Technical Documentation

Engine
Working Instructions B2

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L 40/54

Works No. . . . . . . . . . . . . . . . . . . . . . . . . 1 120 169

Plant No. . . . . . . . . . . . . . . . . . . . . . . . . . H 10314

6701-- 1
MAN Diesel SE : 86224 Augsburg, Germany : Phone ++49 821 3 22--0 : Telefax ++49 821 322 3382

10314 B2--01 E 03.07 101/ 02

. 2007 MAN Diesel SE

All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/microcopy), in
whole or in part, and the translation.

10314 B2--01 E 03.07 102/ 02

Table of contents

N 1 Introduction

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

N 2 Work cards, arranged by subjects/key words

N 3 Work cards, arranged by subassembly groups

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

6701 09.06 L 40/54 101 /01

Introduction

1 Introduction

2 Work cards,
arranged by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 1--02 E 08.97 101/ 01

Table of contents

N 1 Introduction

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

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

6701 09.06 L 40/54 101 /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

Status/availability
Required tools/appliances 1.3

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

Tools/appliances required

Qty Designation No. Availability

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

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

6682 1.3--02 E 03.06 General 101/ 05

Tool Designation Number

Set of basic tools, complete 009.229

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

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

Socket wrench insert DIN 3124 -- 11x12,5 001.751
Socket wrench insert DIN 3124 -- 12x12,5 001.788
Socket wrench insert DIN 3124 -- 13x12,5 001.752
Socket wrench insert DIN 3124 -- 14x12,5 001.753
Socket wrench insert DIN 3124 -- 15x12,5 001.789
Socket wrench insert DIN 3124 -- 16x12,5 001.790
Socket wrench insert DIN 3124 -- 17x12,5 001.754
Socket wrench insert DIN 3124 -- 18x12,5 001.798
Socket wrench insert DIN 3124 -- 19x12,5 001.755
Socket wrench insert DIN 3124 -- 21x12,5 001.799
Socket wrench insert DIN 3124 -- 22x12,5 001.756
Socket wrench insert DIN 3124 -- 24x12,5 001.757
Socket wrench insert DIN 3124 -- 27x12,5 001.758
Socket wrench insert DIN 3124 -- 30x12,5 001.759
Socket wrench insert DIN 3124 -- 32x12,5 001.760
Socket wrench insert DIN 3124 -- 34x12,5 001.769
Socket wrench insert DIN 3124 S -- 36x20 001.771
Socket wrench insert DIN 3124 S -- 41x20 001.772

Cross handle DIN 3122 A -- 12,5 001.891

Extension DIN 3123 B -- 12,5x75 001.908

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

Universal joint DIN 3123 C -- 12,5 001.876

6682 1.3--02 E 03.06 General 102/ 05

Tool Designation Number

Ratchet DIN 3122 C -- 12,5 001.521

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

Combination wrench DIN 3113 AK -- 5,5 002.050

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

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

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

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

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

6682 1.3--02 E 03.06 General 103/ 05

Tool Designation Number

Screw driver for recessed-head screws

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

Hexagon screw driver DIN 911 -- 3L 000.307

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

Tommy bar DIN 900 A -- 5 000.507

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

Adapter DIN 3123 A -- 20x12,5 001.923

Adapter DIN 3123 A -- 12,5x20 001.927

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

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

6682 1.3--02 E 03.06 General 104/ 05

Tool Designation Number

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

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

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

Crow bar S 550 A -- 15 001.391

Gripping pliers with slip joint DIN ISO 8976 A -- 250 002.196

Hammer DIN 1041 -- 300L 000.693

Tool box, 5-parts, 530x200x200 009.470

Table 2. Basic tools

6682 1.3--02 E 03.06 General 105/ 05

Work cards,
arranged by subjects/key words

1 Introduction

2 Work cards,
arranged by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 2--02 E 08.97 101/ 01

Table of contents

N 001 Operating media systems/Pipes

000.03 Operating media systems

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

N 002 Operating media/Auxiliary agents

000.04 Lubricating oil

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

N 003 Machine elements

000.11 Galvanized bearings

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

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Intended for ...
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Middle management
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6701 09.06 L 40/54 101 /03

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

N 004 Hydraulic tensioning tools/ High--pressure pump

000.33 Working and safety regulations

: : N Using high--pressure tools/ hydraulic tensioning tools
009.03 High--pressure pump
: : N Use
009.05 High--pressure hoses
: : N Use
009.11 Hydraulic tensioning tool (single)
: : N Use
009.12 Hydraulic tensioning tool (single)
: : N Disassembling and assembling
009.13 Hydraulic tensioning tool (single)
: : N Use
009.14 Hydraulic tensioning tool (single)
: : N Disassembling and assembling
009.15 Dial gauge (measuring device)
: : N Checking the bolt elongation
009.16 Hydraulic tensioning tool
: : N Use
009.17 Hydraulic tensioning tool
: : N Disassembling and assembling
009.18 Dial gauge (measuring device)
: : N Checking the bolt elongation

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6701 09.06 L 40/54 102 / 03

 N 005 Operating data/Operating results

000.25 Ignition and compression pressures

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

Categories of information
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6701 09.06 L 40/54 103 /03

Operating media systems/Pipes

001 Operating media systems/pipes

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

6682 001--01 E 08.97 101/ 01

Operating media systems
Flushing and cleaning 000.03

Purpose of jobs to be done

Keep operating media systems free from contamination and residues,

prevent operating problems/damage.

Brief description

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

1. Lube oil system

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

▲ Attention! Dirt particles penetrating into the engine interior may

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

6682 000.03--01 E 07.03 General 101/ 06

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

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

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

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

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

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

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

6682 000.03--01 E 07.03 General 102/ 06

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

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

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

6682 000.03--01 E 07.03 General 103/ 06

2. Fuel delivery system

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

6682 000.03--01 E 07.03 General 104/ 06

3. Cooling water system

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

Supplier Product Concentration Duration of cleaning/temperature

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

4. Compressed air system

4.1 Plant-specific system

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

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

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

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

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

6682 000.03--01 E 07.03 General 105/ 06

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

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

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

6682 000.03--01 E 07.03 General 106/ 06

Cooling water system
Cleaning 000.08

Purpose of jobs to be done

Free operating media systems from contamination/residues,

ensure/restore operational reliability.

Brief description

Cooling water systems that show contamination or deposits impede

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

Cleaning

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

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

Manufacturer Product Concentration Duration of cleaning procedure /

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

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

6682 000.08--01 E 03.06 General 101/ 02

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

Manufacturer Product Concentration Duration of the cleaning procedure /

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

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

6682 000.08--01 E 03.06 General 102/ 02

Pipes
Replacement 000.15

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

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

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

Preliminary remarks

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

Instructions

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

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

6682 000.15--01 E 07.97 101/ 02

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

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

6682 000.15--01 E 07.97 102/ 02

Pipes
Cleaning, Acid Bath Treatment and
Preservation 000.16

Purpose of jobs to be done

Keeping operating systems free from contamination and residues,

ensuring/restoring of operational reliability.

Brief description

Pipes, which are replaced or supplemented, must after

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

Preliminary remarks

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

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

Mechanical cleaning

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

6682 000.16--01 E 11.98 General 101/ 03

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

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

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

Acid bath treatment of steel pipes

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

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

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

Important! Copper piping should not be treated in the hydrochloric

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

6682 000.16--01 E 11.98 General 102/ 03

Treating copper pipes

First pickle in sulphuric acid bath, possibly followed by trisodium

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

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

Pressure testing of pipes

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

Preservation of pipes

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

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

6682 000.16--01 E 11.98 General 103/ 03

Solderless screwed pipe unions
Mounting 000.17

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

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

Tools/appliances required

Quant Denomination No. Availability

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

Advantages of solderless screwed pipe unions

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

Sequence of operations

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

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

6682 000.17--01 E 07.97 101/ 03

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

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

1 Union nut 3 Pipe 5 Inner cone

2 Stop 4 Cutting and wedge ring 6 Visible collar

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

6682 000.17--01 E 07.97 102/ 03

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

7 Marking

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

Supplementary notes

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

H= Height of the union

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

Figure 4. Minimum distances/bending radii

6682 000.17--01 E 07.97 103/ 03

Solderless Screwed Pipe Unions
Additional parts 000.18

Purpose of jobs to be done

Use/replacement of components,
proper processing and installation.

Brief description

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

Preliminary remarks

Reinforcing sleeves , insert nozzles and screwed hose connections are

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

Instructions

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

1 Reinforcing sleeve

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

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

6682 000.18--01 E 07.97 101/ 02

 2 Insert nozzle

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

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

3 Hose
4 Hose clamp

Figure 3. Using screwed hose connections

6682 000.18--01 E 07.97 102/ 02

Operating media/Auxiliary agents

001 Operating media systems/pipes

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

6682 002--01 E 08.97 101/ 01

Lubricating oil
Assessing and treating 000.04

Purpose of jobs to be done

Record and assess characteristics of operating media,

keep their condition within the admissible range.

Brief description

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

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

Assessment of oil

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

6682 000.04--02 E 07.04 General 101/ 03

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

Characteristic Limit value Measuring method

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

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

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

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

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

6682 000.04--02 E 07.04 General 102/ 03

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

Oil treatment

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

Oil change

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

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

6682 000.04--02 E 07.04 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 testkit or a corresponding testkit contain-
fresh water quality ing all the necessary instruments and chemicals for determining the water
hardness, the pH value and the chloride content (can be obtained from
MAN 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 producers also contain testing means
for determining the fresh water quality.

When using anti-corrosion oils:

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

6682 000.07--01 E 03.04 General 101/ 03

Check the characteristic values of the water

Brief specification

Characteristic value/ Water for charging Water in circulation

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

*) dGH = German hardness

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

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

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

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

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

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

6682 000.07--01 E 03.04 General 102/ 03

Check the concentration of anti-corrosion agents

Brief specification

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

Check the concentration of The concentration should be checked weekly and/or in accordance with
chemical additives the maintenance schedule, using the testing instruments and reagents
specified by the respective producer, and in accordance with the instruc-
tions issued.
A protection by chemical anti-corrosion agents is only ensured if the con-
centration is exactly adhered to. In this connection, the concentrations
recommended by MAN 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 The concentration is to be checked in accordance with the instructions of
anti-freeze agents the producer, or a suitable laboratory is to be entrusted with the determina-
tion of the concentration. In case of doubt, MAN B&W Diuesel AG, Augs-
burg, should be consulted.

6682 000.07--01 E 03.04 General 103/ 03

Engine or components
Preservation treatment 000.14

Purpose of jobs to be done

Counteract corrosion attacks,

carry out/repeat preventive measures.

Brief description

Specific corrosion prevention and preservation measures are to be applied

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

Corrosion inhibition

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

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

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

6682 000.14--01 E 04.05 General 101/ 04

Corrosion inhibitors

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

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

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

Preserving new engines and spare parts

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

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

6682 000.14--01 E 04.05 General 102/ 04

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

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

gine’s running gear any longer.

Preservation of engines for shut-down

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

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

6682 000.14--01 E 04.05 General 103/ 04

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

6682 000.14--01 E 04.05 General 104/ 04

Loctite Products
Use 000.19

Purpose of jobs to be done

Use of auxiliary agents,

proper processing and mounting.

Brief description

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

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

Preliminary remarks

The filling compound LOCTITE is a liquid synthetic which automatically

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

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

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

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

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

Operating Sequence 1 -- Assembly

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

6682 000.19--01 E 01.05 General 101/ 04

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

Sequence 2 -- Disassembly

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

Sequence 3 -- Reassembly

1. Mechanically remove the old LOCTITE layer on both parts

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

6682 000.19--01 E 01.05 General 102/ 04

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

Thread sealing Surface sealing

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

6682 000.19--01 E 01.05 General 103/ 04

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

2) Tensile shear strength N/mm2

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

6682 000.19--01 E 01.05 General 104/ 04

Machine elements

001 Operating media systems/pipes

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

6682 003--01 E 08.97 101/ 01

Galvanized bearings
Assessing 000.11

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

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

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

Related work cards

Work card Work card Work card

000.10

General

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

Figure 1. Galvanized bearings - structure

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

5600 000.11--01 E 06.99 General 101/ 09

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

Wear limits

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

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

Figure 2. Degree of running surface wear

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

5600 000.11--01 E 06.99 General 102/ 09

Appearance of the bearing surface

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

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

Figure 3. Normal wear pattern

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

Figure 4. Partly worn through running layer

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

Figure 5. Shiny reflections

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

5600 000.11--01 E 06.99 General 103/ 09

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

Figure 6. Edge-carrying wear

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

Figure 7. Carrying wear on one edge

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

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

5600 000.11--01 E 06.99 General 104/ 09

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

Figure 9. Striation and foreign particles in the running surface

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

Figure 10. Cracks

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

5600 000.11--01 E 06.99 General 105/ 09

 9. “Bark Beetle” effect

Figure 11. Barks beetles

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

Figure 12. Separation or detachment of the running layer

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

Figure 13. Smearing of the running layer

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

5600 000.11--01 E 06.99 General 106/ 09

 12. Roughening of bearing-metal layer

Figure 14. Roughening of the running layer

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

Figure 15. Crumbling

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

Figure 16. Overheating of the running layer

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

5600 000.11--01 E 06.99 General 107/ 09

 15. Electro-erosion

Figure 17. Electro-erosion

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

Figure 18. Corrosion

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

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

5600 000.11--01 E 06.99 General 108/ 09

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

Figure 20. Cold shots on the rear of the bearing

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

Bearing spread

D Bearing diameter
S Spread

Figure 21. Bearing spread

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

5600 000.11--01 E 06.99 General 109/ 09

Deep-- groove bearing
Assessing 000.11

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

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

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

Related work cards

Work card Work card Work card

000.10

General

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

6682 000.11--02 E 05.98 101/ 05

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

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

Figure 1. Structure of a deep--groove bearing

Wear criterias

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

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

A B

Figure 2. Wear not critical

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

6682 000.11--02 E 05.98 102/ 05

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

C D

Figure 3. Wear not critical

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

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

E F

Figure 4. Wear of the bearing metal lands

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

6682 000.11--02 E 05.98 103/ 05

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

G H

Figure 5. Wear of the running layer

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

Wear ratio 50% / 50%

Bearing metal lands worn

down

A max. 30% of the

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

Figure 6. Extent of wear zones

6682 000.11--02 E 05.98 104/ 05

 Bearing metal lands worn
down
Running layer broken out

Empty grooves

I max.. 25% of the

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

Figure 7. Extent of wear zones

6682 000.11--02 E 05.98 105/ 05

Bimetal bearings (without a third layer)
Assessing 000.11

Purpose of jobs to be done

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

Brief description

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

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

Related work cards

Work card Work card Work card

000.10

General

1 Bearing metal
2 Aluminium bonding
layer
3 Steel shell

Figure 1. Composition of bearing

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

6682 000.11--03 E 07.97 101/ 03

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

Appraisal of the running behaviour and criteria for replacement

Figure 2. Measuring the wall thickness

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

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

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

1. Bearing wear pattern uniform over the entire bearing width

A B

Figure 3. Normal bearing wear pattern

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

6682 000.11--03 E 07.97 102/ 03

2. Bearing wear pattern showing traces of seizure

C D

Figure 4. Bearing wear pattern showing seizure

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

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

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

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

6682 000.11--03 E 07.97 103/ 03

Seals made from elastomer
Storage, cleaning, mounting 000.21

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

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

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

Explanatory remarks

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

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

Storing elastomer seals

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

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

6682 000.21--01 E 07.97 101/ 03

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

Cleaning

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

Assembly

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

6682 000.21--01 E 07.97 102/ 03

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

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

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

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

6682 000.21--01 E 07.97 103/ 03

Threaded inserts
Use 000.22

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

Threaded inserts serve for making firmly locking threads in components

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

Tools/appliances required

Commercially available twist drills, with diameters as required for the

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

Explanatory remarks

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

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

6682 000.22--01 E 07.97 101/ 03

Operating sequence 1- installation

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

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

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

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

E Core hole diameter

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

Figure 2. Twist drill/bore hole

G Diameter of the special

tap, suitable for A

Figure 3. Special tap

C Tang
H Fitting tool

Figure 4. Fitting tool

6682 000.22--01 E 07.97 102/ 03

 L Tang breaker/punch
M Unfitting tool

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

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

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

Operating sequence 2 - removal

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

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

6682 000.22--01 E 07.97 103/ 03

Tightening of bolted connections
Tightening torques (illustrated) 000.29

Purpose of jobs to be done

Indicating tightening torques for essential bolted connections.

