylin-
der and/or casing, taking note of the position of the longitudinal
groove in the tappet provided for the screw plug (57).
20. Screw the spindle (74) back, place the bridge (200.074-1) diagonally
onto the casing and fasten it by means of hexagon nuts (75) -
refer to Figure 2 /I.
21. Turn the spindle (74) until the thrust pad (200.074-6) contacts the
tappet (refer to Figure 2 /II).
22. Turn the spindle to depress the tappet far enough to allow the screw
plug equipped with a new seal (58) to be fitted (refer to Figure 2 /III).
23. Remove the complete tool.
24. Screw the baffle screws (17) complete with new seals (18) into the
casing and tighten them. Fit the locking wires (76).

6629 200.04--04 E 10.01 32/40 106/ 07

 1-8 Order of tightening
9-19 Order of tightening
48 Hexagon socket bolt
49 Hexagon socket bolt
50 Thrust ring
52 Valve support

Figure 4. Order of tightening the fixing bolts for the monoblock cylinder (on the left) and valve support (on the right)

6629 200.04--04 E 10.01 32/40 107/ 07

.
Fuel injection pump
Check the setting 200.05

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Whenever an injection pump is replaced by a new or overhauled one, the

start and end of delivery is to be checked before putting the engine into
operation.
The work includes:
checking components.

Tools/appliances required

Quant Denomination No. Availability

1 Setting tool 200.080 Optional
1 Open--jaw and ring spanner (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Plastic hose (outside diameter approx. 24 mm, -- Inventory
2m long)

Related work cards

Work card Work card Work card

200.03

Preliminary remarks

These settings have an influence on the ignition pressure, the exhaust gas
emission and other engine operating values. The start and end of delivery
are fixed by the dimensions of the influencing components. Changes are
possible by a matching of the thrust plate and by using the adjusting
device for the injection timing.

Operating sequence 1 - Preparation for check

Starting condition Articulated head separated from fuel rack, all the necessary shut-off
valves closed.

Steps 1. Adjust the control piston for the injection camshaft to the value
recorded in the log.

6629 200.05--01 E 07.97 32/40 101/ 03

 2. Turn the crankshaft to a position of approx. 40ƒ before ignition TDC
of the corresponding cylinder (injection cam starts lifting the tappet).
3. Screw both the baffle screws (17) out of the injection pump (16) and
drain the fuel
Important! If the engine was operated on heavy fuel oil before,
drain the heavy fuel oil while still hot, and flush with Diesel fuel oil if
necessary.
4. Insert the holder (79) of the setting device (200.080) through the
threaded bore for the front baffle screw into the suction bore of the
momobloc cylinder, and tighten the screwed piece (81) by hand.
5. Introduce the plastic hose (82) into the threaded bore for the rear
baffle screw to dispose of the fuel oil vapour that forms. Connect the
hose (76) to the compressed air connection and check the pressure
(6.0 bar).

16 Injection pump
17 Baffle screw
18 Gasket

Figure 1. Baffle screw as screwed down

16 Injection pump
24 Articulated head
25 Fuel rack
28 Monobloc cylinder
33 Injection cam
76 Hose
77 Filter pressure
controller
78 Pressure gauge
79 Holder
80 O-ring seal
81 Screwed piece
82 Plastic hose

Figure 2. Checking the fuel oil injection pump

6629 200.05--01 E 07.97 32/40 102/ 03

Operating sequence 2 - Checking a injection pump

Steps 1. Move the fuel rack (25) to the position fixed in the log.
2. Read the pressure from the pressure gauge (78).
Important! If the pressure exceeds 4.0 bar, turn the engine back
until the pressure drops below 4.0 bar.
3. Turn the engine in the ahead direction until the pressure increases to
4.0 bar. This position is the start of delivery.
4. Read the crank position on the coupling flange and note down.
5. Continue slowly turning in the ahead direction. The pressure will first
rist to 6 bar and then drop again. At 4.0 bar (falling) is the point of
end of delivery.
6. Read the crank position and note down.
Important! For verification, compare the start of delivery which you
have determined with those entered in the log for the neighbouring pumps.
7. Separate the compressed air connection, remove the setting device
and plastic hose.
Important! In case of a longer period of engine shut-down following
the injection pump checking, introduce some oil into the injection pump for
preservation puposes.
8. Screw the baffle screws (17) equipped with new gaskets (18) down
into the injection pump hand-tight.

6629 200.05--01 E 07.97 32/40 103/ 03

.
Fuel injection pump
Baffle screws
Checking and assessing 200.06

Purpose of jobs to be done

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

checking state/wear condition of components,
preventing operating problems/damage.

Brief description

Baffle screws latest have to be checked/replaced in time according to the

maintenance schedule.
The work/steps include:
removal of components,
checking of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.1

Tools/appliances required

Qty Designation No. Availability

1 Socket wrench insert 22x12 200.094 Standard
1 Ring spanner 19x22 000.224 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Magnifier -- Inventory

Related work cards

Work card Work card Work card

200.04

6629 200.06--01 E 10.98 32/40 101/ 04

 1 Fuel injection pump
2 Monoblock cylinder
4 Nose--type baffle
screw (standard
design)
5 Nose--type baffle
screw (output--
improved design)
6 Sealing ring
7 Pump plunger

Figure 1. Sectional view of the fuel injection pump (standard design on the right / output--improved design on the left)

Preliminary remarks

Baffle screws are exposed to high stresses caused by the changing

pressures of the flowing fuel. They are to be considered as wear parts
which help to prevent problems on components of higher value. Smaller
wear particles are removed by the flow of the fuel. Lager particles may
cause damage on pump elements and/or on the seat of the injection valve.
In order to prevent this, the baffle screws are to be checked and/or
replaced latest at the intervals stated in the maintenance schedule.

4 Nose--type baffle
screw (standard
design) with outside
hexagon
5 Nose--type baffle
screw (output--
improved design) with
inside hexagon
8 Wear area

Figure 2. Nose--type baffle screws (standard design at the bottom / output--improved design above)

6629 200.06--01 E 10.98 32/40 102/ 04

Operating sequence 1 -- Remove the baffle screws

Standard design 1. Block the fuel supply and return pipes.

2. Screw out the baffle screws using the ring spanner (000.224).
Output--improved design 1. Block the fuel supply and return pipes.
2. Screw out the baffle screws using socket wrench insert (200.094) and
ring spanner (000.224).

Operating sequence 2 -- Check the wear condition of the baffle screws

The following photos show wear conditions varying in severity. As soon as

damage is found on the surface of a baffle screw, independent of its ex-
tent, the screw is to be replaced.

Figure 3. Damaged nose--type baffle screw

- (A) shows slight material wear--off on the inner contour of the funnel.

Figure 4. Damaged nose--type baffle screw

- (B) shows damage that has already progressed to the outer rim of the
funnel.

Figure 5. Damaged nose--type baffle screw

- (C) shows material wear--off in a large area at the inner contour and
extensive damage on the outer rim of the funnel.

6629 200.06--01 E 10.98 32/40 103/ 04

Operating sequence 3 -- Install the baffle screws

Steps 1. Clean the sealing faces on the injection pump (1).

2. Screw the baffle screws (4/5) back in, together with new sealing rings
(6), and tighten them.
Important! During mounting of the baffle screws, pay attention that
they are not subjected to blows and/or lateral thrust.
3. Open the fuel supply and return pipes.

6629 200.06--01 E 10.98 32/40 104/ 04

Fuel injection pump
Measuring the plunger lift 200.07

Purpose of jobs to be done

Enable/support economic operation.

Brief description

Examine the injection time within the scope of the IMO certification.
The work includes:
determining the plunger lift.

Safety requirements

- Engine shut--down
- Engine secured against starting

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.2
1 Assistant 0.2

Tools/appliances required

Qty Denomination No. Availability

1 Measuring device 200.097 Standard
1 Support 200.097--1 Standard
2 Distance sleeve 200.097--3 Standard
1 Ledge 200.097--5 Standard
1 Bolt 200.097--6 Standard
2 Retaining ring 200.097--7 Standard
1 Bolt 200.097--9 Standard
1 Prism 200.097--10 Standard
1 Dial gauge 200.097--15 Standard
1 Tool box 200.097--18 Standard
1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Memo pad -- Inventory

6629 200.07--01 E 03.99 L 32/40 101/ 03

 2 Injection pump drive
3 Cylinder crankcase
4 Stud
5 Hexagon nut
8 Hexagon socket bolt
M6x18
9 Camshaft casing cover
10 Injection camshaft

Figure 1. Measuring device fitted to the cylinder crankcase

Operating sequence 1 -- Measure the plunger lift

Starting condition Camshaft casing cover removed.

Steps 1. Check the mobility of the ledge (200.097-5) and the prism
(200.097-10).
2. Position the support (200.097-1) on the studs (4) of the camshaft
covering, slip on the distance sleeves (200.097-3) and fasten to the
cylinder crankcase (3) by means of hexagon nuts (5) -- refer to
Figures 1 and 2.
Tip! During attaching, pay attention to the correct fitting position of the
prism.
3. Check the fitting position and/or the position of the prism
(200.097-10) in relation to the injection pump drive (2) -- refer to
Figure 2.
4. Insert the dial gauge (200.097-15) into the support and clamp it using
the hexagon socket bolt (8).
5. Turn the running gear until the cam base circle is reached.
6. Set the dial gauge to “Zero”.
7. Turn the running gear, until the piston has reached ignition-DC (TDC).
Read the dial gauge and note down the gauge value.
8. Compare the value determined with the value of the IMO certification.
9. Remove the complete tool.
10. Determine the values for the other cylinders the same way, noting
them down and comparing them with the values of the IMO
certification.

6629 200.07--01 E 03.99 L 32/40 102/ 03

 1 Fuel injection pump
2 Injection pump drive
3 Cylinder crankcase
4 Stud
5 Hexagon nut
6 Compression spring
7 Spring pin
10 Injection camshaft

A = 120 mm

Figure 2. Fitted measuring device

6629 200.07--01 E 03.99 L 32/40 103/ 03

.
Fuel injection valve

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

6682 221--02 E 04.98 101/ 01

.
Fuel injection valve
Removing and installing 221.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

permit/support economic operation,
prevent operating problems/damage.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work/steps consist of:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Operating media systems closed/depressurised

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 221.182 Standard
1 Extracting sleeve 221.182--1 Standard
1 Threaded spindle 221.182--2 Standard
1 Spindle nut 221.182--3 Standard
1 Extractor 221.181 Standard
1 Lifting eye bolt M12 000.142 Standard
1 Cleaning tool 055.149 Standard
1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Shackle A1.0 002.453 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lifting tackle with rope -- Inventory

6629 221.01--02 E 08.02 32/40 101/ 06

 Qty Designation No. Availability
1 Wooden spatula -- Inventory
1 Wire brush -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.30 221.05 434.01

Operating sequence 1 -- Removal of a fuel injection valve

Important! Engines which normally are operated on heavy fuel oil

have to be operated on Diesel fuel oil for a short period of time before the
injection valves are dismantled

Starting condition Cooling water for the injection valve cooling (if fitted) completely drained.
Shut-off valves on the fuel oil piping closed. Oil pump (standby) shut off,
cylinder head cover taken off, indicator valve opened.

▲▲ Caution! Only dismantle the injection valve with the indicator

valve opened. With this valve closed, a high pressure may exist in
the combustion space.

Steps 1. Disconnect the cooling water admission pipe from the cylinder head
(6) and empty the cooling bores of the injection valve (8) by purging
them with compressed air. Reconnect the pipes.
2. Loosen the hexagon nut (10) and screw it off.
434.01).
3. Remove the fuel injection pipe (refer to work card 434.01
4. Loosen the threaded piece (7), screw it out, and remove it from the
cylinder head.
5. Take the thrust pad (11) off.
6. Screw the extractor (221.181) into the thrust ring (12), and take the
latter off (refer to Figure 2 ).
7. Screw the threaded spindle (221.182-2) onto the injection valve (8)
until seated (refer to Figure 3 ).
8. Slip the extracting sleeve (221.182-1) over the threaded spindle, pay-
ing attention to the recess for the stud (13). Screw the spindle nut
(221.182-3) on.
9. Pull the injection vale out by turning the spindle nut until it comes
loose.
Important! The injection valve may only be removed by means of
the fitting/unfitting tool.
10. Unscrew the spindle nut (221.182-3), and take off the extracting
sleeve (221.182-1).

6629 221.01--02 E 08.02 32/40 102/ 06

 11. Screw the lifting eye bolt (000.142) onto the threaded spindle, attach
the rope to the lifting eye bolt by means of shackle (002.453), and
suspend the rope from the lifting tackle.
12. Carefully pull the injection valve out of the cylinder head, making sure
that the sealing ring (18), too, is dismantled (refer to Figure 4 ).
13. Cover the opening in the cylinder head.
14. Place the injection valve on the work bench, and dismantle the de-
vice.
15. Remove the sealing ring (18).
16. Clean the complete injection valve on the outside, using fuel. Re-
move adhering coke deposits by means of the wire brush. For the
injection nozzle, only use a wooden spatula in order not to damage
the nozzle orifices. Clean the cylindrical projection of the nozzle body
with particular care.
▲ Attention! Cleaning is to be done away from the work bench.

6 Cylinder head
9 Rocker arm with sup-
port
12 Thrust ring
13 Stud

Figure 2. Removal of the thrust ring

6629 221.01--02 E 08.02 32/40 104/ 06

 6 Cylinder head
7 Threaded piece

Figure 3. Removal of the injection valve

Operating sequence 2 -- Installation of a fuel injection valve

Starting condition The injection valve, and especially the cylindrical projection of the nozzle
body, has been carefully cleaned. The injection pressure, tightness and
nozzle bores have been checked.

Important! The injection valve taken from the spares or from a re-
placement delivery should be cleaned and checked on the outside.

Steps 1. Mount the sealing ring (18) on the injection valve (8), making sure
that it tightly fits the nozzle body.
2. Treat new O-ring seals (16) with acid-free grease and fit them in the
ring grooves, taking care that they are evenly tensioned over the
whole circumference and not distorted.
3. Top up the inner space (spring space) of the injection valve with clean
fuel oil through the leakage fuel oil drain hole.
4. Screw the threaded spindle (221.182-2) onto the injection valve.
5. Screw the lifting eye bolt (000.142) onto the threaded spindle
(221.182-2), attach the rope to the lifting eye bolt by means of the
shackle (002.453), and suspend the rope from the lifting tackle.
6. Remove the cover put over the bore hole in the cylinder head (6), and
thoroughly clean the bore hole and the seating face in the cylinder
head using the cleaning device (055.149).
▲ Attention! During cleaning, take care that no foreign matter falls
into the combustion space.
7. Carefully install the injection valve in the bore hole, taking note of the
correct position of the bore hole for the threaded piece (7). Press
down the injection valve until seated.

6629 221.01--02 E 08.02 32/40 105/ 06

 6 Cylinder head 11 Thrust pad
7 Threaded piece 12 Thrust ring
8 Injection valve 13 Stud
9 Rocker arm with support 16 O-ring seal
10 Hexagon nut

Figure 1. Cylinder head with injection valve and parts of the fuel injection pipe

6629 221.01--02 E 08.02 32/40 103/ 06

 8. Take the shackle off the lifting eye bolt, unscrew the lifting eye bolt
and the threaded spindle.
9. Install the thrust ring (12) with the extractor.
10. Place the thrust pad (11) over the stud bolts (13) and onto the thrust
ring.
11. Apply MoS2 lubricant to the thread of the threaded piece (7), screw
the latter into the injection valve, and tighten it to the specified torque
(refer to work card 000.30).
000.30
434.01).
12. Fit the fuel injection pipe in place (refer to work card 434.01
13. Apply MoS2 lubricant to the thread and contact face of the hexagon
nut (10), screw the nut onto the stud (13), hand-tight, and tighten it to
000.30) in several stages.
the specified torque (see work card 000.30
Important! If the injection valve is to be installed in a cylinder head
still at operating temperature, initially fasten the hexagon nut (10), hand-
tight, and tighten it to the specified torque after equalisation of tempera-
tures.
14. Close the indicator valve.
15. Top up cooling water for the injection valve cooling.
16. Open the shut-off valves on the fuel oil pipes.
17. Mount the cylinder head cover.

6 Cylinder head
8 Injection valve
18 Sealing ring

Figure 4. Removal of the injection valve

6629 221.01--02 E 08.02 32/40 106/ 06

Fuel injection valve
Checking 221.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work includes:
checking components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 2

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Connecting piece 221.197--26 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Connecting piece 221.196--26 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Connecting piece 221.195--26 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Connecting piece 221.200--24 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Connecting piece 221.201--23 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Connecting piece 221.202--22 Standard
1 Compressed air max. 15 bar -- Inventory

6629 221.02--03 E 09.02 32/40 upw 101/ 06

 Qty Designation No. Availability
1 Anti--corrosion oil -- Inventory
1 Receptacle for anti--corrosion oil -- Inventory
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard

Related work cards

Work card Work card Work card

221.03 221.04

Remark: The tool numbers of the individual pressure tester components consist of
the tool number of the pressure tester and the item number of the individ-
ual component. Refer to Figures 1 and 2 .
Example: Tool number of the high-pressure hose for engine type
L 58/64: 221.202-6.

Preliminary remarks

The functioning and setting of the injection valve influence the combustion
process, the operating data and the loading of the injection system. In
case the operating data (firing pressure, exhaust gas temperature)
change, the opening pressure and tightness of the valves concerned are
to be checked. The pressure tester permits pressure testing by means of
a hydro-pneumatic high-pressure pump. The device ensures that the work
can be carried out comfortably and under reproducible conditions.

Note

When testing injection valves of modern four-stroke engines, atomisation

no longer is a test criterion, as the nozzle’s behaviour during engine oper-
ation cannot be duplicated by means of the pressure tester.
A poor injection pattern does not permit to draw conclusions on the
nozzle’s performance in the engine. It is fully operational, provided that
the criteria with regard to opening pressure, tightness and unclogged
nozzle bores are fulfilled.

6629 221.02--03 E 09.02 32/40 upw 102/ 06

Structure and diagram of the pressure tester

1 Pressure gauge 0-600 bar 6 High-pressure hose 14 Nozzle-jet collector

2 Air cock 10 Hydraulic pump 15 Collector cover
3 Filter pressure regulator 11 Pressure control valve 16 Fixing head
4 Pneumatic coupling 12 Oil tank
5 Pressure relief valve 13 Oil collecting pan

Figure 1. Pressure tester

Legend: as for Figure 1

9,22,23,24,26
Connecting piece

Figure 2. Pressure tester diagram

6629 221.02--03 E 09.02 32/40 upw 103/ 06

Operating sequence 1 -- Preparation of check

Important! Heavy fuel oil residues in injection valves may adversely

affect the test results and impede cleaning. We therefore recommend op-
erating the engine on Diesel oil for approx. one hour prior to dismantling
injection valves. If this is not possible and the engine has to be shut down
from operation on heavy fuel oil, the injection valve has to be disas-
sembled and cleaned before the checks described here can be carried
out.

Starting condition The injection valve has been removed and cleaned on the outside.

Important! Anti-corrosion oil is to be used for testing the injection

valves because this oil serves as a preservation agent at the same time.
Only absolutely clean anti-corrosion oil may be filled into the pressure
tester; otherwise, disturbances may occur in the pump or in the injection
valve to be tested. The content level in the oil tank (12) is to be checked.

Steps 1. Depending on the engine type, insert the correct reducing jaws into
the fixing head (16) - for the 58/64 engine type, reducing jaws are not
required. Insert the injection valve into the fixing head and clamp it
evenly using the retainer.
2. Depending on the engine type, screw the suitable connecting piece
(9, 22, 23, 24, 26) in at the delivery pipe connection of the injection
nozzle, and screw the high-pressure hose (6) onto the connecting
piece.
3. Place the nozzle-jet collector (13-15) under the injection nozzle and
push it upward so as to ensure that the jets to be expected hit the
outer walls of the nozzle-jet collector.
▲ Attention! Never let the injection nozzle spray into the open, but
always directly into the collector! Fuel jets must not be touched, as
they pierce the skin tissue and cause painful infections! Naked
flames are not allowed in the working area! No smoking at all! If
possible, remove the oil vapour by suction!
Checking and adjusting the injection valves includes the following steps:
- Check the opening pressure,
- check the nozzle bores,
- adjust the specified pressure,
- check for tightness.

Operating sequence 2 -- Check the opening pressure

Steps 1. Turn the knob on the filter pressure regulator (3) all the way to the left
(Minus -), and set the air cock (2) to “Ein” (On).
2. Close the pressure relief valve (5).
3. By turning the knob on the filter pressure regulator (3) to the right
(Plus +), start the hydraulic pump (10) and slowly increase the pres-
sure until the injection valve opens. Note down the opening pressure
and compare it with the specified value (for specified value, refer to
the Operating Instructions, sheet 2.5.2). Keep the pressure tester
running for at least 20 seconds, thus flushing the injection valve.
Important! The hydraulic pressure has to be increased slowly until
the opening pressure is reached, as otherwise faults will occur when read-
ing off the opening pressure. The test pressure must not exceed 400 bar!
When the injection test is carried out for the first time on new nozzle el-
ements, the nozzle needle may be stuck due to preservation and has to be

6629 221.02--03 E 09.02 32/40 upw 104/ 06

 loosened by flushing it thoroughly. In the case of injection nozzles that
have already been used, collect the anti-corrosion oil contaminated with
fuel, and do not fill it back into the pressure tester.

With new nozzles, a drop in opening pressure by 50-90 bar may already
occur after a few operating hours.
This pressure drop does not represent a malfunction and is typical of all
fuel injection valves.

Decision Decrease in opening pressure less than/more than 90 bar?

Decrease in opening pressure less Continue with the next step.

than 90 bar -
Decrease in opening pressure more Disassemble the injection valve
than 90 bar - 221.03).
(according to work card 221.03
Carry out a visual inspection
(spring broken)
If components are in good order,
continue with the next step.

Operating sequence 3 -- Check the nozzle bores

Steps 1. Turn the filter pressure regulator all the way to the left (Minus - ),
open the pressure relief valve (5), and continue as follows (for item-
221.03):
related details, refer to work card 221.03
2. Loosen the hexagon nut (44), and turn back the setting screw (45)
until the tension of the compression spring (49) has been released.
3. Close the pressure relief valve. Start the hydraulic pump by means of
the knob on the filter pressure regulator, and adjust the opening pres-
sure to 30 bar by turning the setting screw (45).
Decision Are all nozzle bores open? Refer to Figure 3 .

Yes - continue with the next step.

No - disassemble the injection valve (according to work card
221.03).
221.03

Figure 3. Judging the nozzle bores. On the left - open, on the right - partly
clogged

Operating sequence 4 -- Adjust the opening pressure to the specified value

Steps 1. Increase the hydraulic pressure by means of the knob on the filter
pressure regulator (3). At the same time, slightly tension the com-
pression spring (49) using the setting screw (45). Repeat the pro-
cess until the specified value (tolerance 20 bar) has been reached
(for specified value, refer to the Operating Instructions, sheet 2.5.2).
Important! Do not adjust a higher pressure than specified as, other-
wise, deformation of the compression spring will result. Only after installa-

6629 221.02--03 E 09.02 32/40 upw 105/ 06

 tion of a new compression spring, adjust the injection pressure to the
specified higher value at first in order to compensate an initial settling of
the compression spring.
2. If the specified value has been adjusted reproducibly, lock the setting
screw (45) by means of the hexagon nut (44), and check the opening
pressure once again.

Operating sequence 5 -- Check the tightness

Steps 1. For checking the tightness, adjust the pressure to 250 bar by means
of the knob on the filter pressure regulator (3), and keep it at this
value. The injection nozzle can be considered tight if no drop falls
within a period of 5 seconds.
Decision Tightness ok? Refer to Figure 4 .

Yes - the injection valve can be used!

No - the injection valve is to be sent to MAN B&W Diesel AG
Augsburg for regeneration.

Figure 4. Judging the tightness. On the left - tight, on the right - dripping

6629 221.02--03 E 09.02 32/40 upw 106/ 06

Fuel injection valve
Disassembling 221.03

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work/steps include:
disassembly of components,
checking of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Socket wrench 221.143 Standard
1 Torque wrench 008.017 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Socket wrench 221.194 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Socket wrench 221.040 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Socket wrench 221.127 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Socket wrench 221.119 Standard

6629 221.03--03 E 09.02 32/40 upw 101/ 06

 Qty Designation No. Availability
1 Torque wrench 008.005 Standard
1 Eye bolt 001.412 Standard
1 Chuck 002.701 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Wire brush -- Inventory
1 Wooden spatula -- Inventory
1 Cleaning wires (set) -- Inventory
1 Depth gauge -- Inventory
1 Tank with fuel -- Inventory
1 Cleaning material (wool) -- Inventory
1 Paper towels -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Securing compound -- Inventory
(Loctite 243)

Related work cards

Work card Work card Work card

000.30 221.02 221.04

Preliminary remarks

Important! Injection valves are to be disassembled if the checks

according to work card 221.02 revealed defects and in case the nozzle
element is to be replaced due to the operating time reached.
Disassembly is carried out in the pressure tester.

Operating sequence 1 -- Disassembly of a fuel injection valve

Steps 1. Rinse the injection valve in fuel, and remove coke deposits sticking to
it by means of a wire brush.
2. Swing the collecting tank (13-15) to the side, and insert suitable re-
ducing jaws into the fixing head (16) of the clamping device (for the
58/64 engine type, reducing jaws are not required).
3. Insert the injection valve into the fixing head, with the injection nozzle
facing downward, and clamp it in place evenly.
4. Loosen the hexagon nut (44), and back off the setting screw (45) until
the tension on the compression spring (49) has been released.
5. Unscrew the hexagon bolts (60) from the fixing head (16). Turn the
fixing head with the injection valve by 180•, and screw the hexagon
bolts back in.
6. Carefully loosen the nozzle tensioning nut (52).

6629 221.03--03 E 09.02 32/40 upw 102/ 06

 Important! If a strong resistance is felt while loosening the nut, it
has to be tried to restore easy movement of the thread by soaking in fuel
oil and by turning the nut back and forth until it can be moved easily. Do
not exert force when loosening the nozzle tensioning nut, as otherwise the
thread may seize and the parts become unusable.

6 High-pressure hose
13-15 Collecting tank
16 Fixing head
60 Hexagon bolt

Figure 1. Pressure tester

7. Unscrew the nozzle tensioning nut and take the nozzle body off.
Take care that the nozzle needle (43) does not fall out.
8. Pull the nozzle needle (43) out of the nozzle body, and immerse it in
fuel for cleaning.
Important! Do not interchange the nozzle needles of the individual
nozzle bodies. They are produced in paires.
9. Unscrew the hexagon bolts (60) from the fixing head (16). Turn the
fixing head with the injection valve back by 180•, and screw the hexa-
gon bolts back in.
10. Remove the injection valve from the fixing head of the pressure
tester, and put it down onto the work bench.
11. Unscrew the setting screw.
12. In case the inner parts are not loose, screw the eye bolt (001.412)
into the thrust pad (48), and pull the thrust pad out. Afterwards, re-
move the compression spring and spring plate (50).
Important! In the case of the 32/40 engine, the set screw (47) has
to be removed for this purpose. On the valves of the larger engines, this
is not required.
13. Immerse all parts in Diesel oil for cleaning, and wash them off, then
blow them by means of compressed air.

6629 221.03--03 E 09.02 32/40 upw 103/ 06

 42 Nozzle body
43 Nozzle needle
44 Hexagon nut
45 Setting screw
46 Holder
47 Set screw
48 Thrust pad
49 Compression spring
50 Spring plate
51 Parallel pin
52 Nozzle tensioning nut

Figure 2. Injection valve (figure shows injection valve of the 32/40 engine type)

Operating sequence 2 -- Check the components

The component check includes the following:

- the nozzle bores,
- the condition of the fitting area,
- the movability of the needle,
- traces of corrosion on the nozzle tensioning nut and on the nozzle
body,
- the nozzle specification.
Tip! Pay particular attention to such sources of error that caused un-
satisfactory results when the injection valve was checked.

6629 221.03--03 E 09.02 32/40 upw 104/ 06

Steps 1. Distinguishing characteristics of nitride-hardened nozzle elements
and seat-insert nozzle elements (refer to Figure 3 ).

Figure 3. Distinguishing characteristic:

On the left - nitride-hardened nozzle element, on the right - seat-insert nozzle el-
ement
2. For nozzle-bore cleaning, clamp a suitable cleaning wire into the
chuck (002.701) and run it through the nozzle bores (refer to Fig-
ure 4 ).

41 Cleaning wire
42 Nozzle body

Figure 4. Cleaning the nozzle bores

3. Inspect all components, especially the sealing faces, for damage/
traces of wear.
Important! The seats and fitting areas must neither be reworked by
hand nor remachined, as the required accuracy cannot be achieved.
4. Check to see if the nozzle needle can be easily moved in the nozzle
body, without noticeable resistance (refer to Figure 5 ).

42 Nozzle body
43 Nozzle needle

Figure 5. Checking the nozzle needle for movability

6629 221.03--03 E 09.02 32/40 upw 105/ 06

 5. Inspect the nozzle body for traces of corrosion. These may be max.
2.5 mm deep. Check the nozzle cooling water outlet temperature; if
necessary, increase it to max. 90ƒ C.
6. Read the nozzle specification off at the collar of the nozzle body, and
compare it with the required specification (refer to Figure 6 ).
For the original specification, please refer to the engine’s acceptance
records.

Figure 6. Nozzle element. On the left - nozzle specification, on the right - regener-
ation marking.
7. Replace damaged parts. Always replace nozzle needle and nozzle
body together. If necessary, have them regenerated by MAN B&W
Diesel AG, Augsburg or Hamburg. Other workshops are not autho-
rised to do this job.
Important! Regenerated nozzle elements are marked by RA or RH
and the date of regeneration. Repeated regeneration is only possible in
the case of seat-insert nozzle elements.

6629 221.03--03 E 09.02 32/40 upw 106/ 06

Fuel injection valve
Assembling 221.04

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work includes:
reassembling components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Socket wrench 221.143 Standard
1 Torque wrench 008.017 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Socket wrench 221.194 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Socket wrench 221.040 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Socket wrench 221.127 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Socket wrench 221.119 Standard
1 Torque wrench 008.005 Standard

6629 221.04--02 E 09.02 32/40 upw 101/ 04

 Qty Designation No. Availability
1 Eye bolt 001.412 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard

Related work cards

Work card Work card Work card

000.30 221.02 221.03

42 Nozzle body
43 Nozzle needle
44 Hexagon nut
45 Setting screw
46 Holder
47 Set screw
48 Thrust pad
49 Compression spring
50 Spring plate
51 Parallel pin
52 Nozzle tensioning nut

Figure 1. Injection valve (figure shows injection valve of the 32/40 engine type)

6629 221.04--02 E 09.02 32/40 upw 102/ 04

Operating sequence 1 -- Assembly of a fuel injection valve

Important! Prior to assembly, check whether the specification of the

injection nozzle coincides with the required specification. The original
specification can be gathered from the acceptance record (number,
number of nozzle bores, bore diameter, injection angle).

Starting condition The injection valve has been disassembled, all individual components
carefully cleaned and defective parts replaced.

Steps 1. This applies only to the 32/40 engine: Carefully clean the set screw
(47) and the bore hole according to Loctite specification.
2. Screw the eye bolt (001.412) into the thrust pad (48), hold the holder
(46) at an angle (with the sealing face pointing up), and insert the
thrust pad including compression spring (49) and spring plate (50),
paying attention to the position of the groove for the set screw (47) -
refer to Figure 1 .
Verify that the spring plate has been positioned correctly.
3. This applies only to the 32/40 engine: Coat the thread of the set
screw with Loctite 234 securing compound over a length of 5 mm,
and screw the set screw into the holder until it does no longer pro-
trude.
Verify that the thrust pad is still movable in axial direction.
4. Unscrew the eye bolt.
5. Screw the setting screw (45) in, do not yet tension the compression
spring.
6. Depending on the engine type, insert a suitable reducing jaw into the
fixing head (16) of the pressure tester (for the 58/64 engine type, re-
ducing jaws are not required) - refer to Figure 2 .

6629 221.04--02 E 09.02 32/40 upw 103/ 04

 6 High-pressure hose
13-15 Receptacle
16 Fixing head
60 Hexagon bolt

Figure 2. Pressure tester

7. Insert the holder (46) into the fixing head (16) in such a way that the
sealing face for the nozzle body (42) points down, and clamp it
evenly. Turn the fixing head by 180ƒ and fix it in place.
8. Dip the nozzle needle (43) into clean fuel oil, and insert it into the
nozzle body. Verify that it moves easily.
9. Check the nozzle needle lift between the upper edge of the nozzle
body and the step on the nozzle needle.
For the specified value, refer to Volume B1, section “Technical Data”.
10. Wipe the sealing face dry using a paper towel. Slip the nozzle body
and the nozzle needle onto the holder, paying attention to the position
of the two parallel pins (51).
11. Coat the thread of the holder and nozzle tensioning nut (52) with
MoS2 lubricant.
12. Screw the nozzle tensioning nut onto the holder, hand-tight, and
tighten it to the specified torque (see work card 000.30)
000.30 in a second
step. Turn the fixing head by 180ƒ and fix it in place.
13. Screw the hexagon nut (44) loosely onto the setting screw, and
tighten it only after adjusting the injecton pressure (see work card
221.02).
221.02

6629 221.04--02 E 09.02 32/40 upw 104/ 04

Fuel injection valve
Seat in the cylinder head
Grinding 221.05

Purpose of jobs to be done

Ensure correct execution of work,

assess wear pattern/condition,
restore contact pattern.

Brief description

The injection valve seat in the cylinder head is to be checked by means of

a touching test and, if necessary, remachined every time the fuel injection
valve is removed.
The work concerns:
establishment of a correct contact pattern.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Grinding tool 055.197 Standard
1 Spindle 055.197--1 Standard
1 Guide bush 055.197--3 Standard
1 Guide bush 055.197--5 Standard
1 Grinding wheel 055.197--7 Standard
1 Small grinding plates (set) 055.197--13 Standard
1 Pliers for retaining rings 055.197--19 Standard
1 Quick--acting cleanser Loctite 7061 055.197--21 Standard
1 Tap wrench 055.197--23 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Depth gauge -- Inventory
1 Torch -- Inventory

Related work cards

Work card Work card Work card

221.01

6629 221.05--02 E 04.00 32/40 101/ 03

Operating sequence 1 -- Grinding the seat

Starting condition Fuel injection valve removed.

Steps 1. Screw out the hexagon bolt (63) and remove the washer (62) - refer
to Figure 1.

6 Cylinder head
15 Sleeve
62 Washer
63 Hexagon bolt

Figure 1. Securing the sleeves in the cylinder head

2. Slip the grinding wheel (055.197-7) onto the spindle (055.197-1) and
fasten it by means of the hexagon nut (61) - refer to Figure 4.
3. Pull worn small grinding plates (055.197-13) off the grinding wheel
and remove possible remnants of adhesive material using
quick-acting cleanser (055.197-21).
4. Paste new small grinding plates onto the grinding wheel - refer to
Figure 2.

Figure 2. Pasting on the small grinding plates

5. Insert the grinding tool into the cylinder head (6), paying attention to
the guide bush (055.197-5).
6. Slip on the guide bush (055.197-3) with an outer diameter of 71 mm,
using it to guide the grinding tool in the sleeve (15).
7. Move the grinding tool to and fro, turning it in the process, lift it now
and then and blow off the grinding dust by means of compressed air.
Important! Only grind off as much material as necessary to obtain a
valve seat which is polished over the whole width and free from damage.

6629 221.05--02 E 04.00 32/40 102/ 03

 Therefore, frequently check the valve seat during the grinding process.
Maximum permissible dimension A: 400 mm. In case this dimension is
exceeded, the sleeve (17) has to be replaced - refer to Figure 3.

6 Cylinder head
15 Sleeve
17 Sleeve

A Max. permissible
dimension

Figure 3. Foreshortened representation of the max. permissible dimension for

grinding the fuel injection valve seat
8. After the grinding process has been finished, take the grinding tool
(055.197) out and thoroughly clean the valve seat by means of the
cleaning tool (055.149) - refer to Figure 4.
9. Using the hexagon bolt (63), mount the washer (62) on the cylinder
head (6).