Guaranteeing 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.

6701 000.29--04 E 09.01 L 40/54 101/ 05

Figure 1. Cross-section / side view of engine

6701 000.29--04 E 09.01 L 40/54 102/ 05

Figure 2. Attached cooling water and lube oil pump / torsional vibration damper / crankshaft / crankshaft gear wheel / main
bearing (external bearing) / covering on coupling side (splash ring) / flywheel / crankshaft extension

6701 000.29--04 E 09.01 L 40/54 103/ 05

Figure 3. Clamping device for eccentric shaft / eccentric shaft for fuel pump cam follower / automatic blocking of the eccentric
shaft / camshaft thrust bearing / drive for speed governor / indicator valve

6701 000.29--04 E 09.01 L 40/54 104/ 05

Figure 4. Charge air cooler attachment / turbocharger attachment / quick-acting coupling for exhaust pipe

6701 000.29--04 E 09.01 L 40/54 105/ 05

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.

6701 000.30--04 E 03.02 L 40/54 101/ 09

6701 000.30--04 E 03.02 L 40/54 102/ 09
6701 000.30--04 E 03.02 L 40/54 103/ 09
6701 000.30--04 E 03.02 L 40/54 104/ 09
6701 000.30--04 E 03.02 L 40/54 105/ 09
6701 000.30--04 E 03.02 L 40/54 106/ 09
6701 000.30--04 E 03.02 L 40/54 107/ 09
6701 000.30--04 E 03.02 L 40/54 108/ 09
6701 000.30--04 E 03.02 L 40/54 109/ 09
Tightening of bolted connections
Tightening torques (turning moment) 000.31

Purpose of jobs to be done

Indicating tightening torques for essential bolted connections.

Guaranteeing operating safety.

Brief description

Screwed connections should be tightened by means of torque spanners as

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

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

Strength class 5.6 6.8 10.9 12.9

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

6682 000.31--01 E 08.97 101/ 02

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

6682 000.31--01 E 08.97 102/ 02

Tightening of bolted connections
General remarks 000.32

Purpose of jobs to be done

Impart the necessary knowledge,

ensure the operational reliability of bolted connections.

Brief description

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

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

Related work cards

Work card Work card Work card

000.29 000.30 000.31

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

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

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

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

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

6682 000.32--01 E 06.05 General 101/ 02

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

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

6682 000.32--01 E 06.05 General 102/ 02

Surface examination by means of
penetration methods 000.34

Purpose of jobs to be done

Examination of components for cracks/surface defects.

Evaluation regarding usability/remachining possibilities/tightness.

Brief description

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

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

Tools/appliances required

Qty Designation No. Availability

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

Application ranges

Surface examinations by the penetration method are based on the

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

6682 000.34--01 E 05.01 General 101/ 06

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

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

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

Precleaning

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

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

Operating sequence 2 -- Application of the penetrant

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

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

Penetration process

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

Figure 2. Possibilities for applying the penetrant

6682 000.34--01 E 05.01 General 102/ 06

Operating sequence 3 -- Intermediate cleaning of the component surface

The excessive penetrant which adheres to the component surface has to

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

Intermediate cleaning

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

Figure 3. Possibilities for intermediate cleaning

Operating sequence 4 -- Drying of the cleaned component surface

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

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

Drying process

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

Figure 4. Possibilities for component drying

Operating sequence 5 -- Developing process

Apply the developer to the component surface to be examined as

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

6682 000.34--01 E 05.01 General 103/ 06

 Developing process

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

Figure 5. Possibilities for applying the developer

Operating sequence 6 -- Evaluation of the results

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

Evaluation of results

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

Figure 6. Possibilities for recording the examination results

1 Cold cracks 6 Accumulation of pores

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

Figure 7. Fault indications

6682 000.34--01 E 05.01 General 104/ 06

 Figure 8. Valve cone with stress cracks at the fillet

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

6682 000.34--01 E 05.01 General 105/ 06

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

Manufacturing firm Special cleaner Penetrant Developer

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

Figure 10. Test chemicals of various manufacturers

(special cleaner/penetrant/developer respectively)

6682 000.34--01 E 05.01 General 106/ 06

Surface examination by means of
Magnetic flux leakage methods 000.34

Purpose of jobs to be done

Examination of components for cracks/surface defects.

Evaluation regarding usability/remachining possibilities/tightness.

Brief description

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

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

Tools/appliances required

Qty Denomination No. Availability

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

Application ranges

Surface examinations by Magnaflux test cause magnetic discontinuities

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

6682 000.34--02 E 03.99 General 101/ 05

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

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

Figure 2. Permanent magnet with special varnish and magnetic particles

in spray cans (source Messrs Helling)

6682 000.34--02 E 03.99 General 102/ 05

Yoke magnetising

Figure 3. Course of flux lines during yoke magnetising

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

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

B Component with defect

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

C Component with defect

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

6682 000.34--02 E 03.99 General 103/ 05

Applying the magnetic particles

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

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

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

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

Execution of the Magnaflux testing

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

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

6682 000.34--02 E 03.99 General 104/ 05

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

Magnetic particle indications

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

Figure 6. Valve cone with stress cracks at the fillet

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

Demagnetising

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

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

6682 000.34--02 E 03.99 General 105/ 05

Hydraulic tensioning tools/
High-- pressure pump

001 Operating media systems/pipes

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

6682 004--01 E 08.97 101/ 01

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

Purpose of jobs to be done

Impart the necessary knowledge,

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

Brief description

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

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

Preliminary remarks

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

Safety regulations

J Study work cards carefully and observe safety regulations.

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

6682 000.33--01 E 05.05 General 101/ 06

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

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

value), the cause is to be traced (negligent tightening, wear, pro-
nounced settling of the screwed connection).
If the loosening pressure is 10% or more below the specified value,
MAN B&W Diesel AG, Augsburg, is to be consulted for appropriate
checking measures.
If the loosening pressure is too high (tightening pressure plus 5% are
not sufficient for loosening), the cause is to be eliminated as far as
possible (screwed connection damaged/corroded / blocked by paint,
tensioning tool damaged/incorrectly mounted).
If it is not possible to undo the connection in spite of such improving
measures, the tensioning pressure may only be increased far enough
to allow the connection to be released if MAN B&W Diesel AG, Augs-
burg, verifiably has 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.

Storage and care of the tools

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

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

Basic safety instructions

Obligations and liabilities Obligations and liabilities

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

6682 000.33--01 E 05.05 General 102/ 06

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

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

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

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

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

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

Warranty and liability Warranty and liability

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

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

The hydraulic tensioning tool serves for tightening and loosening the
tightening-screw connections on the Diesel engine specified by MAN B&W
Diesel AG, Augsburg. This is effected by applying a high operating pres-

6682 000.33--01 E 05.05 General 103/ 06

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

Inappropriate use Inappropriate use

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

Supplementary to the operating instructions, the general legal and other

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

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

Informal safety measures Informal safety measures

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

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

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

Instructing the personnel Instructing the personnel

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

Safety measures in normal Safety measures in normal operation

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

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

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

6682 000.33--01 E 05.05 General 104/ 06

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

Points of particular danger Points of particular danger

Period of use of hydraulic hose pipes and seals

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

6682 000.33--01 E 05.05 General 105/ 06

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

6682 000.33--01 E 05.05 General 106/ 06

High-- pressure pump
Use 009.03

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

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

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

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.341 Standard
1 Tools, basic scope 000.002 Standard
1 Anti--corrosion oil (Viscosity 6--16 mm2/s) -- Inventory

Technical details

Term Information
Quality Anti--corrosion oil
Pressure range 0 -- 1500 bar
Test pressure 1500 bar
Oil filling 5 litres
Compressed air connection 6 -- 15 bar
Dimensions 444x240x320 mm
Weight 30 kg

Structure/operating principle

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

connections:
- the high-pressure pump,

6682 009.03--04 E 03.05 32/40, L 40/54, L 58/64, 48/60 B 101/ 04

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

Putting into operation

▲ Attention! Observe the safety instructions given in Work Card

000.33!
000.33

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

6682 009.03--04 E 03.05 32/40, L 40/54, L 58/64, 48/60 B 102/ 04

Taking out of operation

Steps 1. Set the shut-off valve (A) to Position II / OUT OF OPERATION, thus
venting the air side of the high-pressure pump.
2. Open the relief valve (B) to depressurise the oil side of the high-pres-
sure pump (the oil pressure gauge will indicate zero). Pressure
decay in the high-pressure hose takes longer. Therefore, leave the
high-pressure hose connected to the high-pressure pump with the
relief valve open for approx. three minutes after pressure relief.
Otherwise, an internal pressure may remain, which would block the
009.05).
hose coupling (for corrective action, see Work Card 009.05
3. Disconnect the quick-lock coupling of the high-pressure hose.
▲ Attention! Never open quick-lock couplings under pressure. Ac-
cident hazard! The oil pressure gauge (9) must indicate zero.
Tip! If several screwed connections are to be tensioned successively at
the same pressure, the setting of the pressure regulating valve (C) re-
mains the same, it need not be newly adjusted.
4. Leave the high-pressure hose on the hose connection (2) and re-
move the anti-corrosion oil from the hydraulic tensioning tool (for the
description of this procedure, see work card for the respective ten-
sioning tool).
5. Disconnect the high-pressure hose.

Maintenance

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

checked for tightness from time to time, and overhauled if necessary. The
set of wear parts (3) for the high-pressure pump and pressure regulating
valve (C) has been attached behind the front plate (4).
Prior to use, the oil level is always to be checked on the oil level gauge (5)
and topped up if necessary. The high-pressure pump must never run
completely dry because air would then be aspirated. Approx. once a year,
the oil charge is to be drained, and fresh anti-corrosion oil is to be be filled
in. On every oil change, the oil space is also to be cleaned.
To remove water from the compressed-air filter on the compressed-air reg-
ulator, the front plate (4) is to be removed, and the screw plug at the bot-
tom of the compressed-air regulator is to be screwed in by a few turns so
that the water can pressure controller is to be screwed further in by a few
turns in order that the water can flow out. Afterwards, retighten the screw
plug again. See operating instructions of the manufacturer.

In the case of operating troubles

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

Reason 2: Venting holes are clogged with ice.

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

6682 009.03--04 E 03.05 32/40, L 40/54, L 58/64, 48/60 B 103/ 04

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

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

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

Reason 2: The suction filter is clogged.

Remedy: Clean the suction filter.

2. Hydraulic oil emerges at the silencer.

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

1 Casing cover
2 Hose connection
(tensioning tool)
3 Set of wear parts
4 Front plate
5 Oil level gauge
6 Hose connection
(compressed air)
7 Oil admission socket
with filling strainer
8 Compressed-air pres-
sure gauge
9 Oil pressure gauge

A Shut-off valve
B Relief valve
C Pressure regulating
valve
Figure 1. High-pressure pump, GERUS make, type 15

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

Figure 2. High-pressure pump - functional diagram

6682 009.03--04 E 03.05 32/40, L 40/54, L 58/64, 48/60 B 104/ 04

High-- pressure hoses
Use 009.05

Purpose of jobs to be done

Impart the necessary knowledge,

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

Brief description

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

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

Tools/appliances required

Qty Designation No. Availability

1 High--pressure hose 009.304 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-pres-

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

6682 009.05--01 E 05.05 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!
Take the maximum usability specified by the manufacturer into ac-
count!

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

1 Hydraulic nipple 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 05.05 32/40, 40/45, 40/54, 48/60, 58/64 102/ 02

Hydraulic tensioning tool (single)
Use 009.11

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

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

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Resetting device 009.021 Standard
1 Bridge 009.021--1 Standard
1 Threaded piece 009.021--4 Standard
1 Hydraulic tensioning tool 009.010 Standard
1 Tommy bar, 10 mm 000.263 Standard
1 Ring spanner (cranked) 24x27 000.247 Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.12

Technical details

Term Information
Nominal pressure 1,200 bar
Test pressure 1,300 bar
Thread diameter M48
Outside diameter 146 mm

6647 009.11--01 E 08.03 V 48/60, V 48/60 B 101/ 05

 Term Information
Height 108 mm
Weight 8.5 kg
Effective piston area 72.72 cm2
Delivery stroke 7 mm

Preliminary remarks

By means of the piston and the casing of the hydraulic tensioning tool,
supplemented by a thrust pad, the bolt is elongated relative to the compo-
nents to be connected. This is done by anti-corrosion oil being pressed
against the piston underside by means of the high-pressure pump. If a suf-
ficiently high pressure is applied, the nut of the bolt comes clear and can
either be loosened or fastened to specification.
Hydraulic tensioning tools as well as high-pressure hoses must be com-
pletely filled with anti-corrosion oil prior to use. They have to be vented if
required. The unit should be checked for tightness from time to time (see
009.12).
Work Card 009.12

Operating sequence 1 -- Untensioning a bolt

Starting condition The thread of the bolt has been cleaned.

Steps 1. Place the thrust pad (3) over the nut (4).
2. Screw the hydraulic tensioning tool (1) onto the bolt (5), making sure
that the thrust pad (3) is centred by the hydraulic tensioning tool.
Refer to Figure 1 .
▲ Attention! Prior to fitting the hydraulic tensioning tool, verify that
the piston is moved in completely (stroke = zero). Reset the piston,
if necessary (refer to operating sequence 3)!
3. Turn the hydraulic tensioning tool (1) back by the back-off angle (see
Work Card 000.30).
000.30 Refer to Figure 1 .
4. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool (1) and to the high-pressure pump (009.338).
009.03), and
5. Switch the high-pressure pump on (see Work Card 009.03
close gap (A) produced by turning back.
▲▲▲ Danger! During untensioning, make sure that there is no one
along the extended axis of the bolt to be untensioned!
6. Pump the hydraulic tensioning tool (1) up until the nut (4) can be
loosened.
▲▲ Caution! The pressure applied must not be more than 7%
below and 5% above the tensioning pressure (see Work Card
000.30)!
000.30
7. Insert the tommy bar (2) through the opening in the thrust pad (3) and
turn the nut (4) back (for back-off angle, see work card 000.30).
000.30
8. Release the pressure, disconnect the high-pressure hose from the
hydraulic tensioning tool (1) and high-pressure pump.
9. Remove the tensioning tool.
10. Reset the piston of the hydraulic tensioning tool (refer to operating
sequence 3).

6647 009.11--01 E 08.03 V 48/60, V 48/60 B 102/ 05

Operating sequence 2 -- Tensioning a bolt

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

▲ Attention! Correct tensioning of a bolted connection requires the

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

Steps 1. Put the thrust pad (3) over the nut (4).
2. Screw the hydraulic tensioning tool (1) onto the bolt (5), making sure
that the thrust pad (3) is centred by the hydraulic tensioning tool.
Refer to Figure 2 .
▲ Attention! Prior to fitting the hydraulic tensioning tool, verify that
the piston is moved in completely (stroke = zero). Reset the piston,
if necessary (refer to operating sequence 3)!
3. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool (1) and high-pressure pump (009.338).
4. Switch the high-pressure pump on (see Work Card 009.03009.03), and ten-
sion the bolt (5) to the specified tensioning pressure (see Work Card
000.30).
000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the bolt to be tensioned!
5. Insert the tommy bar (2) through the opening in the thrust pad (3),
and turn the nut (4) down, hand-tight.
6. Release the pressure, disconnect the high-pressure hose from hy-
draulic tensioning tool (1) and the high-pressure pump.
7. Remove the tensioning tool.
8. Reset the piston of the hydraulic tensioning tool (refer to operating
sequence 3).