6 Cylinder head 17 Sleeve

9 Rocker arm casing 61 Hexagon nut M12

Figure 4. Grinding (on the left) and cleaning (on the right) the fuel injection valve seat in the cylinder head

6629 221.05--02 E 04.00 32/40 103/ 03

.
Fuel injection valve
Sealing faces on the threaded piece
Grinding 221.06

Purpose of jobs to be done

Ensure correct execution of work,

assess wear pattern/condition,
restore contact pattern.

Brief description

The sealing faces on the threaded piece to the fuel injection valve are to
be checked for damage and, if necessary, remachined every time it is
removed.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Quant Denomination No. Availability

1 Grinding device for delivery pipe 434.042 Optional
1 Locating plate 434.042--1 Optional
1 Threaded ring 434.042--2 Optional
1 Bearing ring 434.042--3 Optional
1 Bearing flange 434.042--4 Optional
1 Spacer ring 434.042--7 Optional
1 Spacer ring 434.042--8 Optional
1 Stop gauge (threaded piece) 434.042--9 Optional
2 Bearing block 434.042--10 Optional
1 Swivel arm 434.042--11 Optional
1 Bracket 434.042--12 Optional
1 Stop 434.042--13 Optional
1 Grinding wheel 434.042--16 Optional
1 Base plate 434.042--17 Optional
1 Sliding carriage 434.042--18 Optional
1 Shaft 434.042--19 Optional
1 Stop 434.042--20 Optional
1 Counter flange (threaded piece) 434.042--21 Optional
1 Adapter flange (threaded piece) 434.042--22 Optional
1 Ball bearing 434.042--24 Optional
1 Ball bearing 434.042--25 Optional
1 Hook spanner 434.042--37 Optional
1 Face spanner 434.042--38 Optional

6629 221.06--02 E 04.98 32/40 101/ 05

 Quant Denomination No. Availability
2 Clamping lever 434.042--41 Optional
1 Clamping piece 434.042--42 Optional
5 Emery paper 434.042--44 Optional
1 Hexagon screw driver 5 000.294 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Tommy bar 8 000.262 Standard
1 Cleaning agent -- Inventory
1 Safety goggles -- Inventory

Related work cards

Work card Work card Work card

221.01

1 Fuel injection pipe 2 Hexagon socket bolt 3 Grinding device

M5x10 4 Support adjusting crank

Figure 1. Grinding device for delivery pipe with attached fuel injection pipe

6629 221.06--02 E 04.98 32/40 102/ 05

 2 Hexagon socket bolt
M5x10
5 Stop

Figure 2. Grinding device for delivery pipe

Operating sequence 1 -- Attaching the threaded piece to the grinding device for delivery pipe

Important! The grinding device for the delivery pipe must be

installed and operated on a solid support. Vibrations of the grinding device
have an influence on the surface quality of the sealing faces to be ground.
The injection delivery pipes to be ground must be absolutely free from lube
oils and greases. Any kind of contamination, especially lubricants, reduce
the service time of the grinding wheel considerably.

Steps 1. Loosen both clamping levers (434.042--41) and swivel out the
grinding device (3) together with the bracket (434.042--12) up to the
right--hand stop.
2. Screw the adapter flange (434.042--22) onto the threaded ring
(434.042--2) by means of the hexagon socket bolts (2) and tighten
them.
3. Attach the stop gauge (434.042--9) to the adapter flange using two
hexagon socket screws (6).
Tip! When fastening the stop gauge to the adapter flange by means of
the tommy bar (000.262), hold up at the threaded ring.
4. Screw the counter flange (434.042--21) onto the threaded piece (1).
Tip! The threaded piece has a left--hand thread on the injection valve
side.
5. Screw the delivery pipe into the adapter flange by means of the
counter flange, until the cone of the delivery pipe contacts the stop
gauge.

6629 221.06--02 E 04.98 32/40 103/ 05

 6. Screw the counter flange onto the adapter flange and tighten it using
the face spanner (434.042--38) and hook spanner (434.042--37).
7. Attach the clamping piece (434.042--42) to the end of the threaded
piece (see Figure 1).
8. Remove stop gauge (434.042--9).
9. Push the tommy bar (000.262) radially into the threaded ring
(434.042--2), screwing the ring in until it contacts the locating plate
(434.042--1).
10. Press the yellow stop knob on the grinding device, put the grinding
wheel (434.042--16) together with the emery paper (434.042--44) onto
the grinding device and tighten by means of mounting nut.
11. Pull the sliding carriage (434.042--18) back by means of the support
adjusting crank (4).
12. Swivel the bracket (434.042--12) back in again until it contacts the
stop, blocking it on the sliding carriage by means of the two clamping
levers (434.042--41).

1 Fuel injection pipe

6 Hexagon socket bolt
M6x35

Figure 3. Attaching the threaded piece on the grinding device for delivery pipe

Operating sequence 2 -- Regrinding of the sealing faces on the delivery pipe

Starting condition Threaded piece correctly attached to the grinding device for delivery pipe.
Grinding wheel with new emery paper mounted on the grinding device.

▲ Attention! The remachining of the sealing faces is intricate and

requires particular care. It is recommended to have this work carried
out in a service centre or by personnel of MAN B&W Diesel.

Steps 1. Swing the swivel arm (434.042--11) with the grinding device to the
right--hand stop (5).
2. Move the grinding wheel (434.042--16) towards the sealing face of
the threaded piece by means of the support adjusting crank until the
grinding wheel touches the sealing face.
3. Move the swivel arm to the left--hand stop (434.042--13) so that the
front side of the grinding wheel faces the threaded piece.
▲▲ Caution! Wear safety goggles when grinding delivery pipes!
4. Establish the voltage supply for the grinding device and switch the
device on.
5. Turn the threaded piece evenly at the clamping piece (434.042--42),
and, at the same time, move the swivel arm with the grinding device
around the sealing face contour.
▲ Attention! The grinding wheel must not contact the adapter
flange.

6629 221.06--02 E 04.98 32/40 104/ 05

 6. The feed is effected at the threaded ring (434.042--2) by means of the
tommy bar (000.262). Maximum feed per operation is a scale mark
at the threaded ring.
▲ Attention! The feed is not effected at the support adjusting
crank. The adjusted position remains unchanged during the whole
grinding process. Sealing faces are to be slightly remachined only,
merely to be smoothed, removing as little of the material as
possible.
7. Move the swivel arm to the left--hand stop so that the front face of the
grinding wheel faces the threaded piece and turn off the grinding
device.
8. Evaluate the result of the grinding process. Repeat the grinding
process until the sealing face has been ground evenly bright.
Important! In case the required contact pattern can no longer be
realised by means of the grinding device for delivery pipe, the grinding
device is to be sent to an MAN service centre for repair.

Tip! Remove used up emery paper immediately and replace by new

emery paper.
9. Remove the threaded piece from the grinding device for delivery pipe
and take off the counter flange.

6629 221.06--02 E 04.98 32/40 105/ 05

.
Charge air and exhaust pipe

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

6682 280...--02 E 04.98 101/ 01

.
Exhaust pipe
Checking 289.01

Purpose of jobs to be done

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

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

The exhaust pipe is to be checked at regular intervals for tightness of the

flanged connections and compensators.
The work/steps include:
checking of components
disassembling and assembling of components.
installation of components.

Tools/appliances required

Quant Denomination No. Availability

1 Torque wrench 008.017 Standard
2 Eye bolt M12 000.142 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Wire brush -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant for hot parts -- Inventory

Related work cards

Work card Work card Work card

000.30

Operating sequence 1 - Checking and disassembling the exhaust manifold

Starting condition Casing of the exhaust manifold removed on respective parts.

Steps 1. Chech exhaust manifold for leak-proof condition on flange

connections and compensators.
Tip! Leaky exhaust manifolds will be noted by dark areas on the
respective insulation at spots where the leaks have occured.
2. Screw eye bolts (000.142) into eyes (12) on exhaust manifold scetion
(6) and fasten with rope to lifting tackle.

6629 289.01--01 E 10.97 L 32/40 101/ 03

 3. Screw off hexagon nuts (3) and dismantle bolted coupling (2). Re-
move flange joint (13).
4. Pull the exhaust manifold section up slowly. During this process,
watch that compensators are not damaged.
5. Dismount remaining exhaust manifold sections and compensators.
6. Clean exhaust manifold sections and compensators.

Operating sequence 2 - Reassemble exhaust manifold

Starting condition Assembling is a reversal of the disassembling process. The following

points are to be observed.
1. When installing compensators watch for correct installation position
(protective tube inside in flow direction, see figure; detail X)
2. Tighten bolted coupling (2) and flansh joints (13) with specified torque
(cf. work card 000.30).
000.30
▲▲ Caution! If piston or valve damages have occured the exhaust
manifold has to be checked for foreign matter. Broken pieces can be
drawn into the turbine by the flow of the exhaust gases and cause
serious damages.

1 Connection piece 4 Compensator 9 Cylinder head

2 Bolted coupling 6 Exhaust manifold section 11 Flow direction
3 Hexagon nut 7 Turbocharger 12 Eye
13 Flange joint

Figure 1. Exhaust manifold

6629 289.01--01 E 10.97 L 32/40 102/ 03

 6 Exhaust manifold
section
8 Hexagon bolt
9 Cylinder head
10 Casing
13 Flange joint

Figure 2. Exhaust manifold

6629 289.01--01 E 10.97 L 32/40 103/ 03

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

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

6682 300...--02 E 04.98 101/ 01

.
Lube oil pump
Disassembling and assembling 300.01

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Lubricating--oil pumps require little or no maintenance. But if operating

problems occur, it is necessary to check the individual components for
damage, and replace them if necessary. If there is damage to the
bearings, replace the entire pump.
The work/steps include:
removal of components,
disassembly and assembly,
mounting of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 3
1 Assistant 3

Tools/appliances required

Qty Designation No. Availability

1 Forcing--off device 009.340 Optional
1 Counterbrace 009.340--11 Optional
1 Forcing--off device 009.331 Optional
1 Forcing--off device 009.331--3 Optional
1 Pipe 009.331--6 Optional
1 Forcing--off disk 009.331--8 Optional
1 Forcing--off bolt 009.331--9 Optional
1 Torque wrench 008.011 Standard
1 Torque wrench 008.017 Standard
1 Power amplifier 008.030 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 25x20 001.924 Optional
1 Adapter 20x12.5 001.923 Standard
1 Cross handle 001.892 Optional
1 Cross handle 001.891 Standard

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 101/ 04

 Qty Designation No. Availability
1 Socket wrench insert 55x25 001.804 Optional
1 Socket wrench insert 14x12.5 001.753 Standard
1 Socket wrench insert 30x12.5 001.759 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Depth gauge -- Inventory
2 Threaded rod -- Standard
1 Lifting tackle with rope -- Inventory
1 Collecting tank -- Inventory
1 Hammer (wood/plastic) -- Inventory
1 Sealing compound -- Inventory

Related work cards

Work card Work card Work card

000.30

3 Drive cover
4 Blank flange
5 Pump casing
6 Ring seal
7 Ring seal
8 Bearing unit (two-part)
9 Hexagon-head bolt
10 Valve casing
11 Valve head
12 Compression spring
13 Ring seal
14 Hexagon-head screw
15 Valve bonnet
16 Screw plug
17 Adapter disk
19 Drive shaft
20 Impeller axle
22 Sleeve
23 Hexagon-head bolt

Figure 1. Lubricating-oil pump (two-stage)

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 102/ 04

 1 Nut 24 Cap screw A Spacing
2 Drive gear-wheel

Figure 2. Forcing-off device for gear-wheel of lubricating-oil pump

Introductory remarks

The lube-oil pump consists of two separate pumps of identical construc-

tion, which are connected by means of the adapter disk (17).

Operating sequence 1 -- Removing and disassembling the lubricating-oil pump

Steps 1. Disconnect the pipes and blank flanges (4) from the lube-oil pump,
allowing the oil to drain into the tank. Be careful not to damage
gaskets and ring seals.
2. Sling the pump from the lifting tackle with a rope, and tauten the
rope.
3. Unscrew the fastening screws on the drive cover (3), remove the
pump carefully, and set it down on a wooden rest.
4. Remove the cap screw (24) that secures nut (1) with the screwdriver
(000.293).
5. Mount the forcing-off device (009.331-3) on the drive gear-wheel (2),
slide the pipe (009.331-6) on, and unscrew nut (1).
6. Force off the drive gear-wheel, using the forcing-off device and the
forcing-off disk (009.331-8).
7. Loosen and unscrew the hexagon-head bolts (23) between the pump
casing (5) and the adapter disk (17).
8. Separate Pump 2 from Pump 1, being careful not to damage the
cylindrical pins. Remove the adapter disk (17).
9. Loosen and unscrew the hexagon-head bolts (23) between the pump
casing (5) and the drive cover (3).
10. Mark the drive shafts (19), impeller axles (20), and bearing units (8)
on both pumps, so that they can be re-installed in the same position.
11. Remove the drive shafts, impeller axles, and bearing units.
12. Remove the taper pins on the drive cover (3) with suitable equipment,
and remove the drive cover with the bolted-on bearing unit.
13. Unscrew the hexagon-head bolts (9) and separate the pressure relief
valve from Pump 2, being careful not to damage the cylindrical pins).
Important! Only disassemble the pressure relief valve if it malfunc-
tions. In that case, proceed as follows:

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 103/ 04

 14. Unscrew two opposite hexagon-head screws (14) on the valve cover
(15), and replace them by two M8-size threaded spindles, about 100
mm long.
15. Screw two M8 hexagon nuts all the way onto the two spindles, until
they rest against the valve cover, and unscrew the other hexagon-
head screws.
16. Relieve the initial tension of the compression springs (12) by backing
off the two M8 hexagon nuts uniformly; steady with the two threaded
spindles.
17. Remove the valve cover (15) and the compression spring (12) with
valve disk (11).
Important! Do not unscrew the screw plug (16). Do not unscrew or
re-adjust the lock screw.
18. Clean all parts, and check them for damage; check the appearance
and wear of the bearing and sliding surfaces. Replace all ring seals,
gaskets, and spring washers.
▲ Attention! If there is damage to the bearings, replace the entire
lube-oil pump.

Operating sequence 2 -- Assembling and mounting the lubricating-oil pump

Starting condition All parts cleaned and checked. All ring seals, gaskets, and spring washers
replaced.
Assembly and mounting are done by analogy to disassembly and removal,
in reverse order. Mind the following points:
1. Lubricate all moving parts with oil.
2. Do not change the setting of the pressure-relief valve (opening pres-
sure set to 7.5 bars).
3. Do not insert paper gaskets between the drive cover, casing, and
pressure-relief valve.
4. Coat the threads of the hexagon-head bolts (9, 23) with oil, screw
them in – not forgetting the spring washers (circlips) – and tighten
000.30).
with the specified tightening torque (see Work Card 000.30
5. If Pump 2 is mounted onto Pump 1, make sure that the teeth of the
drive shafts (19) engage correctly.
6. Check the entire pump for ease of movement.
7. To remount the drive gear-wheel (2), place it on the lightly oiled tap-
ered section of the drive shaft (19), mount the forcing-off device
(009.331-3), and slide the pipe (009.331-6) on.
8. Oil nut (1), screw it onto the drive shaft (19), and tighten it with the
specified initial torque (see Work Card 000.30).
000.30
9. Measure and note down the distance (A) between the end face of the
drive shaft (19) and the nut (1) with a depth gauge.
10. Tighten the nut with the specified tightening torque (see Work Card
000.30).
000.30 Repeat the measurement according to Item 9, and compare
the two values.
The spacing (A) must have increased by 0.6 mm to 1.5 mm.
11. Secure the nut (1) by tightening the cap screw (24) firmly.
12. Before installing, clean the sealing surface between the pump and
engine and coat it with Hylomar SW32M sealant.
13. Fill the pump with oil.
14. Connect the pipes (unpressurized) to the pump, and screw on the
blank flanges (4).
15. When starting the engine, check the pump and piping for leaks and
noises. Loud noises indicate that the lube-oil pump is aspirating air,
so that the pump does not deliver at full capacity and cavitation may
occur.

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 104/ 04

Lube oil pump
Assessing the individual components 300.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Lubricating--oil pumps require little or no maintenance. But if operating

problems occur, it is necessary to check the individual components for
damage, and replace them if necessary. If there is damage to the
bearings, replace the entire pump.
The work /steps include:
Measure components and
assess wear pattern/condition.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Feeler gauge (set) 000.451 Standard
1 Micrometer (outside) -- Inventory
1 Micrometer (inside) -- Inventory
1 Abrasive (emery cloth K400) -- Inventory
1 Oil stone -- Inventory
1 Sealing compound -- Inventory

Related work cards

Work card Work card Work card

300.01

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 101/ 05

Preliminary remarks

These criteria are provided for the evaluation of wear parts on lube oil
pumps. The stated criteria are to render it possible to decide which
components of the gear pump can further be used and which not.
The criteria for the evaluation regarding re-usability are based on the
assumption that the operating conditions of the lube oil pump do not
change during the course of the operating time. This especially applies to
quality and cleanliness of the lubricant used, its treatment and the
occurring maximum temperatures and loading of the pumps.
Components, the re-usability of which is uncertain, are to be replaced in
principle or the time interval to the next pump inspection is to be shortened
in order to rule out the risk of an unexpected pump failure.
Already for the removal of components, proper tools are to be used, in
order to avoid that parts are damaged during dismantling.
The parts to be inspected are to be cleaned thoroughly after removal.
During the assembly of the pump, it is important, beside scrupulous
cleanliness, to make sure that all the re-used components are remounted
as originally positioned within the pump.

Criteria for the evaluation of wear parts on lube oil pumps

1. Seals
On principle, seals are to replaced by new ones every time the lube oil
pump is dismantled.
Grooves, in which O-ring seals are positioned, have to be cleaned
thoroughly and checked for foreign body or damage on the groove edges.
Minor edge damage can manually be smoothed out by means of emery
cloth (grain size 400 according to DIN 69176, part 1 or finer) and a
scraper.
Residues from liquid sealing have to be removed completely before the
pump can be remounted using a new sealing agent.
2. Gear shafts
2.1 Tooth system

1 Tooth flanks
2 Axial butting face
3 Crest of the tooth

Figure 1. Gear shaft

The replacement of gear shafts due to damage in the area of the tooth
system is only necessary if it is determined that material has broken off the
crest of the tooth > 3 mm in longitudinal direction.
Further use of the gear shafts is possible in case of
- scores or scratches on tooth flanks, even if they can be distinctly seen
or felt. Sharp-edged burrs on the tooth system which might exist,

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 102/ 05

 especially on the crests of the teeth, should, as far as possible, be
removed or smoothed by means of a scraper, oil stone or emery cloth
to such an extent that a smooth meshing of theeth with the second
gear shaft is possible, if such a gear shaft is to be re-used.
- individual indentations < 1 cm2 on tooth flanks.
- chip-off of material particles < 1 cm2 in the area of the transition
between axial butting face and tooth flank
2.2 Bearing journal

4 Bearing journal

Figure 2. Bearing journal

Further use of the gear shafts is not possible due to damage in the area of
the bearing journal if
- scores, scratches or chip-offs are found on the bearing journal which
are so deep that they can be made out by touching with the finger nail
or the tip of a pencil.
- material changes due to overheating or distinct blue discolorations are
found on the bearing journals.
2.3 Axial butting faces

2 Axial butting faces

Figure 3. Front surface of the gear shaft

A further use of the gear shaft and/or bearing support due to damage in
the area of the axial butting faces is not possible if
- scores or scratches are found on the axial butting faces which are so
deep that they can be made out by touching with the finger nail or the
tip of the pencil.
Important! Gear shaft and bearing support are adapted to each
other. It is, therefore, not possible here to replace individual components.
It is recommended to replace the lube oil pump and to have the damaged
one repaired by MAN B&W Diesel or by an authorised service center.

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 103/ 05

 3. Bearing bushes
3.1 Structure and wear characteristics
The bearing bushes of the lube oil pumps consist of a steel bush onto
which a bronze layer is sintered. The bronze layer contains a mixture of
PTFE and lead in the pores in way to the shaft which form a grey-green
glimmering slide layer as against the bearing journal of the gear shaft.
During the course of pump operation, the slide layer is gradually worn off
and the bronze layer lying underneath becomes more and more visible.
After a short running-in phase, during the course of which slight deposits
from the slide layer may occur on the bearing journal (harmless), the slide
layer is further worn off approximately analogously to the operating time, if
the stresses acting on the bearing and the operating conditions remain the
same.

3.2 Visual inspection of the bearing bushes

6 Bronze layer
7 Slide layer

Figure 4. Bearing bush in new condition

The bearing bushes are to be replaced when on approx. 70% of the

internal face of the bush the metallic bronze layer is visible.
Further use of the bearing bush is possible if
- the visible bronze portion is less than 35% of the running surface.
- the bearing bushes are otherwise in a good condition, i.e. there are
neither scratches nor scores which penetrate the grey-green slide layer
down to the bronze layer.
- the next maintenance interval corresponds to the operatingt time of the
preceding maintenance interval.

3.3 Bearing bush assessment based on the measurement of the

bearing clearance

A Inner diameter of the

bearing bush
B Outer diameter of the
bearing journal

Figure 5. Diameter for determining the bearing clearance

If there is uncertainty concerning the assessment of the wear condition

based on visible indicators, the measurement of the bearing clearance can

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 104/ 05

 provide more precise information regarding the condition of the bush.
For this purpose, the inner diameter (A) of the bearing bushes and the
outer diameter (B) of the appertaining bearing journals (4) have to be
mesasured.
Further use of the bearing bush is possible if
- in case of a shaft diameter of 60 mm: A -- B < 0.36 mm
- in case of a shaft diameter of 50 mm: A -- B < 0.34 mm

C,D Measuring level

Figure 6. Measuring levels for determining the bearing clearance

Important! Measuring the diameter has to be carried out at both

measuring levels (C, D) of the bearing bush and bearing journal. In case
the limiting value for further use is exceeded, even if this is only the case
on one of the two front surfaces, the bush has to be replaced.

3.4 Evaluation of the bearing bushes regarding scores or scratches

Individual scores and scratches, which are located within the grey-green
slide layer, permit the further use of the bearing bushes, unless the
assessment criterion mentioned under 3.2 is not complied with.
In case, however, there are scores or scratches in the internal face of the
bush which distinctly extend into the bronze layer or into the steel jacket,
the bushes have to be replaced.

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 105/ 05

.
Cooling water pump
Disassembling and assembling 350.01

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Cooling water pumps are, to a large extent, maintenance free. Should,

however, operating problems occur, it is necessary to check the individual
components for damage and to replace them, if necessary.
The work/steps include:
removal of components,
disassembly and assembly,
mounting of components.

Tools/appliances required

Qty Designation No. Availability

1 Forcing--off device 350.011 Optional
1 Forcing--off bolt 350.011--1 Optional
1 Forcing--off disk 350.011--3 Optional
1 Forcing--off device 009.331 Optional
1 Forcing--off device 009.331--3 Optional
1 Pipe 009.331--6 Optional
1 Forcing--off disk 009.331--8 Optional
1 Forcing--off bolt 009.331--9 Optional
1 Torque wrench 008.011 Standard
1 Pliers for retaining rings C 19--60 002.162 Standard
1 Extension piece 12.5x125 001.911 Standard
1 Socket wrench insert 27x12.5 001.758 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Hexagon screw drivers (set) -- Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Securing compound -- Inventory
(Loctite 243)
1 Sealing compound -- Inventory
1 Lifting tackle with rope -- Inventory

6629 350.01--07 E 01.02 32/40 101/ 05

Related work cards

Work card Work card Work card

000.30

Operating sequence 1 -- Removal and disassembly of the cooling water pump

Starting condition The cooling water has been cut off and drained from the cooling water
pump, the engine has been secured against inadvertent starting.

3 Shaft 17 Seal
4 Bearing casing 18 Flange
5 Roller bearing 19 Volute casing
6 Snap ring 20 Screw plug
8 Roller bearing 21 Hexagon nut
10 Seal 22 Washer
11 Screw plug 33 Gearwheel
12 Hexagon nut 34 Washer
13 Washer 35 Hexagon bolt
15 Wheel nut 36 Hexagon bolt
16 Impeller A Gap dimension

Figure 1. Cooling water pump

Steps 1. Loosen oil and water pipes from the cooling water pump and remove
them, paying attention to the seals.
2. Attach cooling water pump to lifting tackle by means of rope, and
tighten the rope.
3. Loosen the hexagon bolts (36) and screw them out.
4. Force off the cooling water pump by means of two hexagon bolts with
pin (M16), take it off carefully and place it onto wooden pad.

6629 350.01--07 E 01.02 32/40 102/ 05

 5. Loosen the hexagon nuts (12), screw them off and take off the inlet
flange (18), paying attention to the washers (13) and sealing ring
(17).
6. Loosen the hexagon nuts (21), screw them off, and take off the volute
casing (19). Pay attention to the seal (10) and the washer (22).
7. Loosen the wheel nut (15), holding up at the gearwheel (33) by
means of the forcing-off device (009.331-3) - refer to Figure 3 .
Tip! Depending on the sense of rotation of the cooling water pump, the
wheel nut has a right-hand or a left-hand thread.
8. Using the forcing-off device (350.011), pull off the impeller (16) -
refer to Figure 3 .
9. Remove the slide seal ring (25 - 27), paying attention to the individual
parts.

3 Shaft
4 Bearing casing
16 Impeller
25 Slide seal ring
26 Thrust ring
27 Seat ring
30 Shaft seal

Figure 2. Set of shaft seals

4 Bearing casing
16 Impeller
31 Hexagon bolt M8x90
and/or M10x90
32 Hexagon bolt
M10x120/M16x100/
M10x90
33 Gearwheel

Figure 3. Removal of the impeller

10. Loosen the hexagon bolt (35), holding up by means of the forcing-off
device (009.331-3) - refer to Figure 4 .
11. Force off the gearwheel (33) - refer to Figure 4 .
12. Take off the snap ring (6) and remove shaft (3) including roller bear-
ing (5).
13. Remove the shaft seal (30), if necessary.
14. Check ball bearings (8 and 5), replace them if necessary.
15. Clean all parts, check them for wear, renew damaged or worn parts.

6629 350.01--07 E 01.02 32/40 103/ 05

 3 Shaft 32 Hexagon bolt 34 Washer
4 Bearing casing 33 Gearwheel 35 Hexagon bolt

Figure 4. Removal of the gearwheel

Operating sequence 2 -- Assembly and mounting of the cooling water pump

Starting condition For assembly resp. mounting, proceed in the reverse order followed for
removal resp. disassembly, observing the following items:
1. Install the shaft (3) prior to fitting the shaft seal (30), in case it had
been removed.
2. When installing the shaft seal, observe the following items (3 - 5):
3. Check the sealing lip for damage, remove any impurities.
4. Grease the shaft seal and knead it somewhat by hand.
5. Install the shaft seal correctly (the sealing lip must point towards the
ball bearing). Make sure that the sealing lip is not damaged.
6. Mount the gearwheel (33) as follows (items 7 - 11):
7. Slightly oil the shaft cone and push the gearwheel on so that it fits
snugly.
Important! Use light oil! The gearwheel will only fit firmly on the
shaft cone after displacement of the oil film.
8. Oil the hexagon bolt (35), slip on the washer (34), screw them in to-
gether and tighten to the specified preliminary torque (see work card
000.30).
000.30
9. Measure the gap (A) between gearwheel and bearing casing (4), and
note down the value.
Important! During measuring, the axial clearance must always be
on the same side, pull the shaft out to contact!
10. Tighten the hexagon bolt to the specified final torque (see work card
000.30).
000.30
11. Repeat the measurement according to item 9, and compare both
values. Gap (A) must have been reduced by 0.8 to 0.9 mm.
12. Apply Hylomar sealing compound to the sealing face between volute
casing (19) and bearing casing (4), and mount the volute casing.
13. Check shaft running surface and seat of sealing ring in the bearing
casing for cleanliness, and install the slide seal ring (25 - 27) as de-
scribed below (items 14 - 15):

6629 350.01--07 E 01.02 32/40 104/ 05

 14. Press the seat ring (27) into the slightly oiled seat in the bearing cas-
ing.
15. Apply vegetable oil to the shaft and the bore hole of the slide seal
ring (25), and slip the thrust ring (26) together with the slide seal ring
onto the shaft (refer to Figure 4 ) until the thrust ring contacts the
seat ring.
Important! Do not damage or scratch the sealing faces. Do not let
the shaft seal run dry. Fill the pump with water prior to taking it into oper-
ation!
16. Mount the impeller (16) as follows (items 17, 18):
17. Clean and dry shaft and impeller cone, do not oil them! Slip on the
impeller.
18. Apply Loctite 242 to thread and nut contact face, screw on the wheel
nut (15), and tighten to the specified torque and angle of torsion (see
000.30).
work card 000.30
19. Check shaft for ease of motion.
20. Apply Hylomar sealing compound to the sealing face between bear-
ing casing (4) and cylinder crankcase prior to attachment to the en-
gine.
21. Prior to connecting the water pipe, fill the cooling water pump with
water.
22. After a short period of operation, check cooling water pump and pipe
connections for tightness.

6629 350.01--07 E 01.02 32/40 105/ 05

.
Fuel injection pipe

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

6682 434--02 E 04.98 101/ 01

.
Fuel injection pipe
Removing and refitting 434.01

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

Fuel injection pipes are to be dismounted for maintenance and repair work
on injection valves or injection pumps.
The work/steps include:
dismounting components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Plate--type spanner, 32 mm 009.088 Standard
1 Ratchet 008.023 Standard
1 Torque wrench 008.011 Standard
1 Adapter 20x12.5 001.923 Standard
1 Extension piece 001.913 Inventory
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.30 221.01 434.02

6629 434.01--02 E 02.01 32/40 101/ 04

 1 Cylinder head 8 Delivery pipe 15 Leaked fuel drain pipe
2 Threaded piece 9 Injection pump 16 Hexagon bolt
3 O-ring seal 10 Covering (bottom) 17 Washer
4 Adapter 11 Hexagon bolt 18 Nut (left-handed
5 Nut 12 Hexagon nut thread)
6 Set screw 13 Charge-air pipe
7 Hexagon nut 14 Covering (top)

Figure 1. Fuel injection pipe (illustration shows covering without socket for engine diagnosis system)

Operating sequence 1 -- Remove the fuel injection pipe

Starting condition Covering on the exhaust counterside removed, shut-off valves on the fuel
pipes closed, cylinder head cover dismounted.

Steps 1. Loosen hexagon nuts on the injection valve and screw them off
221.01).
(cf. work card 221.01
2. Remove the leaked fuel drain pipe (15) from the lower part of the cov-
ering (10).
3. In case of engines provided with an engine diagnosis system
(MODIS), pull the plug off the covering.
4. Slacken hexagon nuts (7) and screw set screws (6) half out.
5. Loosen hexagon bolts (16).
6. Slacken nuts (5), screw them off and push back.
7. Pull the delivery pipe (8) off the threaded piece (2) by slightly lifting,
resp. pressing down the adapter (4) and the threaded piece, depend-
ing on the tolerance.

6629 434.01--02 E 02.01 32/40 102/ 04

 Important! If more than one fuel injection pipe has to be dis-
mounted, they have to be appropriately marked so that each of the pipes
can be refitted to the same cylinder.
8. Screw out hexagon bolts, remove washers (17) and adpater.
9. Clean the fuel injection pipe on the outside.
10. Clean the sealing faces on the delivery pipe (8), check for damage
and recondition, if necessary (cf. work card 434.03).
434.03
11. Protect the connection socket on the injection pump (9) against dam-
age and dirt.

Operating sequence 2 -- Mount the fuel injection pipe

Starting condition Fuel injection pipe cleaned.

Steps 1. Clean the sealing faces on the threaded piece (2) and the fuel injec-
tion pump (9), check them for damage and recondition, if necessary
221.06) .
(cf. work card 221.06
2. Place new O-ring seal, which has been coated with acid-free grease,
into ring groove, taking care that it is not twisted.
3. Place adapter (4) on threaded piece (2) and loosely screw in hexagon
bolts (16) together with washers (17).
Important! Before fitting the fuel injection pipe, verify that the nuts
434.02).
(18) on the delivery pipe (8) are on tightly (cf. work card 434.02
4. Coat thread of nuts (5) with MoS2 lubricant.
5. Put delivery pipe (8) together with covering on injection pump (9) and
screw on nuts by two or three turns.
▲ Attention! It is important to fit the delivery pipe to the injection
pump first.
6. Insert delivery pipe into the connection on the threaded piece by
slightly lifting, resp. pressing down the adapter and the threaded
piece, depending on the tolerance.
7. Screw nut onto threaded piece.
000.30).
8. Tighten both nuts (5) to the specified torque (cf. work card 000.30
9. Tighten hexagon nuts (16).
10. Coat threads and seating surfaces of hexagon nuts on the fuel injec-
tion valve with MoS2 lubricant, screw the nuts onto the studs hand-
tight, and tighten them alternately in several steps to the specified
000.30).
torque (cf. work card 000.30
Important! If the fuel injection valve has been installed in a cylinder
head at operating temperature, initially fasten the hexagon nuts only hand-
tight, and tighten them to the specified torque after temperature equalisa-
tion.
11. Initially tighten both set screws (6) so that covering can still be
moved.
12. Check if the tops of the set screws are located in the groove of the
nuts.
Important! Special attention has to be paid to this point, as other-
wise the covering will not be tight at the ends because of inclined fasten-
ing.
13. Tighten the set screws, and screw on hexagon nuts (7) until seated.

6629 434.01--02 E 02.01 32/40 103/ 04

 Important! The covering has to fit snugly!
14. In case of engines provided with an engine diagnosis system
(MODIS), insert plug into socket.
15. Mount the leaked fuel drain pipe to the covering.
16. Mount the covering on the exhaust counterside.
17. Remount the cylinder head cover.

6629 434.01--02 E 02.01 32/40 104/ 04

Fuel injection pipe
Disassembling and assembling 434.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Fuel injection pipes are to be disassembled for checking and

reconditioning the sealing faces of the delivery pipe.
The work/steps include:
disassembly of components,
assembly of components.

Tools/appliances required

Quant Denomination No. Availability

1 Spanner 434.041 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

434.01 434.03

Operating sequence 1 - Disassemble the fuel injection pipe

Starting condition Injection pipe dismounted

Steps 1. Push the nuts (5) back until nuts (18) are accessible.
2. Unscrew the nuts (18) using the spanner (434.041) - left-handed
thread! Pull the nuts (5) off.
▲ Attention! The jacking (10 and 14) must not be disassembled
(points 3 and 4) on engines equipped with the engine diagnosis
(MODIS) to avoid that the line connecting the strain guage with the
socket is damaged or broken.
3. Unscrew the hexagon nuts (12) and remove the hexagon head bolts
(11).
4. Take the jacketing pieces (10 and 14) off the delivery pipe (8).
5. Clean all the parts and check them for damage, replace them if
necessary.

6629 434.02--02 E 07.97 32/40 101/ 02

 ▲ Attention! When cleaning the parts, take care that on engines
equipped with the engine diagnosis system (MODIS) the line
connecting the strain gauge with the socket is not damaged or
broken.
6. Remachine the sealing faces on the delivery pipe, if necessary (cf.
work card 434.03).
434.03

5 Nut
8 Delivery pipe
10 Lower part of jacketing
11 Hexagon head bolt
12 Hexagon nut
14 Upper part of jacketing
18 Nut (left-handed
thread)
19 O-ring seal
20 O-ring seal

Figure 1. Fuel injection pipe (jacketing without socket for the engine deagnosis system being shown in the figure).

Operating sequence 2 - Reassemble the fuel injection pipe

Starting condition All the parts cleaned, sealing faces on the delivery pipe, if damaged,
remachined.
On engines equipped with the engine diagnosis system (MODIS) the
jacketing (10 and 14) not disassembled.