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

▲ Attention! Prior to each tensioning and loosening process, the

piston of the hydraulic tensioning tool (009.010) has to be reset to its
starting position (stroke = zero).
Steps 1. Screw the threaded piece (009.021-4) into the piston (8), down to
contact.
2. Place the bridge (009.021-1) onto the casing (7) of the hydraulic ten-
sioning tool.
3. Oil contact face and thread of the hexagon bolt (6) and screw the bolt
through the bridge into the threaded piece. Refer to Figure 3 .
4. Connect the high-pressure hose (009.306) to hydraulic tensioning
tool and high-pressure pump (009.338).
5. Open the relief valve on the high-pressure pump (see Work Card
009.03),
009.03 and reset the piston (8) by turning the hexagon bolt (6).
6. Disconnect the high-pressure hose from hydraulic tensioning tool and
high-pressure pump.
7. Remove the resetting device (009.021).

6647 009.11--01 E 08.03 V 48/60, V 48/60 B 103/ 05

 1 Hydraulic tensioning
tool
2 Tommy bar
3 Thrust pad
4 Nut
5 Bolt

A Gap

Figure 1. Bolt with tensioning tool attached - Untensioning

1 Hydraulic tensioning
tool
2 Tommy bar
3 Thrust pad
4 Nut
5 Bolt

Figure 2. Bolt with tensioning tool attached - Tensioning

6647 009.11--01 E 08.03 V 48/60, V 48/60 B 104/ 05

 6 Hexagon bolt M16x80
7 Casing
8 Piston

Figure 3. Resetting the piston of the hydraulic tensioning tool

6647 009.11--01 E 08.03 V 48/60, V 48/60 B 105/ 05

Hydraulic tensioning tool (single)
Disassembling and assembling 009.12

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

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

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Opener 009.026 Standard
1 Resetting device 009.021 Standard
1 Bridge 009.021--1 Standard
1 Threaded piece 009.021--4 Standard
1 Ring spanner 24x27 000.225 Standard
1 Hammer (wood/plastic) -- Inventory
1 Copper bolt -- Inventory
1 Depth gauge -- Inventory
1 Belzona Antiseize (lubricant) -- Inventory
1 Anti--corrosion oil -- Inventory

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.11

6647 009.12--01 E 08.03 V 48/60, V 48/60 B 101/ 06

Technical details

Term Information
Outside diameter 146 mm
Height 108 mm
Weight 8.5 kg
Effective piston area 72.72 cm2
Delivery stroke 7 mm
Nominal pressure 1,200 bar
Test pressure 1,300 bar
Thread diameter M48

Tool No./Spare part No.

Item Designation Tool No.

-- Hydraulic tensioning tool, complete 009.010
1 Piston 009.010-3
2 Casing 009.010-10
3* Backing ring 009.010-17
4* O-ring seal 009.010-16
5* O-ring seal 009.010-18
6* Backing ring 009.010-19
7 Threaded piece 009.010-13
8 Sealing ring 009.010-14
9 Quick-acting-coupling half 009.010-12
-- Spare parts package ------------------

* all contained in the spare parts package

Preliminary remark

Hydraulic tensioning tools, like high-pressure hoses, have to be completely

filled with anti-corrosion oil before they are used. They have to be vented
if necessary and checked for tightness occasionally.

The hydraulic tensioning tool has to be disassembled when the backing

rings/O-ring seals are to be replaced and in case of a damage. If they are
disassembled, all the backing rings/O-rings seals should, for practical rea-
sons, be renewed. Due to the high working pressures and the critical
clearances and surfaces, we warn against more extensive interventions/
repair measures. We recommend entrusting MAN B&W Diesel AG or one
of the authorised service bases with the overhaul of the tool, if necessary.

Operating sequence 1 -- Disassembly of the hydraulic tensioning tool

Steps 1. Hydraulic tensioning tool clamped into the vice.

6647 009.12--01 E 08.03 V 48/60, V 48/60 B 102/ 06

 Important! Using the protective jaws, clamp the tensioning tool at
the flat face of the piston.
2. Screw in the threaded piece (009.021-4) until it contacts the piston
(1). Refer to Figure 2 .
3. Connect the high-pressure hose (009.306) to hydraulic tensioning
tool and high-pressure pump (009.338).
4. Switch the high-pressure pump on (see Work Card 009.03009.03), and
pump the hydraulic tensioning tool up until anti-corrosion oil emerges
on the control edge (A). Refer to Figure 2 .
5. Remove the hydraulic tensioning tool from the vice and put it down
onto a clean work bench.
6. Position the hydraulic tensioning tool on the shell of the casing (2).
7. Open the relief valve on the high-pressure pump, and drive the piston
(1) out of the casing (2) by means of copper bolt and hammer, taking
care that it is not tilted.
8. Disconnect the high-pressure hose from hydraulic tensioning tool and
high-pressure pump.
9. Remove the O-ring seals (4 and 5) and backing rings (3 and 6).
10. Clean all the individual components and check them for damage, re-
placing them, if necessary.

Operating sequence 2 -- Assembly of the hydraulic tensioning tool

Starting condition All individual components cleaned, checked for damage and, if necessary,
replaced. Threaded piece (009.021-4) screwed into the piston.

Steps 1. Check new backing rings (3 and 6) as well as O-ring seals (4 and 5)
for undamaged condition.
2. Coat a new backing ring (3) and O-ring seal (4) with anti-corrosion oil
and insert them in the respective groove, taking care that they are
evenly tensioned over the entire circumference and not twisted.
Refer to Figure 1 .
▲ Attention! Make sure that the backing ring and O-ring seal are
positioned correctly! The O-ring seal should always be on the pres-
sure side, the backing ring on the opposite side with its depression
facing the O-ring seal. Refer to Figure 1 .
3. Coat the backing ring (6) with anti-corrosion oil and insert it into the
respective groove.
4. Coat the O-ring seal (5) with anti-corrosion oil, bend it into a kidney
shape, and insert it into the corresponding groove, making sure that it
is not twisted. Refer to Figures 1 and 4 .
▲ Attention! Make sure that the backing ring and O-ring seal are
positioned correctly! The O-ring seal should always be on the pres-
sure side, the backing ring on the opposite side with its depression
facing the O-ring seal. Refer to Figure 1 .
5. Screw the threaded piece (009.021-4) in until it contacts the piston
(1).
6. Apply a thin film of Belzona Antiseize lubricant to the running sur-
faces of the piston (1) and casing (2).
▲ Attention! Backing ring, O-ring seals and grooves must remain
free!
7. Place the piston (1) onto the casing (2), position the bridge
(009.021-1) on the casing, oil the contact surface and thread of the
hexagon bolt (10), and screw the bolt through the bridge and into the
threaded piece (009.021-4). Refer to Figure 3 .
8. Connect the high-pressure hose (009.306) to hydraulic tensioning
tool and high-pressure pump (009.338).

6647 009.12--01 E 08.03 V 48/60, V 48/60 B 103/ 06

 9. Open the relief valve on the high-pressure pump and install the piston
(1) in the casing (2) by turning the hexagon bolt (10).
▲ Attention! For exact alignment of the axes of piston and casing,
turn the bridge several times by 90ƒ during piston installation!
10. Disconnect the high-pressure hose from the hydraulic tensioning tool.
11. Unscrew the hexagon bolt (10), and remove the bridge.
12. Clamp the hydraulic tensioning tool into the vice.
Important! Using the protective jaws, clamp the tensioning tool at
the flat face of the piston.
13. Reconnect the high-pressure hose to the hydraulic tensioning tool.
009.03), and open
14. Switch the high-pressure pump on (see Work Card 009.03
the hydraulic tensioning tool by approx. 8 mm.
15. Disconnect the high-pressure hose from the hydraulic tensioning tool.
16. Remove the hydraulic tensioning tool from the vice, and put it down
onto a clean work bench.
Important! The quick-acting-coupling half (9) is facing upwards.
17. Place the bridge (009.021-1) on the casing (2), oil the contact face
and the thread of the hexagon bolt (10), and screw the bolt through
the bridge and into the threaded piece. Refer to Figure 5 .
18. Attach the opener (009.026) to the quick-acting-coupling half, and
open the non-return valve. Refer to Figure 5 .
19. By turning the hexagon bolt (10), press the piston (1) into the casing
(2) until bubble-free anti-corrosion oil emerges. Press the piston all
the way in.
20. Remove the opener (009.026) and the resetting device (009.021).
21. Mount the hydraulic tensioning tool to a suitable bolt (see corre-
sponding work card) so that the quick-acting-coupling (9) faces up-
wards.
22. Reconnect the high-pressure hose to the hydraulic tensioning tool.
009.03), and
23. Switch the high-pressure pump on (see Work Card 009.03
pump the hydraulic tensioning tool up to the tensioning pressure
000.30). Retain the pressure
specified for this bolt (see Work Card 000.30
for five minutes.
Important! Once the hydraulic tensioning tool has been pumped
up, there must not be any detectable leakage during this period.
24. Release pressure, disconnect the high-pressure hose from the hy-
draulic tensioning tool and high-pressure pump.
25. Remove the tensioning tool.

6647 009.12--01 E 08.03 V 48/60, V 48/60 B 104/ 06

 1 Piston
2 Casing
3 Backing ring
4 O-ring seal
5 O-ring seal
6 Backing ring
7 Threaded piece
8 Sealing ring
9 Quick-acting-coupling
half

Figure 1. Hydraulic tensioning tool

1 Piston
2 Casing

A Control edge

Figure 2. Removal of the piston

6647 009.12--01 E 08.03 V 48/60, V 48/60 B 105/ 06

 1 Piston
2 Casing
10 Hexagon bolt M16x80

Figure 3. Installation of the piston

Figure 4. Bending an O-ring seal into a kidney shape

1 Piston 9 Quick-acting-coupling half

2 Casing 10 Hexagon bolt M16x80

Figure 5. Venting the hydraulic tensioning tool

6647 009.12--01 E 08.03 V 48/60, V 48/60 B 106/ 06

Hydraulic tensioning tool (single)
Use 009.13

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

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

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.079 Standard
1 Hydraulic tensioning tool 009.063 Standard
1 Hydraulic tensioning tool 009.062 Standard
1 Hydraulic tensioning tool 009.053 Standard
1 Tommy bars (set) -- Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.14

Technical details

Tool No. 009.053 009.062 009.063 009.079

Effective piston area (cm)) 115.40 130.18 130.18 226.78
Delivery stroke (mm) 8 8 8 12
Nominal pressure (bar) 1400 1200 1500 1400
Test pressure (bar) 1500 1250 1600 1500
Thread diameter A (mm) M56x4 M56x4 M64x4 M90x4

6644 009.13--01 E 08.03 L 40/54, 48/60, 48/60 B 101/ 05

 Outside diameter B (mm) 192 200 200 285
Height C (mm) 97 97 97 145

Preliminary remark

By means of the piston and the casing of the hydraulic tensioning tool,
supplemented by a thrust pad, the bolt is elongated relative to the compo-
nents to be connected. This is done by anti-corrosion oil being pressed
against the piston underside by the high-pressure pump. If a sufficiently
high pressure is applied, the nut of the bolt comes clear and can either be
loosened or tightened to specification.

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

pletely filled with anti-corrosion oil prior to use. They have to be vented if
required and checked for tightness occasionally (see Work Card 009.14).
009.14

Operating sequence 1 -- Untightening a bolt

Starting condition The thread of the bolt has been cleaned.

Steps 1. Place the thrust pad (3) over the nut (4).
2. Screw the hydraulic tensioning tool (1) onto the bolt (5), making sure
that the thrust pad (3) is centred by the hydraulic tensioning tool.
3. Turn the hydraulic tensioning tool (1) back by the back-off angle (see
000.30). Refer to Figures 1 and 2 .
Work Card 000.30
4. Connect the high-pressure hose (009.306) to hydraulic tensioning
tool (1) and the high-pressure pump (009.338)
5. Switch the high-pressure pump on (see Work Card 009.03009.03) and close
the gap (A) produced by turning back.
▲▲▲ Danger! During untightening, make sure that there is no one
along the extended axis of the bolt to be untightened!
6. Pump the hydraulic tensioning tool (1) up until the nut (4) can be
loosened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see Work Card 000.30)!
000.30

▲▲ Caution! While pumping, watch the stroke gauges (6) of the hy-
draulic tensioning tool! The hydraulic tensioning tool may only be
pumped up until the marking (M) on the stroke gauges reaches the
upper edge of the threaded stop ring (7)! Otherwise, the hydraulic
tensioning tool will be damaged! Refer to Figure 3 .
7. Insert the tommy bar (2) through the opening in the thrust pad (3),
and turn the nut (4) back (for the back-off angle, see Work Card
000.30).
000.30
8. Release the pressure; disconnect the high-pressure hose from the
hydraulic tensioning tool (1) and the high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
009.03).
be connected and its relief valve has to be open (see Work Card 009.03
9. Remove the tensioning tool.

6644 009.13--01 E 08.03 L 40/54, 48/60, 48/60 B 102/ 05

Operating sequence 2 -- Tightening a bolt

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

▲ Attention! Correct tightening of a bolted connection requires the

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

Steps 1. Place the thrust pad (3) over the nut (4).
2. Screw the hydraulic tensioning tool (1) onto bolt (5), making sure that
the trust pad (3) is centred by the hydraulic tensioning tool. Refer to
Figure 4 .
3. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool (1) and the high-pressure pump (009.338).
4. Switch the high-pressure pump on (see Work Card 009.03009.03), and ten-
sion the bolt (5) to the specified tensioning pressure (see Work Card
000.30).
000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the bolt to be tensioned!

▲▲ Caution! While pumping, watch the stroke gauges (6) of the hy-
draulic tensioning tool! The hydraulic tensioning tool may only be
pumped up until the marking (M) on the stroke gauges reaches the
upper edge of the threaded stop ring (7)! Otherwise, the hydraulic
tensioning tool will be damaged! Refer to Figure 3 .
5. Insert the tommy bar (2) through the opening in the thrust pad (3) and
screw down the nut (4), hand-tight.
6. Release the pressure; disconnect the high-pressure hose from the
hydraulic tensioning tool (1) and the high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
009.03).
be connected and its relief valve has to be open (see Work Card 009.03
7. Remove the tensioning tool.