Steps Important! On engine equipped with the engine diagnosis system

(MODIS), start with reassembly at point 4.
1. Apply acid-free grease to a new O-ring seal (20) and insert it into the
ring groove, taking care not to distort it.
2. Push th jacketing parts (10 and 14) over the delivery pipe (8) and fit
them togehter, insert hexagon head bolts (11) and loosely screw the
hexagon head nuts (12) in place.
3. Align the jacketing parts and tighten the hexagon nuts.
4. Apply acid-free grease to new O-ring seals (19) and insert these into
the ring groove, taking care not to distort them.
5. Put the nuts (5) onto the delivery pipe.
6. Using the spanner (434.041), screw the nuts (18) onto the delivery
pipe down to contact (left-handed thread!) - refer to FIgure 1,
detail Y.
Important! If the fuel injection pipe is to be mounted at a later time,
pull the nuts (5) over the delivery pipe ends as aprotection for the sealing
faces on the delivery pipe.

6629 434.02--02 E 07.97 32/40 102/ 02

 Qty Denomination No. Availability
5 Emery paper 434.042--44 Optional
1 Hexagon screw driver 5 000.294 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Tommy bar 8 000.262 Standard
1 Cleaning agent -- Inventory
1 Safety goggles -- Inventory

Related work cards

Work card Work card Work card

434.01 434.02

1 Fuel injection pipe

2 Hexagon socket bolt
M5x10
3 Grinding device
4 Support adjusting
crank

Figure 1. Grinding device for delivery pipe with attached fuel injection pipe

6629 434.03--02 E 04.98 32/40 102/ 05

Fuel injection pipe
Sealing faces on the delivery pipe
Grinding 434.03

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

The sealing faces on the delivery pipe of the fuel injection pipe are to be
checked for damage and, if necessary, remachined every time it is
removed.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Qty Denomination No. Availability

1 Grinding device for delivery pipe 434.042 Optional
1 Locating plate 434.042--1 Optional
1 Threaded ring 434.042--2 Optional
1 Bearing ring 434.042--3 Optional
1 Bearing flange 434.042--4 Optional
1 Adapter flange (delivery pipe) 434.042--5 Optional
1 Counter flange (delivery pipe) 434.042--6 Optional
1 Spacer ring 434.042--7 Optional
1 Spacer ring 434.042--8 Optional
2 Bearing block 434.042--10 Optional
1 Swivel arm 434.042--11 Optional
1 Bracket 434.042--12 Optional
1 Stop 434.042--13 Optional
1 Stop gauge (delivery pipe) 434.042--14 Optional
1 Grinding wheel 434.042--16 Optional
1 Base plate 434.042--17 Optional
1 Sliding carriage 434.042--18 Optional
1 Shaft 434.042--19 Optional
1 Stop 434.042--20 Optional
2 Ball bearing 434.042--24 Optional
2 Ball bearing 434.042--25 Optional
1 Hook spanner 434.042--37 Optional
1 Face spanner 434.042--38 Optional
2 Clamping lever 434.042--41 Optional

6629 434.03--02 E 04.98 32/40 101/ 05

 2 Hexagon socket bolt
M5x10
5 Stop

Figure 2. Grinding device for delivery pipe

Operating sequence 1 -- Attaching the fuel injection pipe to the grinding device for the delivery pipe

Starting condition Fuel delivery pipe partly disassembled (see work card 434.02
434.02) and
cleaned.

Important! The grinding device for the delivery pipe must be

installed and operated on a solid support. Vibrations of the grinding device
have an influence on the surface quality of the sealing faces to be ground.
The fuel injection pipes to be ground must be absolutely free from lube oils
and greases. Any kind of contamination, especially lubricants, reduce the
service time of the grinding wheel considerably.

Steps 1. Loosen both clamping levers (434.042-41) and swivel out the grinding
device (3) together with the bracket (434.042-12) up to the stop.
2. Screw the adapter flange (434.042-5) onto the threaded ring
(434.042-2) by means of the hexagon socket bolts (2) and tighten.
3. Attach the stop gauge (434.042-14) to the adapter flange using two
hexagon socket bolts (6).
Tip! When fastening the stop gauge to the adapter flange by means of
the tommy bar (000.262), hold up at the threaded ring.
4. Screw the counter flange (434.042-6) onto the fuel injection pipe (1).
Tip! The delivery pipe of the fuel injection pipe has a left-handed
thread.
5. Screw fuel injection pipe together with counter flange into adapter
flange until cone of delivery pipe contacts the stop gauge.

6629 434.03--02 E 04.98 32/40 103/ 05

 6. Screw the counter flange onto the adapter flange and tighten it using
the face spanner (434.042-38) and hook spanner (434.042-37).
7. Remove stop gauge (434.042-14).
8. Push the tommy bar (000.262) radially into the threaded ring
(434.042-2), screwing the ring in until it contacts the locating plate
(434.042-1).
9. Press the yellow stop knob on the grinding device, put the grinding
wheel (434.042-16) together with the emery paper (434.042-44) onto
the grinding device and tighten by means of mounting nut.
10. Pull the sliding carriage (434.042-18) back by means of the support
adjusting crank (4).
11. Swivel the bracket (434.042-12) back in again until it contacts the
stop, blocking it on the sliding carriage by means of the two clamping
levers (434.042-41).

1 Fuel injection pipe

6 Hexagon socket bolt
M6x35

Figure 3. Attaching the fuel injection pipe on the grinding device for delivery pipe

Operating sequence 2 -- Regrinding the sealing faces on the delivery pipe

Starting condition Fuel injection pipe correctly attached to the grinding device for delivery
pipe. Grinding wheel with new emery paper mounted on the grinding
device.

▲ Attention! Remachining the sealing faces is difficult and requires

particular care. It is recommended to have this work carried out in a
service centre or by personnel of MAN B&W Diesel.

Steps 1. Swing the swivel arm (434.042-11) with the grinding device to the
right-hand stop (5).
2. Move the grinding wheel (434.042-16) towards the sealing face of the
fuel injection pipe by means of the support adjusting crank until the
grinding wheel touches the sealing face.
3. Move the swivel arm to the left-hand stop (434.042-13) so that the
front side of the grinding wheel faces the fuel injection pipe.
▲▲ Caution! Wear safety goggles when grinding delivery pipes!
4. Establish the voltage supply for the grinding device and switch the
device on.
5. Turn the fuel injection pipe evenly, and, at the same time, move the
swivel arm with the grinding device around the sealing face contour.
▲ Attention! The grinding wheel must not contact the adapter
flange.
6. The feed is effected at the threaded ring (434.042-2) by means of the
tommy bar (000.262). Maximum feed per operation is a scale mark
at the threaded ring.

6629 434.03--02 E 04.98 32/40 104/ 05

 ▲ Attention! The feed is not effected at the support adjusting
crank. The adjusted position remains unchanged during the whole
grinding process.
Sealing faces are to be slightly remachined only, merely to be
smoothed, removing as little of the material as possible.
7. Move the swivel arm to the left-hand stop so that the front face of the
grinding wheel faces the fuel injection pipe and turn off the grinding
device.
8. Evaluate the result of the grinding process. Repeat the grinding
process until the sealing face has been ground evenly bright.
Important! In case the required contact pattern can no longer be
realised by means of the grinding device for delivery pipe, the grinding
device is to be sent to an MAN service centre for repair.

Tip! Remove used up emery paper immediately and replace by new

emery paper.
9. Remove the fuel injection pipe from the grinding device for delivery
pipe and take off the counter flange.

6629 434.03--02 E 04.98 32/40 105/ 05

.
Buffer piston
Checking 434.04

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Buffer pistons are to be dismantled at regular intervals. In this connection,

the set of piston sealing rings is to be renewed.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Tools/appliances required

Qty Denomination No. Availability

1 Thickness gauges 0.05--1 000.451 Standard
1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Hexagon bolt M10x200 -- Inventory
1 Lubricant (copa slip) -- Inventory
1 Locking wire -- Inventory
1 Pliers for locking wire -- Inventory
2 Flat strip (nylon) -- Inventory

Spare parts required

Qty Denomination No.

1 Set of piston sealing rings 434.20.018
434.20

Preliminary remarks

Knocking noises of the buffer piston during operation are an indication of

compression spring fracture. Undamped relief pressure waves of the fuel
injection pumps in the fuel admission and discharge system may also
result from a seized piston. An increased leakage fuel amount may be
caused by a damaged set of OMEGAT piston sealing rings (2) or by wear
on piston (1) and bush (3). Disassembly of the buffer pistons is to be
carried out immediately upon such findings.

6629 434.04--01 E 11.99 General 101/ 03

 1 Piston
2 Set of OMEGAT piston
sealing rings
3 Bush
4 Cover
5 Stop screw
6 Inner spring
7 Outer spring
8 Hexagon nut
10 Locking wire
11 Seal
12 Connection for leakage
fuel pipe

Figure 1. Sectional drawing of the buffer piston

Operating sequence 1 -- Checking of the buffer piston (during operation)

Starting condition Engine is running at operating temperature.

Steps 1. For the operational check of the piston (1), remove the locking wire
(10) and cautiously screw out the stop screw (5).
2. Insert the test pin (e.g. a long screw driver) into the cover (4) and
ascertain whether the piston carries out pulsating motions.
3. Screw the stop screw back in and secure it by means of the locking
wire (refer to Figure 1).
4. For checking the set of OMEGAT piston sealing rings (2), cautiously
remove the leakage fuel pipe from connection (12).
5. In case of leakage fuel, the set of piston sealing rings is to be
replaced as described under operating sequence 3.

Operating sequence 2 -- Disassembly and checking of the buffer piston components

Starting condition Engine stopped, fuel pipe shut off.

Steps 1. Loosen the hexagon nuts (8) evenly and screw them off.
Take off the cover (4), paying attention to the seal (11).
▲ Attention! Normally, the springs (6 and 7) have been released
before the hexagon nuts (8) are removed. In case the piston (1)
seized in its end position, however, there are still spring forces
acting on the cover when unscrewing the hexagon nuts. Avoid
staying in the axial direction of the buffer piston on opening, danger
of injury!

Dimension Process tolerance Maximum

when new clearance
Piston 90 f7 0.036 ... 0.106 mm 0.250 mm
Bush 90 H7
Table 1. Dimensions and clearances of the buffer piston components
2. Take out the springs (6 and 7), checking them for incipient cracks
and/or fractures.

6629 434.04--01 E 11.99 General 102/ 03

 3. Screw hexagon head bolt M10x200 into the thread on the piston
crown and pull the piston out.
4. Take off the set of OMEGAT piston sealing rings (2), check piston
and bush for free movement, measure wear by means of the feeler
gauge (000.451).
Important! In case the maximum piston clearance is exceeded,
use new parts. Scored bushes should be replaced, since they cause an
increase in leakage fuel. The set of OMEGAT piston sealing rings is to be
renewed every time the buffer piston is checked.

Operating sequence 3 -- Renewal of the OMEGAT piston sealing ring set

Starting condition Old sealing ring set removed. Ring groove of the piston cleaned.

Steps 1. Screw the hexagon head bolt M10x200 into the piston crown and
chuck the hexagon head bolt into the vise, paying attention to the
piston (1) and ensuring that the piston is not damaged.
2. Insert the set of OMEGAT piston sealing rings (2) into the ring groove
as far as possible.
Lay two nylon tapes around the set of OMEGAT piston sealing rings
at a distance of approx. 120ƒ (refer to Figure 2). Using the tapes,
pull the set of OMEGAT piston rings cautiously over the piston edge
into the groove. Afterwards remove the tapes carefully, paying
attention that the set of seals is not twisted.

1 Piston
2 Set of OMEGAT piston
sealing rings
9 Nylon tape

Figure 2. Installation of a new set of OMEGAT piston sealing rings

Operating sequence 4 -- Assembly of the buffer piston

For assembly, proceed in the reverse order followed for removal,

observing the following points:
1. Treat the running face of piston and bush with copa slip prior to
assembly.
2. When introducing the piston, do not damage the set of OMEGAT
piston sealing rings.
3. Secure the stop screw (5) by means of the locking wire (refer to
Figure 1).
4. Attach the leakage fuel pipe to the connection (12).

6629 434.04--01 E 11.99 General 103/ 03

.
 Working Card Functional Test and Adjustment of Safety, 609-01.00
Page 1 (3) Alarm and Monitoring Equipment Edition 06H

L32/40

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water See Related Procedure
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description

Function test and adjustment of safety, alarm and

monitoring equipment. Hand tools

See Related Procedure

Starting position

Related procedure

Pressostate 609-05.00
Thermostate 609-05.01
Level switch (LAL 25) 609-05.02
Pressure transmitter 609-05.03
Temperature sensor 609-05.04
Leakage alarm 609-05.05
Pick-up on engine 609-08.00

Man power Replacement and wearing parts

08028-0D/H5250/94.08.12

Working time : xxx hours Plate no Item no Qty. /

Capacity : xxx man

Data

00. 12 - ES0
609-01.00 Functional Test and Adjustment of Safety, Working Card
Edition 06H Alarm and Monitoring Equipment Page 2 (3)

L32/40

Maintenance of Monitoring and Safety Sy-

stems

One of the most important parameters in the pre- It is recommended that all functions are tested every
ventive work is that the alarm system as well as the three month according to the mentioned working
shutdown and overspeed devices are functioning cards.
100%.
The extent of the alarm and safety functions is vari-
If some of these functions are out of operation, they able from plant to plant.
have to be repaired immediately. If this is not pos-
sible because of the present working situation, the For check of these functions use the working cards
engine has to be under constant observation until it mentioned under related procedure on page 1.
can be stopped.

08028-0D/H5250/94.08.12

00.12 - ES0
 Working Card Functional Test and Adjustment of Safety, 609-01.00
Page 3 (3) Alarm and Monitoring Equipment Edition 06H

L32/40

See working card 609-05.00 for the following See working card 609-05.04 for the following tem-
pressostates: perature sensors:

PSL 22 TE 12
PAL 40 TE 22
PAL 70 TE 31
PDAH 21-22 TE 60
TE 61
See working card 609-05.01 for the thermostate TE 62

TSH 12 See working card 609-05.05 for the following leak-

age alarms:
See working card 609-05.02 for the level switch
LAH 42
LAL 25
LAL 28 See working card 609-08.00 for the following pick-
ups:
See working card 609-05.03 for the following pres-
sure transmitters: SE 89
SE 90
PT 10
PT 22
PT 31
PT 32
08028-0D/H5250/94.08.12

00. 07 - ES0
 Working Card
Adjustment and Test of On/Off Pressostate 609-05.00
Page 1 (2) Edition 04H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of on/off pressostate. (lub.

oil,fuel oil, water etc.). Hand tools:

Screw driver.
Testing pump.
Ring and open end spanner, 10 mm.
Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./

Capacity : 1 man

Data:

97.38 - ES0S
609-05.00 Adjustment and Test of On/Off Pressostate Working Card
Edition 04H Page 2 (2)

L32/40

The pressostate switch an electric contact when it

reach the adjusted pressure.

Adjustment

The pressostate can be adjusted if it is out of range

according to the following procedure:

1) Remove the cap see fig 1, pos 1.

2) Turn the screw until the switch react at the

correct pressure, see fig 2.

Fig 2 Adjustment

2) Remove the screw pos. 2.

1 3) Mount the testing pump on the test valve pos.

2.

2
Alarm for Falling Pressure

4) Pump up the pressure until the switch has

changed. The pressure will slowly be relieved and it
3 must be checked that the switch change back to the
pressure stated as the alarm point.

1. Cap for adjustment screw

Alarm for Rising Pressure
2. Test valve
3. Shut off valve 5) Pump up the pressure until the switch chang-
es, and check that it happens at the stated alarm
point.
Fig 1 Pressostate switch

6) After the final check and adjustment, remove

the testing pump, mount the screw pos. 2 and open
Test the valve pos. 3.

It is possible to make a functional test of the pressure

08028-0D/H5250/94.08.12

switch. This is to be carried out according to the

following procedure:

1) Shut off system pressure with the valve pos. 3,

fig 1.

97.38 - ES0S
 Working Card
Adjustment and Test of On/Off Differential Pressostate 609-05.00
Page 1 (2) Edition 05H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of on/off pressostate. (lub.

oil,fuel oil, water etc.). Hand tools:

Screw driver.
Testing pump.
Ring and open end spanner, 10 mm.
Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./

Capacity : 1 man

Data:

97.38 - ES0S
609-05.00 Adjustment and Test of On/Off Differential Pressostate Working Card
Edition 05H Page 2 (2)

L32/40

The differential pressostate switch an electrical con-

tact when the difference of pressure between the low
pressure inlet, and the high pressure inlet exceed the
adjusted range.

Adjustment

The differential pressostate can be adjusted if it is out

of range according to the following procedure:

1) Remove the cap see fig 1, pos 1.

2) Turn the screw until the switch react at the

correct differential pressure, see fig 2. Fig 2 Adjustment

2) Remove the screws pos. 2.

1 3) Mount the testing pumps on the test valves

pos. 2.

2 Alarm for Falling Differential Pressure

4) Pump up the differential pressure until the

switch has changed. The pressure will slowly be
relieved and it must be checked that the switch
3 change back to the pressure stated as the alarm
point.

1. Cap for adjustment screw

2. Test valve Alarm for Rising Differential Pressure
3. Shut off valve
5) Pump up the differential pressure until the
switch changes, and check that it happens at the
Fig 1 Differential pressostate switch
stated alarm point.

6) After the final check and adjustment, remove

Test the testing pumps, mount the screws pos. 2 and
open the valve pos. 3.
08028-0D/H5250/94.08.12

It is possible to make a functional test of the differential

pressostate switch. This is to be carried out according
to the following procedure:

1) Shut off system pressure with the valves pos.

3, fig 1.

97.38 - ES0S
 Working Card
Adjustment and Test of On/Off Thermostate 609-05.01
Page 1 (2) Edition 04H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of on/off thermostate. (lub.

oil, fuel oil, water etc.). Hand tools:

Screw driver.
Special testing devices.

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. /

Capacity : 1 man

Data:

97.38 - ES0S
609-05.01 Adjustment and Test of On/Off Thermostate Working Card
Edition 04H Page 2 (2)

L32/40

Adjustment: Test:

1) When the thermostate cover is removed and 3) The funcional test of the thermostate is to be
locking screw pos. 5, fig. 1 is loosened, the range can carried out according to the following procedure.
be set with the spindle pos. 1 while at the same time
the scale pos. 2 is read. 4) Take out the sensor of the pocket.