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

A Gap
M Marking on the stroke
gauge

Figure 1. Bolt with tensioning tool attached - Untightening

6644 009.13--01 E 08.03 L 40/54, 48/60, 48/60 B 103/ 05

 3 Thrust pad A Gap

Figure 2. Bolt with tensioning tool attached - Untightening (position of gap (A) in the case of a horizontally or invertently
mounted tensioning tool)

6 Stroke gauge
7 Threaded stop ring

M Marking on the stroke

gauge

Figure 3. Position of the marking on the stroke gauge at maximum stroke of the
hydraulic tensioning tool

6644 009.13--01 E 08.03 L 40/54, 48/60, 48/60 B 104/ 05

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

M Marking on the stroke

gauge

Figure 4. Bolt with tensioning tool attached - Tightening

6644 009.13--01 E 08.03 L 40/54, 48/60, 48/60 B 105/ 05

Hydraulic tensioning tool (single)
Disassembling and assembling 009.14

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

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

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Set of tools 009.134 Standard
1 Insert 22x12.5 009.134--3 Standard
1 Insert 19x12.5 009.134--4 Standard
1 Side nippers 009.134--10 Standard
1 Screw driver 1x6.5 009.134--12 Standard
1 Screw driver 1.2x8 009.134--13 Standard
1 Marking pin 009.134--16 Standard
1 Hammer (wood/plastic) 009.134--18 Standard
1 Mandril 009.134--25 Standard
1 Extractor 009.134--26 Standard
1 Flat strip (nylon) 009.134--27 Standard
1 Opener 009.026 Standard
1 Extension piece 12.5x125 001.911 Standard
1 Cross handle 001.891 Standard
1 Screw drivers (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Belzona Antiseize (lubricant) -- Inventory
1 Felt--tip pen/Marking pen -- Inventory
1 Anti--corrosion oil -- Inventory

6644 009.14--01 E 08.03 L 40/54, 48/60, 48/60 B 101/ 07

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.13

Technical specifications

Tool No. 009.053 009.062 009.063 009.079

Effective piston area (cm)) 115.40 130.18 130.18 226.78
Delivery stroke (mm) 8 8 8 12
Nominal pressure (bar) 1400 1200 1500 1400
Test pressure (bar) 1500 1250 1600 1500
Thread diameter A (mm) M 56 x 4 M 56 x 4 M 64 x 4 M 90 x 4
Outer diameter B (mm) 192 200 200 285
Height C (mm) 97 97 97 145

Tool No./Spare part No.

Item Designation Tool No. Tool No. Tool No. Tool No.
- Hydr. tensioning tool, complete 009.053 009.062 009.063 009.079
1* Quick-acting-coupling half 009.053-3 009.062-3 009.063-3 009.079-7
2* Double nipple 009.053-12 009.062-12 009.063-12 009.079-8
3 Piston 009.053-2 009.062-2 009.063-2 009.079-2
4 Stroke gauge 009.053-16 009.062-16 009.063-16 009.079-6
5 Threaded stop ring 009.053-13 009.062-13 009.063-13 009.079-3
6* O-ring seal 009.053-7 009.062-7 009.063-7 009.079-12
7* TURCON ring 009.053-6 009.062-6 009.063-6 009.079-11
8* O-ring seal 009.053-5 009.062-5 009.063-5 009.079-10
9* Valve ring 009.053-4 009.062-4 009.063-4 009.079-9
10 Casing 009.053-1 009.062-1 009.063-1 009.079-1
11 Screw plug 009.053-15 009.062-15 009.063-15 009.079-17
12* Compression spring 009.053-14 009.062-14 009.063-14 009.079-16
13 Set screw 009.053-18 009.062-18 009.063-18 009.079-19
14 Screw plug, 009.053-17 009.062-17 009.063-17 009.079-18
for dial gauge connection
- Lifting eye bolt M12 -------------- -------------- -------------- 009.079-22
- Protective cap 009.053-19 009.062-19 009.063-19 009.079-23
- Spare parts package 009.099 009.101 009.101 009.136
* All contained in the spare parts package

Preliminary remark

Hydraulic tensioning tools, like high-pressure hoses, have to be completely

filled with anti-corrosion oil before they are used. They have to be vented
if necessary and checked for tightness occasionally.

6644 009.14--01 E 08.03 L 40/54, 48/60, 48/60 B 102/ 07

 The hydraulic tensioning tool has to be disassembled when the TURCON
ring/valve rings/O-ring seals are to be replaced and in case of a damage.
If they are disassembled, the TURCON ring/valve rings/O-rings seals
should, for practical reasons, be renewed. Due to the high working pres-
sures and the critical clearances and surfaces, we warn against more ex-
tensive interventions/repair measures. We recommend entrusting MAN
B&W Diesel AG or one of the authorised service bases with the overhaul
of the tool, if necessary.

Operating sequence 1 -- Disassembly of the hydraulic tensioning tool

Steps 1. Mark the position of the casing, threaded stop ring, and piston (10, 5
and 3) relative to one another.
2. Unscrew the screw plugs (11), and remove the compression springs
(12).
3. Dismantle the stroke gauges (4) using the extractor (009.134-26).
Refer to Figure 2 .
4. Remove the protective cap from the quick-acting-coupling half (1).
5. Clamp the hydraulic tensioning tool into the vice (23), using the pro-
tective jaws (22) and the mandrel (009.134-25). Refer to Figure 3 .
6. Screw off the quick-acting-coupling half (1), and unscrew the double
nipple (2).
7. Remove the hydraulic tensioning tool from the vice.
8. Unscrew the set screw (13).
9. Screw out the threaded stop ring (5) by hand, backing off slightly from
time to time, in order to prevent it from tilting.
▲ Attention! Should there be any resistance, do not turn the
threaded stop ring any further; instead, loosen it by means of light
taps with a plastic hammer (009.134-18)!
10. Drive the piston (3) out of the casing (10), using the plastic hammer.
11. Using the side nippers (009.134-10), cut up the valve rings (9) and
the TURCON ring (7) and remove them.
12. Remove the O-ring seals (6 and 8) by means of the marking pin
(009.134-16).
13. Clean all individual parts and check them for damage; replace them if
necessary.

Operating sequence 2 -- Assembly of the hydraulic tensioning tool

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

Steps 1. Check the new O-ring seals (6 and 8) for intactness.

2. Coat the running surface of the piston (3) and O-ring seal (6) with
anti-corrosion oil.
3. Insert the O-ring seal (6) into the respective groove, making sure that
it is evenly tensioned over the entire circumference and not twisted.
4. Bend the O-ring seals (8) into a kidney shape, and insert them into
the respective groove, taking care that they are not twisted. Refer to
Figure 4 .
5. Place new valve rings (9) in boiling water for five minutes, take them
out and dry them, bend them into a kidney shape, and insert them
into the respective groove.
▲▲ Caution! Do not place the valve rings in boiling water or take
them out again with your bare hands. Danger of scalding!

6644 009.14--01 E 08.03 L 40/54, 48/60, 48/60 B 103/ 07

 Important! When installing the valve rings, be careful to install
them in the correct position, with the groove on the pressure side. Refer
to Figure 1 /Detail X.
6. Clamp the piston (3) into the vice (23), using the protective jaws (22).
7. Place a new TURCON ring (7) in boiling water for five minutes, take it
out again, and dry it. Insert the TURCON ring on one side of the pis-
ton (3) into the respective groove as far as possible, placing two flat
strips (009.134-27) around the TURCON ring, about 120ƒ apart.
Using the flat strips, carefully pull the TURCON ring over the piston
rim and completely into the groove. Remove the flat strips. Refer to
Figure 5 .
▲▲ Caution! Do not place the TURCON ring in boiling water or take
it out again with your bare hands. Danger of scalding!
8. Press the TURCON ring (7) back in its original shape.
Important! The TURCON ring has been stretched during installa-
tion. To restore it to its original shape, press it into the groove with a piece
of round wood or the handle of the hammer. Refer to Figure 6 .
9. Coat the running surface of the piston (3) and the casing (10) with
Belzona Antiseize lubricant.
10. Position the piston (3) on the casing (10), verify that the markings on
piston and casing coincide (Operating Sequence 1, item 1), and
press the piston into the casing, or hammer it in using the plastic
hammer (009.134-18).
11. Screw the threaded stop ring (5) into the casing (10) until the top of
the threaded stop ring is flush with the top of the casing, backing it off
from time to time to prevent it from tilting.
▲ Attention! Should there be any resistance, do not turn the
threaded stop ring any further; instead, loosen it by means of light
taps with a plastic hammer (009.134-18)!
12. Screw in the set screw (13).
13. Verify that the bores for the stroke gauges (4) in the casing (10) and
the threaded stop ring (5) are in alignment.
14. Hammer in the stroke gauges (4) until the top of the stroke gauges is
flush with the top of the threaded stop ring (5). Refer to Fig-
ure 1 /Detail Y.
15. Insert the compression springs (12) into the bore holes, and screw in
the screw plugs (11) until the top of the screw plug is flush with the
top of the threaded stop ring (5). Refer to Figure 1 /Section K-K.
16. Clamp the hydraulic tensioning tool into the vice (23), using the pro-
tective jaws (22) and mandrel (009.134-25). Refer to Figure 3 .
17. Screw a new double nipple (2) into the piston (3) and tighten it.
18. Screw the quick-acting-coupling half (1) onto the double nipple (2),
and tighten it.
19. Remove the hydraulic tensioning tool from the vice (23).
20. Attach the hydraulic tensioning tool to a suitable screw (see corre-
sponding work card) in such a way that the quick-acting-coupling half
(1) faces upwards.
21. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool and the high-pressure pump (009.338).
22. Switch the high-pressure pump on (see Work Card 009.03009.03), and
pump the hydraulic tensioning tool up.
▲ Attention! Be careful not to exceed the tensioning pressure
000.30)!
specified for the screw selected (see Work Card 000.30
23. Release pressure.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated compression springs (this takes approx. 2

6644 009.14--01 E 08.03 L 40/54, 48/60, 48/60 B 104/ 07

 to 3 minutes). For this purpose, however, the high-pressure pump has to
009.03).
be connected and its relief valve has to be open (see Work Card 009.03
24. Disconnect the high-pressure hose. Vent the high-pressure hose by
means of the opener (009.026) - see Work Card 009.05.
009.05
25. Reconnect the high-pressure hose.
26. Pump up the hydraulic tensioning tool to the tensioning pressure
000.30). Retain the pres-
specified for this screw (see Work Card 000.30
sure for five minutes.
Important! Once the hydraulic tensioning tool has been pumped
up, there must not be any detectable leakage during this period.
27. Release pressure, disconnect the high-pressure hose from the hy-
draulic tensioning tool and high-pressure pump.
28. Remove the tensioning tool.
29. Slip the protective cap onto the quick-acting-coupling half (1).

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

A Thread diameter
B Outer diameter
C Height
M Marking on the stroke
gauge

Figure 1. Hydraulic tensioning tool

6644 009.14--01 E 08.03 L 40/54, 48/60, 48/60 B 105/ 07

 Figure 2. Removal of the stroke gauge

21 Hydraulic tensioning
tool
22 Protective jaw
23 Vice

Figure 3. Clamping the hydraulic tensioning tool into the vice

6644 009.14--01 E 08.03 L 40/54, 48/60, 48/60 B 106/ 07

 Figure 4. Bending a ring into a kidney shape

3 Piston
7 TURCON ring
20 Flat strip

Figure 5. Pulling the TURCON ring onto the piston

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

Figure 6. Pressing the TURCON ring into its final position (on the left: prior to
pressing it in, on the right: after pressing it in)

6644 009.14--01 E 08.03 L 40/54, 48/60, 48/60 B 107/ 07

Dial gauge (measuring device)
Checking the bolt elongation 009.15

Purpose of jobs to be done

Tighten and untighten important bolted connections to 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

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.079 Standard
1 Hydraulic tensioning tool 009.063 Standard
1 Hydraulic tensioning tool 009.062 Standard
1 Hydraulic tensioning tool 009.053 Standard
1 Measuring device 009.052 Standard
1 Dial gauge (measuring device) 009.052--1 Standard
1 Extension 009.052--2 Standard
1 Extension 009.052--3 Standard
1 Threaded piece 009.052--4 Standard
1 Screw drivers (set) -- Standard
1 Hexagon screw drivers (set) -- Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.13

6644 009.15--01 E 09.03 L 40/54, 48/60, 48/60 B 101/ 04

Preliminary remark

For bolted connections that are tensioned hydraulically, measuring of the

bolt elongation as against a reference value is of particular significance.
This is to ensure that the necessary preload resulting from the bolt elonga-
tion and from forcing the corresponding components together is really
achieved. This is not the case if the tensioning tool is blocked or if some
of the tensioning pressure is absorbed by friction.

Operating sequence -- Measuring the bolt elongation Dl

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

▲ Attention! Correct tightening of a bolted connection requires the

pressure gauge indication to be faultless! In case of doubt, check
the pressure gauge using a reference pressure gauge!

Steps 1. Remove the screw plug (1) from the hydraulic tensioning tool (3),
screw the threaded piece (009.052-4) into the threaded stop ring (2).
Refer to Figures 1 and 2 .
2. Mount the tensioning tool on the bolt (see Work Card 009.13 or the
work card applicable for the respective bolt).
3. Screw the required extension (009.052-2 or -3) onto the dial gauge
(009.052-1).
4. Insert the dial gauge into the threaded piece and fasten it by means
of the cylindrical screw (4).
▲ Attention! Make sure that the measuring pin of the dial gauge
contacts the piston of the hydraulic tensioning tool!
5. Connect the high-pressure hose (009.306) to hydraulic tensioning
tool (3) and high-pressure pump (009.338).
009.03), and ten-
6. Switch the high-pressure pump on (see Work Card 009.03
sion the bolt to the specified pretensioning pressure (see Work Card
000.30).
000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the bolt to be tensioned!
7. Set the dial gauge to “zero”.
8. Tension the bolt to the specified final tensioning pressure (see Work
000.30).
Card 000.30
9. Screw down the nut, hand-tight, using the tommy bar.
10. Release the pressure.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
009.03).
be connected and its relief valve has to be open (see Work Card 009.03
11. Tension the bolt again to the specified pretensioning pressure, read
the bolt elongation Dl on the dial gauge, note down the value and
000.30).
compare it with the specified value (see Work Card 000.30
▲ Attention! The bolt is to be tensioned to the specified tensioning
pressure, not according to the bolt elongation Dl! Measuring the
bolt elongation Dl only is a control measure!

Important! In case of larger deviations from the specified value, re-

peat the tensioning process. If necessary, check the hydraulic tensioning
tool, the bolted connection and the pressure gauge.

6644 009.15--01 E 09.03 L 40/54, 48/60, 48/60 B 102/ 04

 12. Release the pressure, disconnect the high-pressure hose from hy-
draulic tensioning tool and high-pressure pump.
13. Remove the dial gauge, take off the tensioning tool.
14. Screw out the threaded piece and close the tap hole by means of the
screw plug (1).

1 Screw plug
2 Threaded stop ring
3 Hydraulic tensioning
tool

Figure 1. Hydraulic tensioning tool

6644 009.15--01 E 09.03 L 40/54, 48/60, 48/60 B 103/ 04

 2 Threaded stop ring
3 Hydraulic tensioning
tool
4 Cylindrical screw
M5x12

Figure 2. Hydraulic tensioning tool with dial gauge attached

6644 009.15--01 E 09.03 L 40/54, 48/60, 48/60 B 104/ 04

Hydraulic tensioning tool
Use 009.16

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

Hydraulic tensioning tools serve the purpose of expanding bolts as against

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

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.056 Standard
1 Tommy bar, 12 mm 000.264 Standard
1 Tommy bar, 10 mm 000.263 Standard

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.17

Technical data

Tool No. 009.056

Effective piston area (cm2) 97.2 + 120.8 = 218
Delivery stroke (mm) 10
Nominal pressure (bar) 1000
Test pressure (bar) 1100
Thread diameter (mm) M80x4

6644 009.16--01 E 09.03 L 40/54, L 48/60, L 48/60 B 101/ 04

 Outer diameter (mm) 172
Height (mm) 396

Preliminary remark

By means of the piston and casing of the hydraulic tensioning tool, sup-
plemented by the thrust pad and nut, the bolt is elongated relative to the
components to be connected. This is done by anti-corrosion oil being
pressed against the piston underside by the high-pressure pump. If a
sufficiently high pressure is applied, the nut of the bolt comes clear and
can either be loosened or fastened to specification.

Hydraulic tensioning tools, like high-pressure hoses, have to be completely

filled with anti-corrosion oil before they are used. They have to be vented
if necessary and checked for tightness occasionally (see Work Card
009.17).
009.17

Operating sequence 1 -- Untightening a bolt

Starting condition The thread of the bolt has been cleaned.