5) Test the sensor in a water bath, where the

temperature can be controlled.

Alarm for Falling temperature:

6) Raise the temperature until the switch has

changed.

Then the temperature must slowly be reduced, and

check that the switch changes back.

Alarm for Rising temperature:

7) Raise the temperature until the switch chang-

1. Range spindle.
2. Range scale.
es and check that is happens at the stated alarm
3. Differential spindle. points.
4. Differential scale.
5. Locking screw. 8) Adjust if necessary.

9) The sensor is mounted again.

Fig. 1.

2) Thermostates having an adjustable differenti-

al, the spindle pos. 3 can be used while the scale pos.
4 is read.
08028-0D/H5250/94.08.12

97.38 - ES0S
 Working Card
Function and Test of Level Switch (LAL 25) 609-05.02
Page 1 (2) Edition 04H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Function and test of level switch, LAL 25, in

lubricating oil system. Hand tools:

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. /

Capacity : 1 man

Data:

97.38 - ES0S
609-05.02 Function and Test of Level Switch (LAL 25) Working Card
Edition 04H Page 2 (2)

L32/40

The level switch LAL 25, which is mounted on the

main lubricating oil pipe of the engine, gives alarm for
missing prelubricating oil. Vent pipe

Function.

1) By starting the prelubricating oil pump the main

lubricating oil pipe will be filled with lubricating oil,
which means that the level switch is lifted and the
alarm is disconnected.
Level switch
2) When the prelubricating is interrupted, the lub.
oil will run out of the system through the bearings, Main lubricating oil pipe
which means that level switch is lowered and the
alarm starts.
Fig. 1.

Test:

The test is carried out when the engine is stopped.

3) Start the lubricating oil pump, and let the pump

run about 5 min.

4) Stop the prelubricating oil pump. The alarm

must be released after 0 - 5 min., depending of the
oil viscosity.

08028-0D/H5250/94.08.12

97.38 - ES0S
 Working Card
Adjustment and Test of Pressure Transmitter 609-05.03
Page 1 (2) Edition 04H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of analogous pressure

transmitter. Hand tools:

Ring and open end spanner, 10 mm.

Testing pump.

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./

Capacity : 1 man

Data:

97.38 - ES0S
609-05.03 Adjustment and Test of Pressure Transmitter Working Card
Edition 04H Page 2 (2)

L32/40

The pressure transmitter registers the actual pres-

sure and marks the change to an electrical signal,
which adjusts the pressure.

Adjustment

1) The pressure transmitter can be adjusted,

according to fig 2. The alarm limit must be set on the
alarm plant. Kindly see the instruction book for the
alarm plant.

1 Fig 2 Adjustment.

2 3) Remove the screw on the test valve pos. 2.

4) Mount the testing apparatus on the test valve

pos. 2. and pump on a pressure within the working
area of the transmitter.
3
If the alarm plant has an instrument unit, the pres-
sure can be read on this. Other wise the test can be
carried out by watching if the alarm plant gives any
1. Cap for adjustment screw
alarm, when the alarm limit which is exceeded (if the
2. Test valve alarm plant is adjusted).
3. Shut off valve
Note! If the adjustment is needed, the cap pos. 1
must be removed.
Fig 1 Pressure transmitter.

5) The screw pos. 2 is mounted, and the valve

pos. 3. is opened after the test is finished.
Test

It is possible to make a functional test of the pressure

transmitter. This is carried out according to the
08028-0D/H5250/94.08.12

following procedure:

2) Shut off system pressure with the valve pos. 3,

fig 1.

97.38 - ES0S
 Working Card Adjustment and Test of 609-05.04
Page 1 (2) Analogous Temperature Transmitter Edition 04H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Adjustment and test of analogous temperature

transmitter, (PT 100 sensor). Hand tools:

Special testing devices.

Starting position:

Functional test and adjustment of safety

alarm and monitoring equipment

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./

Capacity : 1 man

Data:

97.38 - ES0S
609-05.04 Adjustment and Test of Working Card
Edition 04H Analogous Temperature Transmitter Page 2 (2)

L32/40

The PT 100 sensor consist of a resistance wire which Otherwise the test can be carried out by watching if
changes resistance depending on the temperature. the alarm plant gives any alarm, when the alarm limit
which is exceeded (if the alarm plant is adjusted).
Look and design varify depending on the place of
measurement and manufacture. 5) The sensor is mounted again.

Adjustment:

1) The PT 100 sensor connot be adjusted, but the

alarm limit must be set on the alarm plant.

Test:

2) The functional trial of the PT 100 sensor can be

carried out according to the following procedure.

3) Take out the sensor of the pocket.

4) Test the sensor by diving the sensor in the

water. Compare the signal from the sensor with the
water temperature.

If the alarm plant has an instrument unit, the tempe-

rature can be read on this.
Fig 1 Temperature sensor, PT 100.

08028-0D/H5250/94.08.12

97.38 - ES0S
 Working Card
Function and Test of Leakage Alarm (LAH 42) 609-05.05
Page 1 (2) Edition 01H

L32/40

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description

Function and test of leakage alarm, LAH 42, in fuel

oil system. Hand tools

Starting position

Functional test and adjustment of safety

alarm and monitoring equipment

Related procedure

Man power Replacement and wearing parts

08028-0D/H5250/94.08.12

Working time : 1/2 Hour Plate no Item no Qty. /

Capacity : 1 man

Data

00.07 - ES0
609-05.05 Function and Test of Leakage Alarm (LAH 42) Working Card
Edition 01H Page 2 (2)

L32/40

The level switch LAH 42, which is mounted on the fuel

oil inlet pipe, gives alarm for waste and leak oil.

Function

1) Waste and leak oil from the compartment, for

the injection equipment, fuel valves, high-pres-
sure pipes and engine feed pump (if mounted)
are led to the fuel leakage box.

2) If the flow of waste and leak oil gets too high, the
level in the fuel leakage box will rise, and
activate the level switch.

Test

3) Unscrew the allen plug, situated on the front

side of the fuel leakage box.
Fig 1 Leakage alarm (LAH 42).
4) Lift the level switch to its upper position and the
alarm must be released.

08028-0D/H5250/94.08.12

00.07 - ES0
 Working card
Adjustment of Pick-ups on Engine 609-08.00
Page 1 (2) Edition 01H

L32/40

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water Scope meter
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circulation

Description

Adjustment of pick-ups for Heinzmann governor

and safety system.

Hand tools

Starting position

Turning gear engaged.

Related procedure

Man power

Working hours : ½ Hours

Capacity : 1 Men
08028-0D/H5250/94.08.12

Data Spare and wearing parts

Plate no Item no Qty/

99.32 - ES0
609-08.00 Adjustment of Pick-ups on Engine Working card
Edition 01H Page 2 (2)

L32/40

Mounting Fine Adjustment

Mount the pick-ups so that there is approx 1 mm to Start the engine at low RPM. Continue to run the
the teeth of the gear rim for the turning gear so that engine slowly up to 800 RPM. If the picture changes
the flat side turns either up or down. on the scope meter, the pick-up must be adjusted
until the picture is as indicated below.
It is of paramount importance that the pick-up turns
correctly compared to the teeth of the turning gear
since the pick-up is directional. The flat side is only Final Control
for guidance. Adjustment of the pick-up is necessary
to find the angle where the pick-up gives the best Item 1 Heinzmann pick-up No 1 line 2001 i
signal. hand terminal is stable 720 +/- 1 RPM

Item 2 Heinzmann pick-up No 2 line 2002 in

Adjustment hand terminal is stable 720 +/- 1 RPM

Mount the scope meter on + and pulse terminal from Item 3 RPM indication of starting box
the pick-up. Turn the engine by means of turning
gear. Adjust the pick-up until the signal shows the Item 4 PLC CS 31 at pick-up error there will be
same as indicated on picture Nos 1 and 2. At 720 rpm tacho-error
the frequency is 660 Hz.
Item 5 Run the engine to overspeed

08028-0D/H5250/94.08.12

Picture No 1 Picture No 2
Pick-up Heinzmann Governor Pick-up CS31 Safety System

Fig 1 Fluke scope meter.

99.32 - ES0
 Working Card
Adjustment of Lambda Controller 609-10.00
Page 1 (3) Edition 14H

L32/40

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut off starting air
Shut off cooling water
Shut off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Adjustment of lambda controller. Adjustablle spanner, 10"-12".

Starting position

Related procedure

Manpower Replacement and wearing parts

08028-0D/H5250/94.08.12

Working time : 1/4 hour Plate no Item no Qty/

Capacity : 1 man

Data

01.41 - ES0
609-10.00 Working Card
Edition 14H
Adjustment of Lambda Controller Page 2 (3)

L32/40

Adjustment of the Lambda Controller

All adjustments are made when the engine is in

standstill position.

1) Check that the free space between the pick-up

and the band steel on the regulating arm is min.
1 mm, see fig 1.

Fig 3 Lambda Controller

2) Turn the lever (fig 2) of the governor a few times

to full load with an adjustable spanner (spring
between governor and fuel rack full com-
pressed). Check that the fuel index is 23 at the
fuel pump.

3) In case of large deviation from index 23

Fig 1 Check of free space
adjustment is done by turning the regulating
arm (4), fig 3. Finally adjustment is done at the
adjustment screw (3), fig 3.

4) Adjustment completed.

Adjustment of the Stop Screw

5) Remove pipe for charge air pressure.

08028-0D/H5250/94.08.12

6) Supply air pressure until the piston rod reaches

its upper position.

7) Turn the lever (fig 2) of the governor to full load

with an adjustable spanner. Adjust the stop
screw (fig 2) to 110 % load (stationary 100%)
according to the test bed, plus 1.5 index. Use
the index arm on the fuel injection pump nearest
to the lambda controller as the control for the
index.

8) Adjustment completed.
Fig 2 Adjustment of the stop screw

01.41 - ES0
 Working Card
Adjustment of Lambda Controller 609-10.00
Page 3 (3)
Edition 14H

L32/40

Adjustment of Start Index, only if mounted

After adjustment of the lambda index the start index

must be adjusted.

Force the piston by the screw on the back, see fig 4.

Check that the index is 17 mm. Adjustment is made
on the self-locking nut on the back of the lambda
controller, see fig 4.

Note : In case of start failure due to wear of the fuel

pump, the start index must be raised to a higher level
by turning the self-locking nut anticlockwise. Fig 4 Adjustment of start index
08028-0D/H5250/94.08.12

01.41 - ES0
 Working card
Retightening and Mounting of Coupling Bolts 610-05.00
Page 1 (2) Edition 01H

L32/40

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circulation

Description

Check of bolts between flywheel and

crankshaft

Hand tools

Starting position

Safety precautions

Related procedure

Man power

Working hours : 2 Hours

Capacity : 1 Men
08028-0D/H5250/94.08.12

Data Spare and wearing parts

Plate no Item no Qty/

00.07 - ES0
610-05.00 Retightening and Mounting of Coupling Bolts Working card
Edition 01H Page 2 (2)

L32/40

Retightening of Coupling Bolts Mounting of New Bolts

The coupling bolts between flywheel and crankshaft Flywheel to be fastened on crankshaft flange with
has to be retightened according to the schedule in the holding screws.
the planned maintenance program.
The dead center marking on wheel and the position
of the pointer at engine casing with 35° from the
horizontal in anti-clockwise direction to be observed.

For this purpose the O marking of the wheel is to be

made to coincide the the TDC1 marking of the
crankshaft flange.

The connection bolts are to be pre-tightened with a

wrench-tightening torque 1500 Nm (lubricated with
molykote).

Dead center marking at the diameter 1570 mm ±1

one angle degree corresponds to 13.7 mm on the
circumference.

Note! Nuts definitely must not be tightened with hook

spanner and hammer for inspection later on.

Attention! Fitting bearing in the engine, loose bear-

ing in the alternator.

Fig 1 Coupling bolts.

Retightening
08028-0D/H5250/94.08.12

1) Remove the flywheel cover on the manoeu-

vring side.
Fig 1 Coupling bolts.
2) Check the bolts with a wrench-tightening torque
of 1500 Nm.

00.07 - ES0
 Working card
Retightening and Mounting of Foundation Bolts 611-05.00
Page 1 (2) Edition 01H

L32/40

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water Hydraulic tools (009.346)
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circulation

Description

Check of bolts between engine frame and

base frame

Hand tools

Starting position

Safety precautions

Related procedure

Man power

Working hours : xxx Hours

Capacity : x Men
08028-0D/H5250/94.08.12

Data Spare and wearing parts

Plate no Item no Qty/

99.06 - ES0
611-05.00 Retightening and Mounting of Foundation Bolts Working card
Edition 01H Page 2 (2)

L32/40

Retightening of Foundation Bolts Mounting of New Bolts

The foundation bolts and fitted bolts between engine 1) Tighten with 950 bar.
frame and base frame has to be retightened accord-
ing to the schedule in the planned maintenance
program. Note! Nuts definitely must not be tightened with hook
spanner and hammer for inspection later on.

Retightening

Check the bolt with a pump pressure of 950 bar.

Fig 1 Fitted and foundation bolts. 08028-0D/H5250/94.08.12

99.06 - ES0
 Working Card
Fuel Oil Split Filter 614-01.15
Page 1 (2) Edition 02H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Disassembly, cleaning and assembly of fuel oil

split filter. Hand tools:

Ring and open end spanner, 13 mm.

Ring and open end spanner, 17 mm.
Kerosene, gas oil or similar.
Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. /

Capacity : 1 man

Data:

97.38 - ES0S
614-01.15 Fuel Oil Split Filter Working Card
Edition 02H Page 2 (2)

L32/40

1) During normal operation both filters should be 3) Position of three way cock, see fig. 2.
in operation, single operation only to be used when
dismantling one of the filters for manual cleaning or
inspection.

2) Normally the filters are cleaned during opera-

4 5
tion by turning the handle, (1) see fig. 1, on the filter
housing top a couple of turns. (clockwise).

Simultaneously with turning of the handle, the drain

cock, (2) in bottom of the filter housing should be
opened in order to drain of the dirt being scraped of
the filter element, (3).

Left Filter Both filters in Right Filter

1 This position is operation. This position is
only for cleaning only for cleaning
of the right filter, of the left filter,
not for continu- not for continu-
ous operating. ous operating.
5

Fig. 2. Fuel oil split filter (top view).

3
Note: Shut-off fuel oil, before dismantling filter ele-
ment.

4) If no drainage occurs when the drain cock is

opened, the filter housing should be dismantled for
manual cleaning. Remove the nuts (5), and take out
the filter element (3).
2
5) Clean the filter element in kerosene gas oil or
similar and blow it dry with working air.

Fig. 1. Fuel oil split filter 6) Mount the filter element again.

7) The filter element itself should never be dis-

08028-0D/H5250/94.08.12

mantled, but has to be replaced if damage or mal

function is experienced.

97.38 - ES0S
 Working Card
Check of Fuel Oil Piping System 614-01.90
Page 1 (2)
Edition 02H

L32/40

Safety precautions Special tools

Stopped engine Plate no. Item no. Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description

Check of fuel oil piping system.

Hand tools

Starting position

Engine is running.

Related procedure
08028-0D/H5250/94.08.12

Man power Replacement and wearing parts

Working time : ½ hour Plate no. Item no. Qty. /

Capacity : 1 man

00.43 - ES0
614-01.90 Check of Fuel Oil Piping System Working Card
Page 2 (2)
Edition 02H

L32/40

Fuel Oil System Lubricate valve spindles with graphite or

similar.
1) Dismount the covers to the injection pumps.
Blow-through drain pipes. 5) Check flexible connections for leaks and
damages.
2) Examine the piping system for leaks.
6) Check the condition of the lower O-ring for the
3) Retighten all bolts and nuts in the piping sy- fuel injecting valves by means of the venting
stem. pipe.

4) Move all valves and cocks in the piping sy- For fuel oil condition, see section 604.
stem.

Venting pipe

Fig. 1. Cross section of cylinder head

08028-0D/H5250/94.08.12

00.43 - ES0
 Working Card
Prelubricating Pump 615-01.05
Page 1 (3) Edition 04H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water Wheel puller for bearing bush.
Shut-off fuel oil Compressed pin.
Shut-off cooling oil Protection cover for shaft seal.
Stopped lub. oil circul. Compressed pin for shaft seal.

(The special tools must be ordered separately

from MAN B&W, Holeby)
Description:

Dismounting, replacement of the rotary shaft seal

and assembly of prelubricating pump.
Hand tools:

Bench vice.
Spanner.
Starting position: Torque spanner.
Plier for lock ring.
Soft hammer.

Related procedure:
08028-0D/H5250/94.08.12

Man power:
Replacement and wearing parts:
Working time : 2-3 Hours
Capacity : 1 man Plate no. Item no. Qty. /

Data: See plate 61504.

97.38 - ES0S
615-01.05 Prelubricating Pump Working Card
Edition 04H Page 2 (3)

L32/40

Overhauls. We advise not to change the bearing bushes. In

connectin with damages on the bearings it is normal
Overhauls for the purpose of avoiding functional that also the shafts and the parts in the gear box will
trouble are not normally necessary for the prelubri- be damaged.
cating pumps, when properly used, there is very little
wear on the pump gear shaft. When ordering spare parts, do not forget to state the
factory no. of the pump.

Spare Parts.
Replacement of mechanical seal.
Before any overhaul is done, please note the following:
1) Disconnect the cable and pipe connection to
If a pump gets unusable by wear, it must be replaced. the pump.
Installation of spare parts cannot bring it back to
normal condition. 2) Remove the pump from the engine base frame.

It pays to keep extra pumps in stock or to have 3) Separate the pump and the el-motor.
repairs (overhauls) carried out at our repair shop.
4) Remove the coupling part and key (12), see
The shaft seal needs only to be replaced in case of fig. 1, from the driving gear shaft (4).
leakage or after dismounting of drive shaft. The
marks from the seal do not necessarily mean that the 5) Tighten the pump to the flange. Pressure
sealing is defective, but there is a risk of leakage control valve (3) upwards.
after replacement of sealing.
6) Loosen screws (9) and take off the pressure
control valve (3).