Steps 1. Place the thrust pad (4) over the nut (7).
2. Using the tommy bar (000.263), check whether the nut (3) on the hy-
draulic tensioning tool (1) has been screwed on firmly.
3. Screw the hydraulic tensioning tool (1) onto the bolt (5), making sure
that the thrust pad (4) is placed concentrically. Refer to Figure 1 .
Tip! For screwing on the hydraulic tensioning tool, insert the tommy
bar (6) into the bore (B) or use the socket wrench.
4. After screwing the hydraulic tensioning tool (1) including nut (3) on,
turn them back by the back-off angle specified for the respective
000.30). Refer to Figure 1 .
bolted connection (see Work Card 000.30
5. Connect the high-pressure hose (009.306) to hydraulic tensioning
tool and high-pressure pump (009.338).
6. Switch the high-pressure pump on (see Work Card 009.03009.03), and
close the gap (A) resulting from turning back.
▲▲▲ Danger! During untightening, make sure that there is no one
along the extended axis of the bolt to be untightened!
7. Pump the hydraulic tensioning tool (1) up until the nut (7) can be
loosened.
▲ Attention! The pressure applied must not be more than 7% below
or max. 5% above the tensioning pressure (see Work Card 000.30)!
000.30
8. Insert the tommy bar (6) through the opening in the thrust pad (4),
and turn the nut (7) back (for back-off angle, see Work Card 000.30).
000.30
9. Release the pressure, disconnect the high-pressure hose from hy-
draulic tensioning tool (1) and high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by a set of disk springs (2) - this takes approx. 2 to 3 min-
utes. For this purpose, however, the high-pressure pump has to be con-
009.03).
nected and its relief valve has to be open (see Work Card 009.03
10. Remove the tensioning tool.

6644 009.16--01 E 09.03 L 40/54, L 48/60, L 48/60 B 102/ 04

Operating sequence 2 -- Tightening a bolt

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

▲ Attention! Correct tightening of a bolted connection requires the

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

Steps 1. Place the thrust pad (4) over the nut (7).
2. Using the tommy bar (000.263), check whether the nut (3) on the hy-
draulic tensioning tool (1) has been screwed on firmly.
3. Screw the hydraulic tensioning tool (1) onto the bolt (5), making sure
that the thrust pad (4) is placed concentrically. Refer to Figure 1 .
Tip! For screwing the hydraulic tensioning tool on, insert the tommy
bar (6) into the bore (B) or use a socket wrench.
4. Connect the high-pressure hose (009.306) to hydraulic tensioning
tool and high-pressure pump (009.338).
5. Switch the high-pressure pump on (see Work Card 009.03009.03), and ten-
sion the bolt (5) applying the specified tensioning pressure (see Work
000.30).
Card 000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the bolt to be tensioned!
6. Insert the tommy bar (6) through the opening in the thrust pad (4),
and screw down the nut (7), hand-tight.
7. Release the pressure, disconnect the high-pressure hose from hy-
draulic tensioning tool (1) and high-pressure pump.
Important! The hydraulic tensioning tool is automatically reset to
zero position by a set of disk springs (2) - this takes approx. 2 to 3 min-
utes. For this purpose, however, the high-pressure pump has to be con-
009.03).
nected and its relief valve has to be open (see Work Card 009.03
8. Remove the tensioning tool.

6644 009.16--01 E 09.03 L 40/54, L 48/60, L 48/60 B 103/ 04

 1 Hydraulic tensioning tool 5 Bolt A Gap
2 Disk spring 6 Tommy bar B Bore for tommy bar
3 Nut 7 Nut 12 dia.
4 Thrust pad 8 Cylinder crankcase C Bore for tommy bar
10 dia.

Figure 1. Bolt with tensioning tool mounted (illustration on the left: loosening / illustration on the right: tightening)

6644 009.16--01 E 09.03 L 40/54, L 48/60, L 48/60 B 104/ 04

Hydraulic tensioning tool
Disassembling and assembling 009.17

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Hydraulic tensioning tools must completely be filled with hydraulic fluid

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

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Plug--in disk 009.104 Standard
1 Hydraulic tensioning tool 009.056 Standard
1 Opener 009.026 Standard
1 Hexagon screw driver 19 000.302 Standard
1 Tommy bar, 12 mm 000.264 Standard
1 Tommy bar, 10 mm 000.263 Standard
1 Screw drivers (set) -- Standard
2 Flat strip (nylon) -- Inventory
1 Hammer -- Inventory
1 Combination pliers -- Inventory
1 Anti--corrosion oil -- Inventory
1 Molecular Gold grease (lubricant) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.16

6644 009.17--01 E 09.03 L 40/54, L 48/60, L 48/60 B 101/ 07

Technical data

Tool No. 009.056

Effective piston area (cm2) 97.2 + 120.8 = 218
Delivery stroke (mm) 10
Nominal pressure (bar) 1000
Test pressure (bar) 1100
Thread diameter (mm) M80x4
Outer diameter (mm) 172
Height (mm) 396

Tool No./Spare part No.

Item Designation Tool No.

- Hydr. tensioning tool, complete 009.056
1 Hydraulic nipple 009.056-8
2 Sealing ring 009.056-7
3 Piston 009.056-3
4 Threaded piece 009.056-6
5 Nut 009.056-5
6 O-ring seal 009.056-15
7 Set of seals 009.056-14
8 Casing 009.056-4
9 O-ring seal 009.056-17
10 Set of seals 009.056-16
11 O-ring seal 009.056-19
12 Set of seals 009.056-18
13 Casing 009.056-2
14 Spring pin 009.056-21
15 Disk spring 009.056-20
16 Piston 009.056-1

Preliminary remark

Hydraulic tensioning tools, like high-pressure hoses, have to be completely

filled with anti-corrosion oil before they are used. They have to be vented
if necessary and checked for tightness occasionally.

The hydraulic tensioning tool has to be disassembled when the sets of

seals/O-ring seals are to be replaced and in case of damage. If they are
disassembled, all the sets of seals/O-ring seals are, for practical reasons,
to be renewed. Due to the high working pressures and the critical clear-
ances and surfaces, we warn against more extensive interventions/repair
measures. We recommend entrusting MAN B&W Diesel AG or one of the
authorised service bases with the overhaul of the tool, if necessary.

6644 009.17--01 E 09.03 L 40/54, L 48/60, L 48/60 B 102/ 07

Operating sequence 1 -- Disassembly of the hydraulic tensioning tool

Starting condition Hexagon screw driver clamped into the vice.

Steps 1. Place the piston (16) on the clamped-in hexagon screw driver
(000.302).
2. Using the tommy bar (000.263), loosen the nut (17) and unscrew it.
3. Remove the spring pin (14) and dismantle the disk springs (15).
4. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool.
5. Using the opener (009.026), open the non-return valve on the high-
009.05).
pressure hose (see Work Card 009.05
Important! If the non-return valve has not been opened, the casing
(13) cannot be pulled off.
6. Pull the casing (13) off.
7. Disconnect the hydraulic hose from the hydraulic nipple (1).
8. Place the piston (16) on the clamped-in hexagon screw driver.
9. Loosen the nut (5), using the plug-in disk (009.104) and applying light
taps with the hammer, and screw it off.
▲ Attention! The screw connection of nut and piston has a left-hand
thread!
10. Pull off piston (3) and casing (8).
11. Remove the sets of seals (7, 10 and 12) and the O-ring seals (6, 9
and 11).
12. Clean all the individual components and check them for damage; re-
place them, if necessary.
13. Purge the oil bores in the piston (16) by means of compressed air.

Operating sequence 2 -- Assembly of the hydraulic tensioning tool

Starting condition All individual components cleaned and checked for damage and, if
necessary, replaced. Hexagon screw driver clamped into the vice.

Steps 1. Check new sets of seals (7, 10 and 12) and O-ring seals (6, 9 and 11)
for undamaged condition.
2. Coat the O-ring seal (6) with anti-corrosion oil and insert it into the
respective groove, making sure that it is evenly tensioned over the
entire circumference and not twisted.
3. Bend the O-ring seals (9 and 11) into a kidney shape and insert them
into the respective groove, making sure that they are not twisted.
Refer to Figure 3 .
4. Place new sets of seals (10 and 12) into boiling water for five min-
utes, take them back out, dry them, bend them into a kidney shape,
and insert them into the respective groove.
▲▲ Caution! Do not place the sets of seals into boiling water or
take them back out with your bare hands. Danger of scalding!
5. Place a new set of seals (7) into boiling water for five minutes, take
them back out and dry them.
▲▲ Caution! Do not place the set of seals into boiling water or take
them back out with your bare hands. Danger of scalding!
6. Insert the set of seals (7) on one side of the piston (3 or 16) as far as
possible into the respective groove, put two flat strips (20) around the
set of seals, about 120ƒ apart. Using the flat strips, carefully pull the
set of seals over the piston rim and completely into the groove. Re-
move the flat strips. Refer to Figure 4 .
7. Press the set of seals (7) back into its original shape.

6644 009.17--01 E 09.03 L 40/54, L 48/60, L 48/60 B 103/ 07

 Important! The set of seals has been streched during installation.
To bring it back into its original shape, press it into the groove with a piece
of round wood or the handle of the hammer.
8. Apply a thin coat of Molecular Gold grease to the running surface of
the pistons (3 and 16) and the casings (8 and 13).
▲ Attention! The sets of seals and the grooves must remain free
from grease!
9. Press the piston (3) into the casing (8).
10. Place both the casing (8) and the piston (3) on the piston (16) and
slip them on.
11. Put the piston (16) onto the clamped-in hexagon screw driver
(000.302).
12. Screw the nut (5) onto the piston until it contacts the latter, and
tighten it by means of the plug-in disk (009.104). Refer to Figure 1 .
▲ Attention! The screw connection of nut and piston has a left-hand
thread!
13. Connect the high-pressure hose (009.306) to the hydraulic nipple (1).
14. Using the opener (009.026), open the nun-return valve on the high-
009.05).
pressure hose (see Work Card 009.05
Important! If the non-return valve has not been opened, the casing
(13) cannot be slipped on.
15. Slip the casing (13) onto the piston (16) until it contacts the latter.
Refer to Figure 1 .
16. Disconnect the high-pressure hose from the hydraulic tensioning tool.
17. Install the disk springs (15) in the right order. Refer to Figure 1 .
18. Insert the spring pin (14) into the casing securing the position of the
disk springs (15) in this way.
19. Screw the nut (17) onto the piston (16) and tighten it, hand-tight.
20. Put the piston (16) onto the clamped-in hexagon screw driver and,
using the tommy bar (000.263), screw the nut (17) on until it is
seated. Refer to Figure 2 .
Important! The disk springs have to be compressed slightly.
21. Attach the hydraulic tensioning tool to a suitable bolt (see the corre-
sponding work card) in such a way that the hydraulic nipple (1) points
upwards.
22. Connect the high-pressure hose to the hydraulic tensioning tool and
high-pressure pump (009.338).
23. Switch the high-pressure pump on (see Work Card 009.03009.03), and
pump the hydraulic tensioning tool up.
▲ Attention! Make sure that the tensioning pressure specified for
000.30)!
the chosen bolt is not exceeded (see Work Card 000.30
24. Release the pressure.
Important! The hydraulic tensioning tool is automatically reset to
zero position by the integrated set of disk springs (this takes approx. 2 to
3 minutes). For this purpose, however, the high-pressure pump has to be
009.03).
connected and its relief valve has to be open (see Work Card 009.03

When the piston is reset by the disk springs, the air in the hydraulic ten-
sioning tool escapes into the high-pressure hose.
25. Disconnect the high-pressure hose.
26. Using the opener, vent the high-pressure hose (see Work Card
009.05).
009.05
27. Reconnect the high-pressure hose.

6644 009.17--01 E 09.03 L 40/54, L 48/60, L 48/60 B 104/ 07

 28. Pump the hydraulic tensioning tool up, applying the tensioning pres-
000.30). Retain the pres-
sure specified for this bolt (see Work Card 000.30
sure for five minutes.
Important! After pumping the hydraulic tensioning tool up, no leak-
age must be recognisable during this period.
29. Release the pressure, disconnect the high-pressure hose from the
hydraulic tensioning tool and high-pressure pump.
30. Remove the tensioning tool.

6644 009.17--01 E 09.03 L 40/54, L 48/60, L 48/60 B 105/ 07

 1 Hydraulic nipple 7 Set of seals 13 Casing
2 Sealing ring 8 Casing 14 Spring pin
3 Piston 9 O-ring seal 15 Disk spring
4 Threaded piece 10 Set of seals 16 Piston
5 Nut 11 O-ring seal
6 O-ring seal 12 Set of seals

Figure 1. Hydraulic tensioning tool

6644 009.17--01 E 09.03 L 40/54, L 48/60, L 48/60 B 106/ 07

 13 Casing
15 Disk spring
16 Piston
17 Nut

C Bore for the tommy

bar, 10 dia.

Figure 2. Hydraulic tensioning tool with the nut screwed on

Figure 3. Bending a ring into a kidney shape

3 Piston
7 Set of seals
20 Flat strip

Figure 4. Pulling the set of seals on the piston

6644 009.17--01 E 09.03 L 40/54, L 48/60, L 48/60 B 107/ 07

Dial gauge (measuring device)
Checking the bolt elongation 009.18

Purpose of jobs to be done

Tighten and untighten important bolted connections to 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

Qty Designation No. Availability

1 Extension 009.450 Standard
1 Extension 009.449 Standard
1 High--pressure pump 009.338 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.056 Standard
1 Measuring device 009.051 Standard
1 Magnetic prism with support 009.051--1 Standard
1 Clamping piece 009.051--5 Standard
1 Sleeve 009.051--6 Standard
1 Dial gauge (measuring device) 009.051--14 Standard
1 Extension 009.051--15 Standard
1 Extension 009.051--16 Standard
1 Screw drivers (set) -- Standard

Related work cards

Work card Work card Work card

000.30 000.33 009.03
009.05 009.16

6644 009.18--01 E 09.03 L 40/54, L 48/60, L 48/60 B 101/ 05

Preliminary remarks

For bolted connections that are tensioned hydraulically, a measurement to

compare the bolt elongation with a reference value is particularly important.
This is to ensure that the necessary pretension resulting from the bolt elonga-
tion and from forcing the corresponding components together is really
achieved. This might not be the case if the tensioning tool is blocked, or if the
tensioning pressure is partly lost due to friction.

Operating sequence -- Measuring the elongation of the bolt Dl

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

▲ Attention! Correct tightening of a bolted connection requires the

pressure gauge indication to be faultless! In case of doubt, check
the pressure gauge using a reference pressure gauge!

Steps 1. Mount the tensioning tool on the bolt (see Work Card 009.16 or the
work card applicable for the respective bolt).
2. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool (4) and high-pressure pump (009.338).
009.03) and tension
3. Switch the high-pressure pump on (see Work Card 009.03
the bolt applying the specified pretensioning pressure (see Work Card
000.30).
000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the bolt to be tensioned!
4. Place the measuring device (009.051) against the casing of the hy-
draulic tensioning tool.
▲ Attention! Make sure that the measuring pin of the dial gauge
contacts the piston of the hydraulic tensioning tool!

Important! The position of the dial gauge and feeler can be adjusted
to suit the particular situation by assembling them in different ways, and by
using the extensions (009.051-15 or 009.051-16). Refer to Figure 2 .