12 11 16 01 04 02 03 09

08028-0D/H5250/94.08.12

Fig 1 Prelubricating Pump.

97.38 - ES0S
 Working Card
Prelubricating Pump 615-01.05
Page 3 (3) Edition 04H

L32/40
7) Take off the gear box (2), if necessary use a Mounting.
soft hammer for separation.
13) The mounting process follows in reverse order,
8) Remove the gear wheels from the cover (1). it is stressed that an exact cleaning works is
Dismounting is only possible by disturbing the rotor necessary.
shaft seal and by breaking the bearing bush.
Especially the sealing faces must be clean.
9) Remove the security ring (11) and take off the
rotary shaft seal (16). Tightening of screw pos. (9):

10) Press out the driving gear shaft bearing bush, R25 10 Nm
pull out the running bearing bush with the inner wheel R35 50 Nm
puller.
In connection with the bearing bush, attention must
11) Gear box (2). Dismounting is only possible by be paid to the placement of the butt joint and the
damaging the shaft bush. Press out the shaft bushes. mounting depth.

12) Pressure control valve (3). The pressure control The new shaft seal cannot be pressed into the
valve can be dismounted also without dismounting protection cover before exact mounting of the pump.
the pump.
O-ring must be changed.
08028-0D/H5250/94.08.12

97.38 - ES0S
 Working Card
Lubricating Oil Thermostatic Valve 615-01.20
Page 1 (2) Edition 03H

L32/40

Safety precautions: Special tools:

Stopped engine Plate No. Item No. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Inspection of thermostatic valve and replacement

of elements. Hand tools:

Ring and open end spanner 24 mm

Copaslip
Tools and cleaning preparation for cleaning.

Starting position:

Lubricating oil drained from engine (if necessary).

Related procedure:

Man power:
08028-0D/H5250/94.08.12

Working time : 2 Hour

Capacity : 1 Man Replacement and wearing parts:

Data: Plate No. Item No. Qty./

61503 03 9/engine
61503 05 9/engine
61503 09 3/engine

97.38 - ES0S
615-01.20 Lubricating Oil Thermostatic Valve Working Card
Edition 03H Page 2 (2)

L32/40

The thermostatic valve cannot be adjusted and Replacement of elements:

under normal working conditions maintenance is not
required. However, in some cases it is necessary to 1) Remove nuts (1) and washers (2), see fig 1.
replace the elements in the thermostatic valve.
2) Disconnect upper and lower part of the housing.

3) Remove the assembled elements (3) and the

1 elements O-ring sealing.
2
3 4) Remove the gaskets between the upper and
lower part of the housing.
5
5) The upper and lower part of the housing are
4 thoroughly cleaned inside and on the gasket surfaces.

6) The sealing rings (4) for the elements in the

housing are replaced and lubricated with a thin layer
of copaslip.

7) Remount the assembled elements in the

housing by wriggling these somewhat over side.

8) Upper and lower part of the housing are

assembled with a new gasket (5), the nuts (1) are
mounted and tightened "cross-wise".

Note:
1. Nut
2. Washer After inspection or replacement of the elements the
3. Element lub. oil temperature is checked to ensure that the
4. O-rings sealing elements are working correctly.
5. Gasket

Fig 1 Thermostatic valve

08028-0D/H5250/94.08.12

97.38 - ES0S
 Working Card
Lubricating Oil Cooler 615-06.00
Page 1 (4) Edition 03H

L32/40

Safety precautions: Special tools:

Stopped engine Plate No Item No Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Separation, cleaning and assembling.

Replacement of plates and gaskets. Hand tools:

Ring and open end spanner 10 mm

Ring and open end spanner 55 mm
Ring and open end spanner 30 mm
Starting position: Adjustable spanner

Cooling water and lub. oil have been drained from

cooler/engine. All pipes are disconnected.

Related procedure:

Manpower:
08028-0D/H5250/94.08.12

Working time : 4 hours Replacement and wearing parts:

Capacity : 1 man
Plate No Item No Qty./
Data:
61506 09 4/cooler

97.38 - ES0S
615-06.00 Lubricating Oil Cooler Working Card
Edition 03H Page 2 (4)

L32/40

Introduction Manual Cleaning

Cleaning of the cooler has to take place, when the Clean the plates with a soft brush and a suitable
pressure drop on the oil and water side is larger than detergent. In case of dense coating of scale or
allowable and/or if the oil cannot be sufficiently organic materials, the plates must be put in a bath of
cooled. detergent.

Note: Never use a steel brush, metal scraper or the

Separation like.

Cooling and Pressure Relief A high-pressure cleaner can be used with care,
however, never with sand or other abrasives added.
Before opening the plate heat exchanger, it has to be
cooled down to below 40o C and be without pressure!
Detergents
The cooling must not exceed 10o C per minute.
The pressure drop must not exceed 10 bar per A detergent is suitable, if it will remove any coating
minute. on the plates without causing any damage to plates
and gaskets.
Note: If these norms are exceeded, the guarantee
will cease to be valid. Note: It is of great importance that decomposition of
the protective film on the stainless steel does
not take place - the film preserves the corrosion
Separation of Edge-clamped Frame resistancy of the steel.

Upon completion of the procedure “Cooling and Do not use chlorine-containing agents such
Pressure Relief”, separate the frame by retaining as hydrochloricacid (HCI)!
two or four diagonally placed bolts.
Oil and fats are removed by using a water
Note: Take care that the movable cover does not tilt! emulsifying oil solvent, e.g. BP-system cleaner.

Loosen all bolts uniformly and diagonally (max. 10 Organic and greasy coatings are removed by using
mm at a time), then push the movable cover towards sodium hydroxide (NaOH):
the pillar. When the pressure plate is not tight
anymore, the plates can be removed. - max. concentration 1.5%
(1.5% concentration corresponds to 3.75 l
Note: When using plate heat exchangers on board 30% NaOH per 100 l water).
ships, the movable covers have to be secured - max. temperature 85o C.
in order to avoid danger due to the movements
of the ship. Stone and lime/calcareous deposits are removed by
08028-0D/H5250/94.08.12

using nitric acid (HNO3):

Cleaning - max. concentration 1.5%

(1.5% concentration corresponds to 1.75 l
The capacity and corrosion resistance of the plate 62% HNO3 per 100 l water).
heat exchangers depend on the purity of the plates. - max. temperature 65o C.
Any coating on the plates can be removed manually.
Note: The nitric acid has an important constructive
effect on the protective film of stainless steel.

97.38 - ES0S
 Working Card
Lubricating Oil Cooler 615-06.00
Page 3 (4) Edition 03H

L32/40

Control of Cleaning Fluid Concentrations Replacement of Glued Gaskets

Sodium hydroxide (NaOH) solution is tritrated with On Plate 61506 are stated gasket and glue quantity.
0.1 n hydro-chloric acid (HCI) with methyl orange or
methyl red as indicator. Please use a degreasing agent on the new gaskets.

Nitric acid (HNO3) solution is titrated with 0.1 n The first plate after the end cover and the connector
sodium hydroxide (NaOH) with phenolphtalin as grid must have gaskets in all grooves. The gaskets
indicator. are to be cut according to the existing gaskets.

The concentration of the cleaning fluid in % can be Loosen the glued gaskets by heating the plate in
calculated from the titration result by means of the water at 100o C. Clean the plates and remove the
following formula: coatings, if any.

Concentration = bxnxm %
a x 10 Cleaning of New Gaskets and Plates

a : ml cleaning fluid taken out for titration New gaskets and gasket grooves of the plates are
b : ml titration fluid used as cover cleaned with a cloth moistened with degreasing
n : the molecular concentration of titration fluid agent. The glue surfaces must be absolutely clean
m : The molecular weight of the cleaning fluid - without finger prints etc.
(NaOH) molecular weight 40, HNO3 molecular
weight 63) Please use our cleaning fluid, which is according to
suppliers recommendations.

Replacement of Plates and Gaskets Alternatively, please use:

Marking - Trichloroethylene
- Chlorothene VG
The plates are marked with material codes and - Acetone
reference numbers at each end, plus codes for non- - Methyl ethyl ketone
glue gaskets, if any, and stamped with the letter V - Ethylacetat
and H at either end (Fig 1).
It is important that all degreasing agent has
Looking towards the gasket side, the plate is evaporated, before the glue is applied. This will
designated as a left plate, when the letter V is turning normally take approx. 15 min. at 20o C.
upwards - and a right plate when the letter H is
turning upwards. Inlets and outlets of the V-plates Clean the new gaskets on the glue surfaces with
are taking place through the corner holes Nos 1 and fine-grain sandpaper instead of the degreasing agent
4. Inlets and outlets of the H-plates are taking place supplied.
08028-0D/H5250/94.08.12

through the corner holes Nos 2 and 3.

Gluing
Replacement of Plates
Pliobond 25, which is a nitrile rubber glue on solvent
Before mounting a spare plate in the plate stack, basis (25% solids). The glue is applied with a brush
please make sure that the spare plate is identical in a thin layer on the backs of the gaskets and the
with the defective plate. gaskets are to dry in a clean place free of dust.

Note: The same corner holes must be open and the Apply a thin layer of glue on the gasket grooves of the
letters V and H must be placed correctly. plates and press the gaskets down into the gasket
grooves.

97.38 - ES0S
615-06.00 Lubricating Oil Cooler Working Card
Edition 03H Page 4 (4)

L32/40

The insertion of gaskets starts at both ends of the The fixed cover has number 1 and the serial numbers
plate - and continues with the straight sections along for the subsequent plates and intermediate frames,
the edges. if any, have the numbers 2, 3, 4, 5 etc.

The gluing process is most easily effected by placing The serial number are stamped in the right top corner
the gaskets and the plates on a table. After having of the plates. Further, please note that the gasket
pressed the gaskets into the grooves of a plate, it is side must face the fixed cover.
stacked.

The plates with the gaskets are now mounted in the Fastening
frame which is lightly clamped. In case of use of
rubber grooves, they are assembled to the minimum Fasten the plate heat exchanger until the movable
measure stated on the engine sign plus 0.2 mm per cover touches the duct spacers.
plate.

Heat up the plate heat exchanger to 90-100°C by

means of water or steam. Serial number
(please state when
Please note: Material Code ordering single plates)

- The temperature must be kept for 1½-2 hours.

- The liquid pressure must be kept as low as 1 2
possible.

If there is no possibility of heating the plate heat

exchanger, it must be placed in a spot as warm as
possible with dismounted connections.
Four last digits Four last digits are the
H
The drying time will at 20°C be approx. 48 hours. At are the ref. ref. number of the plate.
or (only on plates for non-
for instance 40°C, the drying time is reduced to number of plate
V glue gasket)
approx. 24 hours.

Fig. 1.
Assembling

If the plates have been dismounted, they have to be

correctly assembled according to the plate item
numbers.
08028-0D/H5250/94.08.12

97.38 - ES0S
 Working Card
Centrifugal Bypass Filter 615-15.00
Page 1 (3) Edition 05H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Cleaning procedure, cleaning intervals.

Maintenance intervals and procedures. Hand tools:

Big adjustable spanner.

Tools for cleaning.

Starting position:

Isolate the filter for lub. oil inlet

Related procedure:
08028-0D/H5250/94.08.12

Man power:

Working time : 1 Hour Replacement and wearing parts:

Capacity : 1 man
Plate no. Item no. Qty. /
Data:
61515 39 1/Filter
61515 40 1/Filter
61515 41 1/Filter
61515 42 1/Filter

97.39 - ES0S
615-15.00 Centrifugal Bypass Filter Working Card
Edition 05H Page 2 (3 )

L32/40

Cleaning procedure: 6) Reassemble rotor body on to rotor base. Ensure

that locating pins (8) and (9) in joint face of body align
1) Isolate the filter by closing the valve for with holes in cover and that standtube fits correctly
lubricating oil inlet to the filter. in the rotor base.

2) Slacken cover clamp ring (26), see fig. 1. 7) Examine spindle in areas corresponding to top
Unscrew cover nut (27) and lift off cover (31). and bottom bushes. If damaged or worn replace with
body assembly complete (25).

8) Replace rotor on to spindle ensuring rotor

revolves freely. Then replace body cover. Tighten
21 cover nut by hand only and refit safety cover clamp
27
02 24 ring. The clamp ring must be securely fitted at all
31 01 times when the filter is running. Do not run filter with
clamp ring loose.
08
04
9) Open for lubricating oil.
09
10) With filter running, check all joints for leakage.
10 Check for excessive vibration.
18
07

26 Cleaning intervals:
25
It is recommended to clean the centrifugal filter every
100 hours maximum or when the dirt deposit is 25
mm thick, whichever comes first. For cleaning
intervals.

Fig. 1 Centrifugal Bypass Filter Maintenance intervals and procedures:

Recommended maintenance intervals for the filter

3) Lift off rotor assembly (01) having allowed the are as follows:
oil to drain from the nozzles. Ensure that the rotor
assembly is removed from and replaced on to the At 3000 hours change O-rings (23, 06 and 29).
spindle (24) with extreme care so as not to damage Change these sooner if damaged. See Plate 61515.
the bushes (18) and (21).
At 12000 hours change tube assembly (17). The
4) Unscrew rotor cover jacking nut (2) and sepa- procedure for removing the tube assembly is to
secure the rotor base in a tool, loosen circlip (19) and
08028-0D/H5250/94.08.12

rate rotor cover (4) from rotor body (10).

with pressure applied via a fly press or hide mallet
5) Remove sludge from inside the rotor by means extract tube assembly from rotor base. See Plate
of a spatula and wipe clean. Then remove standtube 61515.
(07). Ensure that all rotor components are thoroughly
cleaned and free from deposits of dirt before For inserting new tube assembly invert the rotor
reassembling the rotor. Failure to do so could cause base and follow reverse of above procedure ensuring
an out-of-balance condition which will accelerate that pin (20) is correctly aligned with recess in rotor
bearing and spindle wear. base. See Plate 61515.

At 24000 hours replace the filter complete.

97.39 - ES0S
 Working Card 615-15.00
Page 3 (3 ) Centrifugal Bypass Filter Edition 05H

L32/40

Important note: The spindle/body assembly (25) and the rotor bearing tube
assembly (17) are factory assembled items and should only
The maximum bush clearances when new are 0.10 be replaced with complete assemblies.
mm in the top bush (21) and 0.13 mm in the bottom
bush (18). See fig. 1. All rotors are precision balanced before leaving the
Dependent on the conditions, wear will eventually factory.
take place both on the spindle and on the bushes and
if clearance is found to be in excess of 0.35 mm in top Trouble shooting guide for centrifugal bypass filter.
bush or 0.33 mm in bottom bush, then replace with
new bearing tube assembly.
08028-0D/H5250/94.08.12

97.39 - ES0S
 Working Card
Cooling Water Thermostatic Valve 616-04.00
Page 1 (2) Edition 03H

L32/40

Safety precautions: Special tools:

Stopped engine Plate No. Item No. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Inspection of thermostatic valve and replacement

of elements. Hand tools:

Ring and open end spanner 24 mm

Copaslip
Tools and cleaning preparation for cleaning.

Starting position:

Cooling water drained from engine (if necessary).

Related procedure:

Man power:
08028-0D/H5250/94.08.12

Working time : 2 Hour

Capacity : 1 Man Replacement and wearing parts:

Data: Plate No. Item No. Qty./

61604 03 4/engine
61604 05 4/engine
61604 09 3/engine

97.39 - ES0S-G
616-04.00 Cooling Water, Thermostatic Valve Working Card
Edition 03H Page 2 (2)

L32/40

The thermostatic valve cannot be adjusted and Replacement of elements:

under normal working conditions maintenance is not
required. However, in some cases it is necessary to 1) Remove nuts (1) and washers (2), see fig 1.
replace the elements in the thermostatic valve.
2) Disconnect upper and lower part of the housing.

3) Remove the assembled elements (3) and the

1 elements O-ring sealing.
2
3 4) Remove the gaskets between the upper and
lower part of the housing.
5
5) The upper and lower part of the housing are
4 thoroughly cleaned inside and on the gasket surfaces.

6) The sealing rings (4) for the elements in the

housing are replaced and lubricated with a thin layer
of copaslip.

7) Remount the assembled elements in the

housing by wriggling these somewhat over side.

8) Upper and lower part of the housing are

assembled with a new gasket (5), the nuts (1) are
mounted and tightened "cross-wise".

Note:
1. Nut
2. Washer After inspection or replacement of the elements the
3. Element cooling water temperature is checked to ensure that
4. O-rings sealing the elements are working correctly.
5. Gasket

Fig 1 Thermostatic valve

08028-0D/H5250/94.08.12

97.39 - ES0S-G
 Working card
Fitting Instructions for Resilient Mounting of GenSets 619-03.00
Page 1 (4) Edition 12H

L32/40

Safety precautions Special tools

Stopped engine Plate No. Item No. Note.

Shut-off starting air
Shut-off cooling water Torque spanner, 140 - 760 Nm.
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circulation (The special tools must be ordered
separately from MAN B&W, Holeby)

Description

Mounting and adjustment instruction for new

GenSets, and adjustment instruction for existing
plants.
Hand tools

Ring and open end spanner, 22 mm

Starting position Ring and open end spanner, 30 mm
Allen key, 6 mm
The foundation should be welded and milled off Feeler gauge, 1-2 mm
on shim surfaces. Measurement tool
Hydraulic jack (if necessary)

Related procedure

Check of crankshaft bend (autolog)

Change of conical elements

Man power

Working hours : Hours

Capacity : 2 Men
08028-0D/H5250/94.08.12

Data Spare and wearing parts

Plate No. Item No. Qty./

61903 01 4/conical mount.

61903 02 4/conical mount.
61903 03 1/conical mount.
61903 04 4/conical mount.

00.33 - EO1
619-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
Edition 12H Page 2 (4)

L32/40

Mounting and Adjustment Instructions for If all internal buffers Then

New Generating Sets (Method 1)
Can move freely Let conical elements set-
Make Ready for Adjustment of Conical Ele- tle for 48 hours.
ments
Cannot be moved Turn the four jacking bolts
If the conical elements have not been mounted by in the base casting clock-
the factory, they must be mounted on the prepared wise or anticlockwise to
brackets on the base frame. In case they have been release the internal buffer.
mounted by the factory, please start with item number
2.
Adjustment of Conical Elements after 48
1) Fit the conical elements to the bracket on the Hours Settling
base frame by means of four bolts screwed
into the tapped holes on the top casting (5), After the conical elements have been deflected
see fig 1. under static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the
2) Remove fixing bolt (7), spring washer (8) and recommended laden height.
top lock ring (6) from the conical element, see
fig 1.

3) Position the four jacking bolts in the tapped

holes (9) see fig 1, in the base casting (1).

4) Position the jacking bolts with a through-going

of minimum 40 mm, see fig 2.

5) Lower the generating set until it rests com-

plete-ly on the foundation.

6) Check that all jacking bolts have full contact

with the foundation.

7) Turn all the internal buffers (2), see fig 1, to

check that they can move freely.

7 6
08028-0D/H5250/94.08.12

8 5

3 Fig 2 Conical mounting.

2
8) Check the laden height by measuring the
9 1
height of the individual conical element with a
gauge block micrometer at two positions.

Fig 1 Conical element

00.33 - EO1
 Working card
Fitting Instructions for Resilient Mounting of GenSets 619-03.00
Page 3 (4) Edition 12H

L32/40

The difference between the laden height of the 14) Position each completed steel shim.
individual conical elements should be as small as
possible and not exceed ± 2 mm to secure the overall 15) Lower the generating set until it rests com-
level and load distribution. pletely in itself.

Example: 16) Number each steel shim together with each

conical element.
H1 + H2 + H3 ----- HN
Average =
Number of conical elements
Adjustment of Internal Buffer
If Then
17) Turn the internal buffer clockwise until it makes
Difference exceeds Level the conical element contact with the steel shim.
± 2 mm. by adjusting the jacking
bolts - commencing with 18) Turn the internal buffer anticlockwise until it
the conical element with obtains contact with the base casting.
the largest deviation.
This must be four full turns.
Difference does not ex- The height of the steel
ceed ± 2 mm shim can be measured. 19) Turn the internal buffer 1.5 turn clockwise and
check with a feeler gauge between the base
casting of the conical element and the steel
Measuring of Steel Shim shim that the internal buffer (2), see fig 1, does
not touch the steel shim.
9) Measure the steel shim on several points to
obtain the highest possible accuracy during 20) Lock the internal buffer by remounting the top
preparation. lock ring (6) and turn it to the nearest thread
hole - then secure with fixing bolt (7) and spring
washer (8), see fig 1.
Fabricating Steel Shim

10) Make sure that the minimum height of the steel Mounting of Conical Elements on the Foun-
shim is 40 mm to secure a future replacement dation
of the conical element.
21) Drill four mounting holes in the foundation for
Drill the mounting holes in the steel shim according each conical element, either
to the conical base casting dimensions.
a) Mark the positions of the mounting holes on
the foundation through the conical element
Mounting of the Completed Steel Shim and the steel shim.
08028-0D/H5250/94.08.12

11) Turn the internal buffer anticlockwise until it (Re)move the set completely so that the mark-
contacts the base casting to secure the laden ings can be reached by drilling with conven-
height of each conical element. tional tools.

12) Lift the generating set with crane or hydraulic Place the set on its former position by aligning
jack. it with the drilled holes.

13) Remove all the jacking bolts. or

00.33 - EO1
619-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
Edition 12H Page 4 (4)

L32/40

b) Drill the mounting holes in the foundation by 22) Fix all the conical elements and the steel shims
means of the drilling pattern from the installa- to the foundation with four bolts per conical.
tion drawing.
Note! After completion of all works the buffer clear-
The drilling has to be done on beforehand and ance must be checked, see points 17, 18, 19 and 20.
the set must be aligned with the foundation
holes before the work starts to avoid further
removal of the set.

08028-0D/H5250/94.08.12

00.33 - EO1
 Working card
Fitting Instructions for Resilient Mounting of GenSets 619-03.00
Page 1 (4) Edition 13H

L32/40

Safety precautions Special tools

Stopped engine Plate No. Item No. Note.

Shut-off starting air
Shut-off cooling water Torque spanner, 140 - 760 Nm.
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circulation (The special tools must be ordered
separately from MAN B&W, Holeby)

Description

Mounting and adjustment instruction for new

GenSets, and adjustment instruction for existing
plants.
Hand tools

Ring and open end spanner, 22 mm

Starting position Ring and open end spanner, 30 mm
Allen key, 6 mm
The foundation should be welded and milled off Feeler gauge, 1-2 mm
on shim surfaces. Measurement tool
Hydraulic jack (if necessary)

Related procedure

Check of crankshaft bend (autolog)

Change of conical elements

Man power

Working hours : Hours

Capacity : 2 Men
08028-0D/H5250/94.08.12

Data Spare and wearing parts

Plate No. Item No. Qty./

61903 01 4/conical mount.

61903 02 4/conical mount.
61903 03 1/conical mount.
61903 04 4/conical mount.

00.33 - EO1
619-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
Edition 13H Page 2 (4)

L32/40

Mounting and Adjustment Instructions for 5) Position the jacking bolts with a through-going
New Generating Sets (Method 2) of minimum 10 mm, see fig 2.

Make Ready for Adjustment of Conical Ele- 6) Lower the generating set until it rests com-
ments pletely on the foundation.

If the conical elements have not been mounted by 7) Check that all jacking bolts have full contact
the factory, they must be mounted on the prepared with the foundation.
brackets on the base frame. In case they have been
mounted by the factory, please start with item number 8) Turn the internal buffer (2), see fig 1 to check
2. that it can be moved freely.

1) Fit the conical elements to the bracket of the

base frame by means of four bolts screwed If all internal buffers Then
into the tapped holes on the top casting (5),
see fig 1. Can move freely Let conical elements set-
tle for 48 hours.
A supporting steel shim with a minimum height of 40
mm, to secure a future replacement of the conical Cannot be moved Turn the three jacking
element, complete with tapped holes for three jack- freely bolts in the supporting
ing bolts and mounting holes drilled according to steel shim clockwise, or
conical base casting dimensions, is required. anticlockwise to release
the internal buffer.
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see
fig 1.

3) Position the supporting steel shim as per fig 2

and locate the conical element by means of
dowel pins.

4) Position the three jacking bolts in the tapped

holes in the supporting steel shim as per fig 2.

7 6

8 5
08028-0D/H5250/94.08.12

9 1

Fig 1 Conical element

Fig 2 Conical mounting.

00.33 - EO1
 Working card
Fitting Instructions for Resilient Mounting of GenSets 619-03.00
Page 3 (4) Edition 13H

L32/40

Adjustment of Conical Elements after 48 Mounting of the Completed Steel Shim

Hours Settling
12) Lift the generating set 1 mm totally be means
After the conical elements have been deflected of the three jacking bolts.
under static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the 13) Position each completed steel shim.
recommended laden height.
14) Re-lower the generating set by means of the
9) Check the laden height by measuring the three jacking bolts until it rests completely in
height of the individual conical element with a itself.
gauge block micrometer at two positions.

The difference between the laden height of the Adjustment of Internal Buffer
individual conical elements should be as small as
possible and not exceed ± 2 mm to secure the overall 15) Turn the internal buffer clockwise until it ob-
level and load distribution. tains contact with the supporting steel shim.

Example: 16) Turn the internal buffer anticlockwise until it

obtain contact with the base casting.
H1 + H2 + H3 ----- HN
Average = This must be four full turns.
Number of conical elements
17) Turn the internal buffer 1.5 turn clockwise and
If Then check with a feeler gauge between the base
casting on the conical element and the sup-
Difference exceeds Level the conical element porting steel shim that the internal buffer (2)
± 2 mm. by adjusting the jacking see fig 1, does not touch the supporting steel
bolts - commencing with shim.
the conical element with
the largest deviation. 18) Lock the internal buffer by remounting the top
lock ring (6) and turn it to the nearest thread
Difference does not ex- The height of the steel hole - then secure with fixing bolt (7) and spring
ceed ± 2 mm shim can be measured. washer (8), see fig 1.

Measuring of Steel Shim Mounting of Conical Elements on the Foun-

dation
10) Measure the steel shim on several points to
obtain the highest possible accuracy during 19) Remove the dowel pins.
preparation.
08028-0D/H5250/94.08.12

20) Drill four mounting holes in the foundation for

each conical element, either
Fabricating Steel Shim
a) Mark the positions of the mounting holes on
11) Make sure that the minimum height of the steel the foundation through the conical element
shim is 10 mm. and the steel shims.

Drill the mounting holes in the steel shim according (Re)move the set completely so that the mark-
to the mounting holes in the conical base casting and ings can be reached by drilling with conven-
the mounting holes in the supporting steel shim. tional tools.

00.33 - EO1
619-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
Edition 13H Page 4 (4)

L32/40

Place the set on its former position by aligning 21) Fix all the conical elements and the supporting
it with the drilled holes. steel shims/steel shims to the foundation with
four bolts per conical.
or
22) Weld the lowest steel shim of approx. 10 mm
b) Drill the mounting holes in the foundation by height to the foundation.
means of the drilling pattern from the installa-
tion drawing. Note! After completion of all works, the buffer clear-
ance must be checked, see points 15, 16, 17 and 18.
The drilling has to be done on beforehand and
the set must be aligned with the foundation
holes before the work starts to avoid further
removal of the set.

08028-0D/H5250/94.08.12

00.33 - EO1
 Working card
Fitting Instructions for Resilient Mounting of GenSets 619-03.00
Page 1 (4) Edition 14H

L32/40

Safety precautions Special tools

Stopped engine Plate No. Item No. Note.

Shut-off starting air
Shut-off cooling water Torque spanner, 140 - 760 Nm.
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circulation (The special tools must be ordered
separately from MAN B&W, Holeby)

Description

Mounting and adjustment instruction for new

GenSets, and adjustment instruction for existing
plants.
Hand tools

Ring and open end spanner, 22 mm

Starting position Ring and open end spanner, 30 mm
Allen key, 6 mm
The foundation should be welded and milled off Feeler gauge, 1-2 mm
on shim surfaces. Measurement tool
Hydraulic jack (if necessary)

Related procedure

Check of crankshaft bend (autolog)

Change of conical elements

Man power

Working hours : Hours

Capacity : 2 Men
08028-0D/H5250/94.08.12

Data Spare and wearing parts

Plate No. Item No. Qty./

61903 01 4/conical mount.

61903 02 4/conical mount.
61903 03 1/conical mount.
61903 04 4/conical mount.

00.33 - EO1
619-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
Edition 14H Page 2 (4)

L32/40

Mounting and Adjustment Instructions for 5) Position the jacking bolts with a through-going
New Generating Sets (Method 3) of minimum 10 mm plus permitted thickness,
as specified from the chockfast supplier, see
Make Ready for Adjustment of Conical Ele- fig 2.
ments
6) Lowed the generating set until it rests com-
If the conical elements have not been mounted by pletely on the foundation.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have been 7) Check that all jacking bolts have full contact
mounted by the factory, please start with item number with the foundation.
2.
8) Turn the internal buffer (2), see fig 1, to check
1) Fit the conical elements to the bracket of the that it can be moved freely.
base frame by means of four bolts screwed
into the tapped holes on the top casting (5) see If all internal buffers Then
fig 1.
Can move freely Let conical elements set-
A supporting steel shim with a minimum height of 40 tle for 48 hours.
mm, complete with tapped holes for three jacking
bolts, four mounting holes and four tapped holes, Cannot be moved Turn the three jacking
drilled according to the conical base casting dimen- freely bolts in the supporting
sion, is required see fig 2. steel shim clockwise, or
anticlockwise and slacken
2) Remove fixing bolt (7), spring washer (8) and the four hold-down bolts
top lock ring (6) from the conical element, see to release the internal
fig 1. buffer.

3) Position the supporting steel shim as per fig 2

and locate the conical element by means of
four hold-down bolts.

4) Position the three jacking bolts in the tapped

holes in the supporting steel shim as per fig 2.

7 6

8 5
08028-0D/H5250/94.08.12

9 1

Fig 1 Conical element

Fig 2 Conical mounting.

00.33 - EO1
 Working card
Fitting Instructions for Resilient Mounting of GenSets 619-03.00
Page 3 (4) Edition 14H

L32/40

Adjustment of Conical Element after 48 Hours 11) Drill the mounting holes in the steel shim
Settling according to the mounting holes in the conical
base casting and in the supporting steel shim.
After the conical elements have been deflected
under static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the Adjustment of Internal Buffer
recommended laden height.
12) Turn the internal buffer clockwise until it ob-
9) Check the laden height by measuring the tains contact with the supporting steel shim.
height of the individual conical element with a
gauge block micrometer at two positions. 13) Turn the internal buffer anticlockwise until it
obtains contact with the base casting.
The difference between the laden height of the
individual conical element should be as small as This must be four full turns.
possible and not exceed ± 2 mm to secure the overall
level and load distribution. 14) Turn the internal buffer 1.5 turn clockwise and
check with a feeler gauge between the base
Example: H1 + H2 + H3 ----- HN casting on the conical element and the sup-
porting steel shim that the internal buffer (2),
Number of conical elements
Average = see fig 1, does not touch the supporting steel
shim.

If Then 15) Lock the internal buffer by remounting the top

lock ring (6) and turn it to the nearest thread
Difference exceeds Level the conical element hole - then secure with fixing bolt (7) and spring
± 2 mm. by adjusting the jacking washer (8), see fig 1.
bolts - commencing with
the conical element with
the largest deviation. Mounting of Conical Elements on the Foun-
dation
Difference does not ex- The height of the steel
ceed ± 2 mm shim and the chockfast 16) Drill four mounting holes in the foundation for
can be measured. each conical element according to the sup-
porting steel shim/steel shim, either

Measuring of Steel Shim and Chockfast a) Mark the positions of the mounting holes on
the foundation through the conical element
10) The steel shim should be at least 10 mm high. and the shims.

Check the minimum permitted thickness of chockfast (Re)move the set completely so that the mark-
08028-0D/H5250/94.08.12

for the load and surface of this application with ings can be reached by drilling with conven-
chockfast supplier. tional tools.

Place the set on its former position by aligning

Fabricating Steel Shim it with the drilled holes.

Make sure that the minimum height of the steel shim or

is 10 mm.

00.33 - EO1
619-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
Edition 14H Page 4 (4)

L32/40

b) Drill the mounting holes in the foundation by Make sure that the mounting bolts are isolated from
means of the drilling pattern. the chockfast.

The drilling has to be done on beforehand and Note! After completion of all works, the buffer clear-
the set must be aligned with the foundation ance must be checked, see points 12, 13, 14 and 15.
holes before the work starts to avoid further
removal of the set.

08028-0D/H5250/94.08.12

00.33 - EO1
 Working card
Replacement of Conicals 619-03.05
Page 1 (2) Edition 02H

L32/40

Safety precautions: Special tools:

Stopped engine Plate No. Item No. Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circulation

Description:

Replacement of conicals

Hand tools:

Starting position: Ring and open end spanner, 22 mm

Ring and open end spanner, 30 mm
Safety precautions Hydraulic jack

Related procedure:

Fitting instructions for resilient mounting

Man power:

Working hours : xxx Hours

Capacity : 2 Men
08028-0D/H5250/94.08.12

Data: Spare and wearing parts:

Plate No. Item No. Qty./

97.38 - EO0S-G
619-03.05 Replacement of Conicals Working card
Edition 02H Page 2 (2)

L32/40

Replacement of Conicals

1. Loosen all conicals in one side. 3. Lift the GenSet until the steel shim can be
removed. This will give enough space for removing
damaged conical.
2. Mount a jack under the base frame, see fig 1.

4. Mount the GenSet conical.

Note! Conicals should only be replaced in pairs, see

fig 2 and plate 61903.

5. Lower the GenSet again.

6. Repeat point 1-5 for the other side.

7. Adjust the conicals, see Working Card 619-

03.00 "Fitting Instructions for Resilient Mounting of
GenSet.

Fig 1 Removal of conicals

08028-0D/H5250/94.08.12

Fig 2 The conicals must be pairs

97.38 - ES0S-G
 Working Card
Maintenance of Conicals 619-03.10
Page 1 (2) Edition 02H

L32/40

Safety precautions: Special tools:

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Control and adjustment of conicals.

Hand tools:

Ring and open end spanner.

Feeler gauge, 1-2 mm.
Hexagon socket key 6 mm.
Starting position:

Related procedure:

Check of crankshaft bend (autolog)

Replacement and wearing parts:

Manpower: Plate no Item no Qty/

08028-0D/H5250/94.08.12

Working time : 2 hours

Capacity : 1 man

Data:

97.38 - EO0S-G
619-03.10 Maintenance of Conicals Working Card
Edition 02H Page 2 (2)

L32/40
1. Visual Check 2.2. Result of clearance check.

If Then
1.1. What to check.
Everything is OK Check is completed

Check for oil deposits on the rubber element. Everything is not OK Adjust conicals which do not com-
Check for loose mounting bolts. ply with the clearance demands
Check for damage in the rubber element. acc. to item 2.3. Recheck all con-
cals acc. to item 2.1.

Everything is still not OK Replace conical acc. to

1.2. Result of visual check. Working Card 619-03.05

If Then

Everything is OK Continue to next conical 2.3. Adjustment of conicals.

Oil deposits on rubber Clean rubber element a. Remove protective cap (no 9).
element

Loose mounting bolts Fasten mounting bolts

b. Remove fixing bolt (no 8) and top locking ring
(no 6).
Damage in conicals Replace conical according to
Working Card 619-03.05 c. Turn buffer clockwise until it has contact with
the steel shim (no 1).

2. Clearance Check d. Turn buffer anticlockwise until it has contact

with the conical base casting (no 2). This must be
four full rotations.
2.1. What to check.
e. Turn buffer two full rotations clockwise. This
Check clearance on all conicals between steel shim will ensure full vertical movement for the buffer.
and internal buffer through the slot in the base
casting of the conical (see fig 1) with a feeler gauge f. Check all conicals again.
of app. 2 mm.
g. Replace top locking ring, fixing bolt and protec-
tive cap etc.
08028-0D/H5250/94.08.12

Fig 1 Conical

97.38 - EO0S-G