In cramped locations (e.g. the main bearing bolt on the exhaust end), the view
onto the dial gauge can be improved by using the additional extensions
009.449 and 009.450). Refer to Figure 3 .
5. Set the dial gauge to “Zero”.
6. Tension the bolt with the specified final tensioning pressure (see
Work Card 000.30).
000.30
7. Tighten the nut hand-tight by means of the tommy bar.
8. Release the pressure.
Important! The hydraulic tensioning tool is automatically reset to
zero position by a set of disk springs (this takes approx. 2 to 3 minutes).
For this purpose, however, the high-pressure pump has to be connected
009.03).
and its relief valve has to be open (see Work Card 009.03
9. Tension the bolt again with the specified pretensioning pressure.
10. Measure the bolt elongation Dl on the dial gauge, note it down and
000.30).
compare it to the specified value (see Work Card 000.30
▲ Attention! The bolt should be tensioned to the specified tension-
ing pressure, not according to the bolt elongation Dl! Measuring the
bolt elongation Dl only serves as a countercheck!

6644 009.18--01 E 09.03 L 40/54, L 48/60, L 48/60 B 102/ 05

 Important! In case of larger deviations from the specified value, re-
peat the tensioning process. If necessary, check the hydraulic tensioning
tool, the bolted connection and the pressure gauge.
11. Release the pressure, disconnect the high-pressure hose from the hy-
draulic tensioning tool and the high-pressure pump.
12. Remove the measuring device.
13. Dismantle the tensioning tool.

1 Cylindrical screw, M5x12 3 Stud, M6x50

2 Knurled nut, M6 4 Hydraulic tensioning tool

Figure 1. Measuring device, placed against the hydraulic tensioning tool

6644 009.18--01 E 09.03 L 40/54, L 48/60, L 48/60 B 103/ 05

Figure 2. Measuring device (assembly variations)

6644 009.18--01 E 09.03 L 40/54, L 48/60, L 48/60 B 104/ 05

 2 Knurled nut, M6
3 Stud, M6x50
4 Hydraulic tensioning
tool
5 Cylindrical screw,
M4x8

Figure 3. Measuring device, placed against the hydraulic tensioning tool (for cramped locations)

6644 009.18--01 E 09.03 L 40/54, L 48/60, L 48/60 B 105/ 05

Operating values/Operating results

001 Operating media systems/pipes

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

6682 005--01 E 08.97 101/ 01

Ignition and compression pressures
Determination 000.25

Purpose of jobs to be done

Record and assess operating data,

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

Brief description

Ignition and compression pressures are a significant indicator for the

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

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

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

Preliminary remarks

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

6682 000.25--03 E 04.05 General 101/ 03

Operating sequence 1 -- Record pressures

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

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

▲ Attention! Measuring the compression pressure is only admis-

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

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

Operating sequence 2 -- Evaluation/valuation

The following limit values/requirements have to be observed:

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

6682 000.25--03 E 04.05 General 102/ 03

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

6682 000.25--03 E 04.05 General 103/ 03

Charge air cooler/crankcase
Measuring the differential pressure 000.40

Purpose of jobs to be done

Record operating values,

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

Brief description

Supplementary to the data provided in the maintenance schedule,

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

Tools/appliances required

Quant Denomination No. Availability

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

Preliminary remarks

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

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

Measuring set--up/unit

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

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

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

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

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

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

Safety instructions

The maximum pressure on the unit is 14 bar.

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

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

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

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

Measuring using digital pressure gauge

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

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

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

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

Measuring using U-pipe pressure gauge

Steps 1. Purge the measuring connections as described above.

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

ah = 100 mm WS =10
mbar differential
pressure

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

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

Checking the crankcase pressure

The crankcase also has a measuring connection (approximately at engine

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

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

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

Work cards,
arranged by subassembly groups

1 Introduction

2 Work cards,
arranged by subjects/key words

3 Work cards,
arranged by subassembly groups of the engine

6682 3--02 E 08.97 101/ 01

Table of contents

: : N 009... Foundation/Bearings/ Alignment of the engine

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

: : N Determine/check
012.01 Foundation bolts and foundation
: : N Checking

: : 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 Main bearing bolts (outer bearing) and cross tierods
: : N Checking, untightening and tightening
012.04 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, untightening and tightening
020.02 Coupling bolts
: : N Checking, untightening and tightening
020.03 Crankshaft gear wheel
: : N Installing
020.04 Oil bore of the crankshaft
: : N Blocking

: : N 021 Main bearing/Thrust bearing

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

6701 09.06 L 40/54 101 /07

 021.01 Main bearing shell
: : N Checking
021.02 Main bearing shell (outer bearing)
: : N Checking
021.03 Main thrust bearing
: : N Measuring axial clearance/ checking locating bearing rings

: : N 027 Torsional vibration damper

027.01 Torsional vibration damper

: : N Checking
027.02 Torsional vibration damper of the camshaft
: : N Checking

: : N 030 Connecting rod/Big--end bearing

030.01 Con--rod shank bolts

: : N Loosening and tightening
030.02 Big--end bearing bolts
: : N Checking, untightening and tightening
030.03 Big--end bearing shell (lower)
: : N Checking
030.04 Big--end bearing shell (upper)
: : N Checking

: : N 034 Piston/Piston rings/Top land ring

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

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

6701 09.06 L 40/54 102 / 07

: : N 050 Cylinder liner

050.02 Cylinder liner

: : N Measuring
050.03 Sealing face on cylinder head and sealing groove in top land ring
: : N Grinding
050.05 Cylinder liner
: : N Honing

: : N 055 Cylinder head

055.01 Cylinder head bolts

: : N Checking, untightening and tightening
055.03 Cylinder head
: : N Grinding of seating faces
055.04 Valve seat rings
: : N Removing and installing
055.05 Cylinder head with turnover stand
: : N Machining
055.06 Cylinder head
: : N Refacing of the injection valve seating face

: : N 073 Crankcase cover

071.01 Covering on the coupling side

: : N Removing and refitting
073.01 Safety valve on the crankcase cover
: : N Checking, removing and refitting

: : N 100 Camshaft drive

100.01 Camshaft drive

: : N Checking

: : N 102 Camshaft bearing/ Camshaft thrust bearing

102.01 Camshaft bearing bolts

: : N Checking, untightening and tightening
102.02 Camshaft (thrust bearing)
: : N Checking

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

6701 09.06 L 40/54 103 /07

 102.03 Camshaft bearing shell
: : N Checking

: : N 111 Rocker arm casing/Rocker arm

111.01 Rocker arm casing with rocker arms Valve clearance

: : N Removing, refitting, checking

: : N 112 Cam follower/Push--rod

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

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

: : N rotators

113.01 Inlet valve

: : N Removing and installing
113.02 Valve rotator
: : N Checking
113.03 Inlet and exhaust valve Valve cone and seat surface
: : N Checking and assessing
113.04 Valve seating surface
: : N Grinding
113.05 Valve cone
: : N Grinding
113.08 Inlet and exhaust valve Valve seat surface
: : N measuring
113.09 Valve plate Depth of burning marks and corrosion
: : N Checking
113.10 Valve seating surface
: : N Grinding
113.14 Valve plate -- piston
: : N Measuring the distance
114.01 Exhaust valve
: : N Removing and installing

: : N 125 Operating device

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

6701 09.06 L 40/54 104 / 07

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

: : N 140 Speed control

140.02 Booster servomotor (2--stage)

: : N Maintaining and 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
162.01 Main starting valve
: : N Disassembling and assembling

: : N 200... Fuel injection pump/ Drive of fuel injection pump

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

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

6701 09.06 L 40/54 105 /07

 200.05 Fuel injection pump Baffle screws
: : N Checking and replacing
200.06 Fuel injection pump
: : N Measuring the plunger lift

: : N 203 Control linkage

203.01 Control linkage

: : N Maintaining and checking

: : N 209 Camshaft

209.01 Camshaft
: : N Checking

: : N 221 Fuel injection valve

221.01 Fuel injection valve

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

: : N 280... Charge air and exhaust pipe

280.02 Charge air bypass device

: : N Disassembly and assembly, replacement of sealing elements

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

300.01 Lube oil pump

: : N Disassembling and assembling

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

6701 09.06 L 40/54 106 / 07

 300.02 Lube oil pump
: : N Assessing the individual components

N 322 Charge air cooler

322.01 Charge air cooler

: : N Checking and cleaning

N 434 Fuel injection pipe

434.01 Fuel injection pipe

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

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

6701 09.06 L 40/54 107 /07

Foundation/Bearings/
Alignment of the engine

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

6682 009...--06 E 07.99 101/ 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

Foundation bolts and foundation
Checking 012.01

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

Foundation bolts and foundation are to be checked at regular intervals.

The work/steps include:
Establishing and evaluating the loosing pressure,
tightening the connection at normal pressure,
checking components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Thrust pad 021.089 Standard
1 High--pressure pump 009.341 Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning tool 009.010 Standard
1 Torque wrench 008.017 Standard
1 Socket wrench insert 36x20 001.771 Standard
1 Tommy bar, 10 mm 000.263 Standard
1 Hammer (wood/plastic) -- Inventory
1 Open--jaw and ring wrenches (set) -- Inventory
1 Grease (acid--free) -- Inventory

Related work cards

Work card Work card Work card

000.09 000.10 000.30
000.32 000.33 009.03
009.05 009.11

6701 012.01--02 E 12.05 L 40/54 101/ 06

Preliminary remarks

The maintenance schedule also specifies that the following be checked:

the hydraulically tensioned foundation bolts for correct preload, the
foundation bolts for proper tightening to the correct torque, the chocks and
wedges for firm seat, as well as the synthetic-resin chocking for stability,
for dangerous cracks and crumbling.

A further item in the maintenance schedule is the checking of the crank

web deflections (see Work Card 000.10).
000.10 If this check revealed an imper-
missibly high value (particularly on cylinder 1) and correction by alignment
of the adjoining gear shaft was not possible, the engine has to be newly
aligned. We recommend to have the new alignment carried out by person-
nel of MAN B&W Diesel or an MAN B&W Diesel service base.

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

touching, the position of the engine is to be checked closely and all
foundation bolts are to be retightened! The foundation bolts on the
coupling end and free engine end are most likely to be affected!

Operating sequence 1 -- Checking the cylinder crankcase

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

crankcase, close the starting air bottle, remove the air from the start-
ing air pipe and engage the turning gear in order to prevent starting
of the engine and turning of the running gear! For supplementary
safety regulations, refer to Volume B1 / Operating Instructions!

Steps 1. Thoroughly clean the cylinder crankcase and the oil sump when
doing overhaul work and on every oil change.
2. Inspect the cylinder crankcase for cracks on the inside and outside.

Operating sequence 2 -- Checking the foundation

▲ Attention! For checking the foundation bolts, start on the

coupling end!

Steps 1. Remove the protecting caps (1).

2. Clean the threads of the foundation bolts (3 and 11).
3. Slip the thrust pad (021.089) over the nut (2).
4. Screw the hydraulic tensioning tool (009.010) onto the foundation bolt
(3 or 11), making sure that the thrust pad is centred by the hydraulic
tensioning tool. Refer to Figures 3 and 4 .
▲ Attention! Prior to fitting the hydraulic tensioning tool, verify that
the piston is moved in completely (stroke = zero). Reset the piston,
if necessary (see Work Card 009.11)!
009.11
5. Turn the hydraulic tensioning tool back by 180ƒ .
6. Connect the high-pressure hose (009.306) to the hydraulic tensioning
tool and the high-pressure pump (009.341).
009.03), and
7. Switch the high-pressure pump on (see Work Card 009.03
close the gap produced by turning back.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the foundation bolt!
8. Pump the hydraulic tensioning tool up until the nut (2) can be loos-
ened.

6701 012.01--02 E 12.05 L 40/54 102/ 06

 ▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see drawing “Assembly In-
struction/B11.72760-....” of the respective plant in Volume E1)!
Note down the loosening pressure and compare it with the tensioning
pressure.
9. Adjust the high-pressure pump to the specified tensioning pressure
(see drawing “Assembly Instruction/B11.72760-....” of the respective
plant in Volume E1).
10. Insert the tommy bar (000.263) through the opening in the thrust pad,
and screw down the nut (2), hand-tight.
11. Release the pressure, disconnect the high-pressure hose from the
hydraulic tensioning tool.
12. Remove the tensioning tool.
13. Reset the piston of the hydraulic tensioning tool (see Work Card
009.11).
009.11
14. Reposition the tensioning tool onto the next foundation bolt (3 or 11)
and repeat the process until all foundation bolts have been checked.
See items 3 to 13.
15. After completion of the checks, disconnect the high-pressure hose
form the high-pressure pump.
16. Preserve the thread ends of the foundation bolts (3 and 11) with acid-
free grease and slip the protecting caps (1) on.
17. Check the hexagon nuts (15) of the foundation bolts (16 and 17) ap-
plying the specified torque (see drawing “Assembly Instruc-
tion/B11.72760-....” of the respective plant in Volume E1), and re-
tighten the hexagon nuts if necessary. Refer to Figure 2 .
18. Check the hexagon bolts (12) of the guide rails (6) for firm seat, and
retighten the hexagon bolts if necessary. See Figure 1 .
19. Check the wedges (5) and chocks (14) for firm seat by means of a
wooden or plastic hammer. Refer to Figures 1 and 2 .
20. Check the synthetic-resin chocking (8) for stability, for dangerous
cracks and crumbling. See Figures 1 and 2 .

6701 012.01--02 E 12.05 L 40/54 103/ 06

 1 Protecting cap 7 Steel diaphragm
2 Nut 8 Synthetic-resin chocking
3 Foundation bolt (fitting bolt) 9 Foundation
4 Cylinder crankcase 10 Nut
5 Wedge 11 Foundation bolt
6 Guide rail 12 Hexagon bolt

Figure 1. Semi-resilient support

6701 012.01--02 E 12.05 L 40/54 104/ 06

 4 Cylinder crankcase 14 Chock
7 Steel diaphragm 15 Hexagon nut
8 Synthetic-resin chocking 16 Foundation bolt (fitting bolt)
9 Foundation 17 Foundation bolt
13 Hexagon nut

Figure 2. Semi-resilient support

6701 012.01--02 E 12.05 L 40/54 105/ 06

 3 Foundation bolt (fitting bolt) 11 Foundation bolt
4 Cylinder crankcase

Figure 3. Foundation bolts with tensioning tools attached

2 Nut
3 Foundation bolt
(fitting bolt)
4 Cylinder crankcase
11 Foundation bolt

Figure 4. Foundation bolt with tensioning tool attached

6701 012.01--02 E 12.05 L 40/54 106/ 06

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
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings/Top land ring
050 Cylinder liner
055 Cylinder head
073 Crankcase cover
100 Camshaft drive
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/Rocker arm
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140 Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Drive of fuel injection pump
203 Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pump
322 Charge air cooler
434 Fuel injection pipe

6682 012--06 E 07.99 101/ 01

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

Purpose of jobs to be done

Tighten and untighten important bolted connections to the correct values,

ensure correct execution of work.

Brief description

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

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised
- Operating media systems drained

Tools/appliances required

Qty Designation No. Availability

1 Suspension device 021.150 Standard
2 Thrust pad 021.149 Standard
2 Nut 021.148 Standard
1 Extension 009.450 Standard
1 Extension 009.449 Standard
1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.306 Standard
1 Claw spanner 009.070 Standard
1 Socket wrench 009.067 Standard
2 Hydraulic tensioning tool 009.056 Standard
2 Thrust pad 009.055 Standard
2 Hydraulic tensioning tool 009.053 Standard
2 Measuring device 009.051 Standard
2 Magnetic prism with support 009.051--1 Standard
2 Clamping piece 009.051--5 Standard
2 Sleeve 009.051--6 Standard
2 Dial gauge (measuring device) 009.051--14 Standard
2 Extension 009.051--15 Standard

6701 012.02--01 E 09.01 L 40/54 101/ 12

 Qty Designation No. Availability
2 Extension 009.051--16 Standard
1 Suspension device 009.050 Standard
1 Shackle A1.0 002.453 Standard
1 Ratchet 001.521 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar, 12 mm 000.264 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Screw drivers (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Depth gauge -- Inventory

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.13
009.16 009.18

Technical details

Term Information
Thrust pad 13.5 kg
Hydraulic tensioning tool 66 kg
Bolt projection (A) 190 mm

Operating sequence 1 - Check the cross tie-rods

Steps 1. Remove the protecting caps (14).

2. Clean the threads of the cross tie-rods (11).
3. Slip the thrust pads (009.055) over the nuts (10).
4. Screw the hydraulic tensioning tools (009.053) onto the cross tie-
rods; make sure that the thrust pads are centered by the hydraulic
tensioning tools. See Figures 2 and 3 .
5. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
6. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03) and close
7. Switch on the high-pressure pump (see Work Card 009.03
the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the cross tie-rods!
8. Pump up the tensioning tools until the nuts can be loosened.
▲ Attention! The pressure applied must not be more than 7% below or
5% above the tensioning pressure (see Work Card 000.30)!
000.30

6701 012.02--01 E 09.01 L 40/54 102/ 12

 ▲▲ Caution! During pumping, watch the stroke gauge (17) of the
hydraulic tensioning tools! The hydraulic tensioning tools may only
be pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (16)! Otherwise the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it to the tensioning
pressure.
9. Adjust the high-pressure pump to the specified tensioning pressure
000.30).
(see Work Card 000.30
10. Using the tommy bar (000.264), screw down both nuts through the
openings in the thrust pads, hand-tight.
11. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero by the integrated compression springs (this takes approx. 2 to 3 min-
utes). For this purpose, however, the high-pressure pump must be con-
nected.
12. Remove the tensioning tools.
13. Slip the protecting caps onto the threads of the cross tie-rods.

1 Hexagon nut
2 Washer
3 Protecting cap
4 Nut
5 Main bearing bolt
8 Main bearing cap
9 Cylinder crankcase
10 Nut
11 Cross tie-rod
12 Ring
14 Protecting cap
15 Nut

Figure 1. Main bearing bolt and cross tie-rod

6701 012.02--01 E 09.01 L 40/54 103/ 12

 5 Main bearing bolt
9 Cylinder crankcase
11 Cross tie-rod
12 Ring

Figure 2. Main bearing bolt and cross tie-rod with tensioning tools mounted

9 Cylinder crankcase
10 Nut
11 Cross tie-rod
12 Ring
13 O-ring seal
16 Threaded stop ring
17 Stroke gauge

M Marking

Figure 3. Cross tie-rod with tensioning tool mounted

6701 012.02--01 E 09.01 L 40/54 104/ 12

Operating sequence 2 - Check the main bearing bolts

Starting condition Cooling water for cooling fuel-injection valve completely drained.

Steps 1. Remove all pipes that are in the way (e.g. lube-oil pipe for lubricating
rocker arm, air pipe for starting valve, etc.).
2. Remove the protecting caps (3).
3. Clean the threads of the main bearing bolts (5).
4. Attach the suspension device (021.150) to the thrust pad (021.149);
fasten the rope (18) to the suspension device by means of the
shackle (002.453), and hang it on the lifting tackle. See Figure 4 .
5. Move the thrust pad over the main bearing bolt, and position it over
the nut (4). Remove the suspension device.
6. Place the second thrust pad over the second nut in the same way
(Items 4 and 5).
7. Verify that the nuts (021.148) are screwed tightly onto the hydraulic
tensioning tools (009.056).
8. Screw the suspension device (009.050) into the hydraulic tensioning
tool; fasten the rope (18) to the suspension device by means of the
shackle (002.453), and hang it on the lifting tackle. See Figure 5 .
9. Position the hydraulic tensioning tool over the main bearing bolt, set it
down on the latter, and screw it on by a few turns. Remove the sus-
pension device.
10. Place the socket wrench (009.067) on the hydraulic tensioning tool,
mount the ratchet (001.521), and screw the hydraulic tensioning tool all
the way onto the main bearing bolt. Remove the tools. See Figure 6 .
11. Mount the second hydraulic tensioning tool on the second main bearing
bolt in the same way (Items 8 to 10).
12. Back off the hydraulic tensioning tools by the angle of back-off (see Work
000.30).
Card 000.30
13. Connect the high-pressure hoses (009.306) to the hydraulic tensioning
tools and high-pressure pump (009.338).
14. Switch on the high-pressure pump (see Work Card 009.03 009.03), and close
the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the main bearing bolts!
15. Pump up the hydraulic tensioning tools until the nuts (4) can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below or
5% above the tensioning pressure (see Work Card 000.30)!
000.30
Note down the loosening pressure and compare it to the tensioning
pressure.
16. Adjust the high-pressure pump to the specified tensioning pressure
000.30).
(see Work Card 000.30
17. Using the tommy bar (000.264), screw down both nuts through the
openings in the thrust pads, hand-tight.
18. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero by the integrated disk springs (this takes approx. 2 to 3 minutes). For
this purpose, however, the high-pressure pump must be connected.
19. Unscrew the hydraulic tensioning tools by means of the socket
wrench (009.067), and remove it using the suspension device
(009.050).
20. Remove the thrust pads by means of the suspension device
(021.150).
21. Fasten the protecting caps (3) onto the main bearing bolts.
22. Re-connect the dismantled pipes.

6701 012.02--01 E 09.01 L 40/54 105/ 12

 4 Nut
5 Main bearing bolt
9 Cylinder crankcase
18 Rope
19 Hexagon bolt M6x16

Figure 4. Suspending the thrust pad

18 Rope

Figure 5. Suspending the hydraulic tensioning tool

6701 012.02--01 E 09.01 L 40/54 106/ 12

 Figure 6. Screwing the hydraulic tensioning tool on/off

4 Nut
5 Main bearing bolt
9 Cylinder crankcase

A Bolt projection

Figure 7. Main bearing bolt with tensioning tool mounted

Operating sequence 3 -- Untensioning the cross tie-rod

Steps 1. Remove the protecting caps (14).

2. Clean the threads of the cross tie-rods (11).
3. Slip the thrust pads (009.055) over the nuts (10).
4. Screw the hydraulic tensioning tools (009.053) onto the cross tierods;
make sure that the thrust pads are centered by the hydraulic tension-
ing tools. Refer to Figures 2 and 3 .
5. Back off the hydaulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
6. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).

6701 012.02--01 E 09.01 L 40/54 107/ 12

 7. Switch on the high-pressure pump (see Work Card 009.03
009.03) and close
the gap produced by backing off.
▲▲▲ Danger! During untensioning, make sure that there is no one
along the extended axis of the cross tie-rods being untensioned!
8. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see Work Card 000.30)!
000.30

▲▲ Caution! During pumping, watch the stroke gauge (17) of the

hydraulic tensioning tools! The hydraulic tensioning tools may only
be pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (16)! Otherwise the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the tensioning
pressure.
9. Using the tommy bar (000.262), back off both nuts through the open-
000.30).
ings in the thrust pads (for angle of back-off, see Work Card 000.30
10. Release the pressure, and disconnect the high- pressure hoses from
the hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero by the integrated compression springs (this takes approx. 2 to 3 min-
utes). For this purpose, however, the high-pressure pump must be con-
nected.
11. Remove the tensioning tools.

Operating sequence 4 -- Untensioning the main bearing bolts

Starting condition Cooling water for cooling fuel-injection valve completely drained.

Steps 1. Remove all pipes that are in the way (e.g. lube-oil pipe for lubricating
rocker arm, air pipe for starting valve, etc.).
2. Remove the protecting caps (3).
3. Clean the threads of the main bearing bolts (5).
4. Attach the suspension device (021.150) to the thrust pad (021.149);
fasten the rope (18) to the suspension device by means of the the
shackle (002.453), and hang it on the lifting tackle. See Figure 4 .
5. Move the thrust pad over the main bearing bolt, and position it over
the nut (4). Remove the suspension device.
6. Place the second thrust pad over the second nut in the same way
(Items 4 and 5).
7. Check that the nuts (021.148) are screwed tightly onto the hydraulic
tensioning tools (009.056).
8. Screw the suspension device (009.050) into the hydraulic tensioning
tool; fasten the rope (18) to the suspension device by means of the
shackle (002.453), and hang it on the lifting tackle. See Figure 5 .
9. Position the hydraulic tensioning tool over the main bearing bolt, set it
down on the latter, and screw it on by a few turns. Remove the sus-
pension device.
10. Place the socket wrench (009.067) on the hydraulic tensioning tool,
mount the ratchet (001.521), and screw the hydraulic tensioning tool
all the way onto the main bearing bolt. Remove the tools. See Fig-
ure 6 .
11. Mount the second hydraulic tensioning tool on the second main bear-
ing bolt in the same way (Items 8 to 10).
12. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30

6701 012.02--01 E 09.01 L 40/54 108/ 12

 13. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03), and
14. Switch on the high-pressure pump (see Work Card 009.03
close the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the main bearing bolts!
15. Pump up the hydraulic tensioning tools until the nuts (4) can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below or
5% above the tensioning pressure (see Work Card 000.30)!
000.30
Note down the loosening pressure and compare it to the tensioning
pressure.
16. Using the tommy bar (000.264), back off both nuts through the open-
ings in the thrust pads, hand-tight (for angle of back-off, see Work
000.30).
Card 000.30
17. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero by the integrated disk springs (this takes approx. 2 to 3 minutes). For
this purpose, however, the high-pressure pump must be connected.
18. Unscrew the hydraulic tensioning tools by means of the socket
wrench (009.067), and remove them using the suspension device
(009.050).
19. Remove the thrust pads by means of the suspension device
(021.150).

Operating sequence 5 -- Tensioning the main bearing bolts and cross tie-rods

Starting condition Main bearing cap has been raised all the way and is touching the cylinder
crankcase; all nuts (4 and 6) have been screwed on and tightened hand-
tight. Threads of main bearing bolts and cross tie-rods have been
cleaned.

▲ Attention! The main bearing bolts and cross tie-rods are tigh-
tened in several steps! Make sure to follow the correct sequence of
tightening!
Correct tightening of a bolted connecton requires the ressure gauge
indication to be correct! In case of doubt, check the pressure gauge
against a reference pressure gauge!

Steps 1. Check the projection (A) of the main bearing bolts (7).
2. Verify that the gap of the parting line between the main bearing cap
(8) and the cylinder crankcase (9) is equal on both sides.
3. Slip the thrust pads (009.055) over the nuts (10).
4. Screw the hydraulic tensioning tools (009.053) onto the cross tie-
rods; make sure that the thrust pads are centered by the hydraulic
tensioning tools. Refer to Figures 2 and 3 .
5. Attach the suspension device (021.150) to the thrust pad (021.149),
then fasten the rope (18) to the suspension device by means of the
shackle (002.453), and hang it on the lifting tackle. See Figure 4 .
6. Move the thrust pad over the main bearing bolt, and place it over the
nut (4). Remove the suspension device
7. Position the second thrust pad over the second nut in the same way
(Items 5 and 6).
8. Verify that the nuts (021.148) are tightly screwed onto the hydraulic
tensioning tools (009.056).

6701 012.02--01 E 09.01 L 40/54 109/ 12

 9. Screw the suspension device (009.050) into the hydraulic tensioning
tool, fasten the rope (18) to the suspension device by means of the
shackle (002.453), and hang it on the lifting tackle. See Figure 5 .
10. Move the hydraulic tensioning tool over the main bearing bolt, set it
down on the latter, and screw it on by a few turns. Remove the sus-
pension device.
11. Place the socket wrench (009.067) on the hydraulic tensioning tool,
mount the ratchet (001.521), and screw the hydraulic tensioning tool
all the way onto the main bearing bolt. Remove the tools. See Fig-
ure 6 .
12. Mount the second hydraulic tensioning tool on the second main bear-
ing bolt in the same way (Items 9 to 11).
13. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools on the cross tie-rods and to the high-pressure pump
(009.338).
14. Switch on the high-pressure pump (see Work Card 009.03009.03), and ten-
sion the cross tie-rod with a pretensioning pressure of 300 bars.
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the cross tie-rods or main bearing bolts
being tensioned!

▲▲ Caution! During pumping, watch the stroke gauge (17) of the

hydraulic tensioning tools! The hydraulic tensioning tools may only
be pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (16)! Otherwise the hydraulic
tensioning tools will be damaged!
15. Using the tommy bar (000.262), tighten the two nuts, hand-tight,
through the opening in the thrust pads.
16. Release the pressure, and disconnnect the high-pressure hoses from
the hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero by the integrated compression springs (this takes approx. 2 to 3 min-
utes). For this purpose, however, the high-pressure pump must be con-
nected.
17. Connect the high-pressure hoses to the hydraulic tensioning tools of
the main bearing bolts.
18. Switch on the high-pressure pump (see Work Card 009.03009.03), and ten-
sion the main bearing bolts with a pretensioning pressure of 300
bars.
19. Using the tommy bar (000.264), tighten the two nuts, hand-tight,
through the opening in the thrust pads.
20. Release the pressure, and disconnnect the high-pressure hoses from
the hydraulic tensioning tools.
21. Connect the high-pressure hoses to the hydraulic tensioning tools of
the cross tie-rods again.
22. Switch on the high-pressure pump (see Work Card 009.03009.03), and ten-
sion the cross tie-rods with the specified tensioning pressure (see
Work Card 000.30).
000.30
23. Using the tommy bar, tighten the two nuts, hand-tight, through the
opening in the thrust pads.
24. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools.
25. Connect the high-pressure hoses to the hydraulic tensioning tools of
the main bearing bolts.
26. Switch on the high-pressure pump (see Work Card 009.03009.03) and ten-
sion the main bearing bolts with a pretensioning pressure of 300
bars.
27. Position the measuring device (009.051) against the housing of the
hydraulic tensioning tool. See Figure 8 .

6701 012.02--01 E 09.01 L 40/54 110 / 12

 ▲ Attention! Make sure that the feelers of the dial gauges are touching
the pistons of the hydraulic tensioning tools!

Important! The position of the dial gauge and the feeler can be ad-
justed to suit the situation by various assembly arrangements and the use
009.18).
of the extensions (see Work Card 009.18

For a better view onto the dial gauge in the case of the main bearing bolt
on the exhaust side, use the additional extensions (009.449 and 009.450)
as well.
28. Set the dial gauges to zero.
29. Tension the main bearing bolts with the specified tensioning pressure
(see Work Card 000.30).
000.30
30. Using the tommy bar, tighten the two nuts, hand-tight, through the
opening in the thrust pads.
31. Release the pressure.
32. Tension the main bearing bolts again with a pretensioning pressure
of 300 bars. Read the bolt elongation al off the dial gauges, note it
000.30).
down, and compare it with the desired value (see Work Card 000.30
▲ Attention! The bolt must be tensioned with the specified tension-
ing pressure, not according to the bolt elongation al! Measuring the
bolt elongation al is only intended as a check!

Important! If there are substantial deviations from the desired value,

repeat the tensioning procedure, and if necessary, check the tensioning
tools, bolted connections, and pressure gauge.
33. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools and the high-pressure pump.
34. Remove the measuring devices.
35. Unscrew the hydraulic tensioning tools by means of the socket
wrench (009.067), and remove them using the suspension device
(009.050).
36. Remove the thrust pads by means of the suspension device
(021.150).
37. Attach the protecting caps (3) to the main bearing bolts.
38. Re-install the dismantled pipes (e.g. lube-oil pipe for lubricating the
rocker arm, air pipe for starting valve, etc.).
39. Remove the tensioning tools from the cross tie-rods.
40. Place the protecting caps (14) on the threads of the cross tie-rods.

Operating sequence 6 -- Tensioning the cross tie-rods

Remark Operating sequence 6 describes the tensioning of the cross tie-rods of the
adjacent main bearings after installation of the main bearing shells (see
Work Cards 021.01 and 021.02).
021.02

Starting condition Nuts have been screwed down, hand-tight. Threads of cross tie-rods
have been cleaned.

▲ Attention! Correct tensioning of a bolted connection requires the

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

Steps 1. Slip the thrust pads (009.055) over the nuts (10).
2. Screw the hydraulic tensioning tools (009.053) onto the cross tie-rods
(11); make sure that the thrust pads are centered by the hydraulic
tensioning tools. See Figures 2 and 3 .
3. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).

6701 012.02--01 E 09.01 L 40/54 111 / 12

 4. Switch on the high-pressure pump (see Work Card 009.03009.03) and ten-
sion the cross tie-rods with the specified tensioning pressure (see
Work Card 000.30).
000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the cross tie-rod being tensioned!

▲▲ Caution! During pumping, watch the stroke gauge (17) of the hy-
draulic tensioning tools! The hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the upper
edge of the threaded stop ring (16)! Otherwise the hydraulic tensioning
tools will be damaged!
5. Using the tommy bar (000.262), screw down both nuts through the
opening in the thrust pads, hand-tight.
6. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero by the integrated compression springs (this takes approx. 2 to 3 min-
utes). For this purpose, however, the high-pressure pump must be con-
nected.
7. Remove the tensioning tools.
8. Slip the protecting caps (14) onto the threads of the cross tie-rods.

Figure 8. Hydraulic tensioning tool with mounted measuring device (Left-hand side: for main bearing bolt on control side -
Right-hand side: for main bearing bolt on exhaust side)

6701 012.02--01 E 09.01 L 40/54 112 / 12

Main bearing bolts
(outer bearing) and cross tie-- rods
Checking, untightening and tightening 012.03

Purpose of jobs to be done

Tighten and untighten important bolted connections to the correct values,

ensure correct execution of work.

Brief description

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

Tools/appliances required

Qty Designation No. Availability

2 Thrust pad 055.112 Standard
2 Tension screw 055.111 Standard
1 Foot board (for oil sump) 011.006 Standard
1 Foot board (for oil sump) 011.002 Standard
1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.306 Standard
2 Thrust pad 009.055 Standard
4 Hydraulic tensioning tool 009.053 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Open--jaw and ring wrenches (set) -- Standard

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.13

Operating sequence 1 -- Check the cross tie-rods

Steps 1. Remove the protecting caps (5).

2. Clean the threads of the cross tie-rods (6).
3. Slip the thrust pads (009.055) over the nuts (7).
4. Screw the hydraulic tensioning tools (009.053) onto the cross tie-
rods; make sure that the thrust pads are centred by the hydraulic ten-
sioning tools. Refer to Figures 2 and 3 .

6701 012.03--01 E 09.01 L 40/54 101/ 07

 5. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
6. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03) and close
7. Switch on the high-pressure pump (see Work Card 009.03
the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the cross tie-rods!
8. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see Work Card 000.30)!
000.30

▲▲ Caution! During pumping, watch the stroke gauge (11) of the

hydraulic tensioning tools! The hydraulic tensioning tools may only
be pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (10)! Otherwise, the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the tensioning
pressure.
9. Adjust the high-pressure pump to the specified tensioning pressure
000.30).
(see Work Card 000.30
10. Using the tommy bar (000.262), screw both nuts down through the
opening in the thrust pads, hand-tight.
11. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump must
be connected.
12. Remove the tensioning tools.
13. Slip the protecting caps onto the threads of the cross tie-rods.

1 Main bearing cap

2 Main bearing cap
3 Ring
4 O-ring seal
5 Protecting cap
6 Cross tie-rod
7 Nut
8 Nut
9 Cylinder crankcase

Figure 1. Main bearing (outer bearing)

6701 012.03--01 E 09.01 L 40/54 102/ 07

 1 Main bearing cap
2 Main bearing bolt
3 Ring
6 Cross tie-rod
9 Cylinder crankcase

Figure 2. Main bearing bolt and cross tie-rod with tensioning tools attached

3 Ring
4 O-ring seal
6 Cross tie-rod
7 Nut
9 Cylinder crankcase
10 Threaded stop ring
11 Stroke gauge

M Marking

Figure 3. Cross tie-rod with tensioning tool attached

Operating sequence 2 -- Checking the main bearing bolts

Starting condition Casing cover on the camshaft drive removed.

Steps 1. Insert the foot board (011.006 for standard oil sump or 011.002 for
reinforced oil sump) in the oil sump.
2. Clean the threads of the main bearing bolts (2).
3. Screw the tension screws (055.111) all the way onto the main bearing
bolts.
4. Slip the thrust pads (055.112) over the tension screws and the nuts
(8).
5. Screw the hydraulic tensioning tools (009.053) onto the main bearing
bolts – see Figures 2 and 4 .

6701 012.03--01 E 09.01 L 40/54 103/ 07

 6. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
7. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03) and close
8. Switch on the high-pressure pump (see Work Card 009.03
the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the main bearing bolts!
9. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see Work Card 000.30)!
000.30

▲▲ Caution! During pumping, watch the stroke gauge (11) of the

hydraulic tensioning tools! The hydraulic tensioning tools may only
be pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (10)! Otherwise, the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it to the tensioning
pressure.
10. Adjust the high-pressure pump to the specified tensioning pressure
000.30).
(see Work Card 000.30
11. Using the tommy bar (000.262), screw down both nuts through the
opening in the thrust pads, hand-tight.
12. Release the pressure, and disconnect the high-pressure hoses from
hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump must
be connected.
13. Remove the tensioning tools.
14. Remove the foot board from the oil sump.

1 Main bearing cap

2 Main bearing bolt
8 Nut
10 Threaded stop ring
11 Stroke gauge

M Marking

Figure 4. Main bearing bolt with tensioning tool attached

6701 012.03--01 E 09.01 L 40/54 104/ 07

Operating sequence 3 -- Untensioning the cross tie-rods

Steps 1. Remove the protecting caps (5).

2. Clean the threads of the cross tie-rods (6).
3. Slip the thrust pads (009.055) over the nuts (7).
4. Screw the hydraulic tensioning tools (009.053) onto the cross tie-
rods; make sure that the thrust pads are centred by the hydraulic ten-
sioning tools. Refer to Figures 2 and 3 .
5. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
6. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03), and
7. Switch on the high-pressure pump (see Work Card 009.03
close the gap produced by backing off.
▲▲▲ Danger! During untensioning, make sure that there is no one
along the extended axis of the cross tie-rods to be untensioned!
8. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (refer to Work Card 000.30)!
000.30

▲▲ Caution! During pumping, watch the stroke gauge (11) of the

hydraulic tensioning tools! The hydraulic tensioning tools may only
be pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (10)! Otherwise, the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the tensioning
pressure.
9. Using the tommy bar (000.262), back off both nuts through the open-
000.30).
ings in the thrust pads (for angle of back-off, see Work Card 000.30
10. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump must
be connected.
11. Remove the tensioning tools.

Operating sequence 4 -- Untensioning the main bearing bolts

Starting condition Casing cover on the camshaft drive removed. Temperature sensor (if
fitted) removed. Cross tie-rods untensioned.

▲ Attention! Prior to untensioning the main bearing bolts, the cross

tie-rods must be untensioned (refer to Operating Sequence 3)!

Steps 1. Insert the foot board (011.006 for standard oil sump or 011.002 for
reinforced oil sump) in the oil sump.
2. Clean the threads of the main bearing bolts (2).
3. Screw the tension screws (055.111) all the way onto the main bearing
bolts.
4. Slip the thrust pads (055.112) over the tension screws and the nuts
(8).
5. Screw the hydraulic tensioning tools (009.053) onto the main bearing
bolts – refer to Figures 2 and 4 .

6701 012.03--01 E 09.01 L 40/54 105/ 07

 6. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
7. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03), and
8. Switch on the high-pressure pump (see Work Card 009.03
close the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the main bearing bolts to be untensioned!
9. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see Work Card 000.30)!
000.30

▲▲ Caution! During pumping, watch the stroke gauge (11) of the

hydraulic tensioning tools! The hydraulic tensioning tools may only
be pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (10)! Otherwise, the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the tensioning
pressure.
10. Using the tommy bar (000.262), back off both nuts through the open-
ing in the thrust pads, hand-tight (for angle of back-off, see Work
000.30).
Card 000.30
11. Release the pressure, and disconnect the high-pressure hoses from
hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump must
be connected.
12. Remove the tensioning tools.

Operating sequence 5 -- Tensioning the main bearing bolts and the cross tie-rods

Starting condition Main bearing cap has been lifted all the way so that it touches the cylinder
crankcase, all nuts (7 and 8) have been screwed on and tightened hand-tight.
Threads of the main bearing bolts and the cross tie-rods have been cleaned.
The foot board has been inserted into the oil sump.

▲ Attention! Tightening the main bearing bolts and cross tie-rods is

effected in several steps! Make sure to follow the correct sequence
of tightening!
Correct tightening of a bolted connection requires the pressure
gauge indication to be correct! In case of doubt, check the pressure
gauge against a reference pressure gauge!

Steps 1. Verify that the gap of the parting line between the main bearing cap
(1) and the cylinder crankcase (9) is equal on both sides.
2. Place the thrust pads (009.055) over the nuts (7).
3. Screw the hydraulic tensioning tools (009.053) onto the cross tie-rods
(6); make sure that the thrust pads are centred by the hydraulic ten-
sioning tools. Refer to Figures 2 and 3 .
4. Screw the tension screws (055.111) all the way onto the main bearing
bolts (2).
5. Slip the thrust pads (055.112) over the tension screws and the nuts
(8).
6. Screw the hydraulic tensioning tools (009.053) onto the main bearing
bolts – refer to Figures 2 and 4 .

6701 012.03--01 E 09.01 L 40/54 106/ 07

 7. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools of the cross tie-rods and to the high-pressure pump
(009.338).
009.03) and ten-
8. Switch on the high-pressure pump (see Work Card 009.03
sion the cross tie-rods applying a pretensioning pressure of
300 bar.
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the cross tie-rods and/or main bearing
bolts to be tensioned!

▲▲ Caution! During pumping, watch the stroke gauge (11) of the

hydraulic tensioning tools! The hydraulic tensioning tools may only
be pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (10)! Otherwise, the hydraulic
tensioning tools will be damaged!
9. Using the tommy bar (000.262), screw down both nuts through the
opening in the thrust pads, hand-tight.
10. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump must
be connected.
11. Connect the high-pressure hoses to the hydraulic tensioning tools of
the main bearing bolts.
12. Switch on the high-pressure pump (see Work Card 009.03009.03), and ten-
sion the main bearing bolts to the specified tensioning pressure (see
Work Card 000.30).
000.30
13. Using the tommy bar (000.262), screw down both nuts through the
opening in the thrust pads, hand-tight.
14. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools.
15. Connect the high-pressure hoses to the hydraulic tensioning tools of
the cross tie-rods again.
16. Switch on the high-pressure pump (see Work Card 009.03009.03) and ten-
sion the cross tie-rods to the specified tensioning pressure (see Work
000.30).
Card 000.30
17. Using the tommy bar (000.262), screw down both nuts through the
opening in the thrust pads, hand-tight.
18. Release the pressure, and disconnect the high-pressure hoses from
hydraulic tensioning tools and high-pressure pump.
19. Remove the tensioning tools from main bearing bolts and cross tie-
rods.
20. Slip the protecting caps onto the threads of the cross tie-rods.
21. Remove the foot board from the oil sump.

6701 012.03--01 E 09.01 L 40/54 107/ 07

Cylinder head bolts
Removal and installation 012.04

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

Qty Denomination No. Availability

1 Bolt extractor 014.015 Standard
1 Tommy bar 16 000.266 Standard
1 Open--jaw and ring wrench (set) -- Standard

Related work cards

Work card Work card Work card

000.30 055.02

Technical details

Term Information
Cylinder head bolt 32.5 kg

Operating sequence 1 -- Remove the cylinder head bolts

Starting condition Cylinder head removed.

Steps 1. Mount bolt extractor (014.015) onto cylinder head bolt (1).
2. Loosen cylinder head bolt and screw it out.
3. Remove the bolt extractor.
4. Take off the O-ring seal (5).

6644 012.04--01 E 01.99 L 40/54, 48/60 101/ 03

 5. Remove the O-ring seals (2) and ring (3) from the cylinder crankcase
(4).
6. Clean the cylinder head bolt.

1 Cylinder head bolt

2 O-ring seal
3 Ring
4 Cylinder crankcase
5 O-ring seal

Figure 1. Cylinder head bolt in the cylinder crankcase

1 Cylinder head bolt

2 O-ring seal
3 Ring
5 O-ring seal

Figure 2. Mounting the bolt extractor

6644 012.04--01 E 01.99 L 40/54, 48/60 102/ 03

Operating sequence 2 -- Install the cylinder head bolts

Starting condition Cylinder head bolt cleaned.

Steps 1. Carefully clean the bore and thread in the cylinder crankcase (4) and
slightly oil them.
2. Insert the cylinder head bolt (1) through the bore in the backing ring.
3. Slip new O-ring seals (2) and ring (3) carefully over the thread onto
the screw shaft.
Important! Pay attention that the O-ring seals are not damaged
while being slipped over the thread of the cylinder head bolt.
4. Place a new O-ring seal (5) over the thread into the ring groove,
making sure that the O-ring seal is not twisted.
5. Mount the bolt extractor (014.015) onto the cylinder head bolt.
6. Screw the cylinder head bolt into the bore, turning it in, hand-tight, by
means of the tommy bar (000.266).
7. Grease the O-ring seals (2).
8. Push O-ring seals and ring into the bore using appropriate means,
making sure that the O-ring seals are not twisted.
055.02).
9. Mount the cylinder head (refer to work card 055.02
055.01).
10. Tension the cylinder head bolts (see work card 055.01
Important! Before proceeding with the hydraulic tensioning of the
cylinder head bolts, make sure that the cylinder 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.

6644 012.04--01 E 01.99 L 40/54, 48/60 103/ 03

Crankshaft/Coupling bolts

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

6682 020--06 E 07.99 101/ 01

Crankshaft
Measure the crank web deflection 000.10

Purpose of jobs to be done

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

Brief description

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

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

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.15
1 Assistant 0.15

Tools/appliances required

Qty Designation No. Availability

1 Guide tube 021.032 Standard
1 Tools, basic scope 009.229 Optional
1 Dial gauge (measuring device) 008.171 Optional
1 Thickness gauges 0.05--1 000.454 Standard
1 Felt--tip pen/Marking pen -- Inventory

Related work cards

Work card Work card Work card

000.09

6682 000.10--03 E 09.06 32/40, L 40/54, 48/60, L 58/64 101/ 04

Preliminary remarks

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

the main bearings and the bearings of the driven shaft. Should the mea-
sured values exceed the admissible maxima, the cause must be remedied/
the crankshaft has to be realigned. Possible causes include:
- Uneven wear of main bearings,
- the position of the driven shaft has changed, or
- the engine mounting on the foundation or the foundation as such has
changed.

The results of crank web deflection measurements have a coherence with

the alignment checks of the crankshaft flange relative to the driven flange.

Operating sequence 1 -- Measure the crank web deflection

Dial gauge readings should be taken at the points BDCR and BDCL if the
connecting rod is in place. With the connecting rod removed, readings are
to be taken in BDC position.
The designation refers to the position of the crank pin, but not that of the
dial gauge.
The sides and the sense of rotation are to be understood from the end
viewing onto the coupling flange.

Steps 1. Remove the crankcase doors.

2. Turn the crankshaft so that the number 1 cylinder comes to be in the
starting position; depending on the normal sense of rotation of the
engine, this is either the BDCL or the BDCR position.
3. Using the thickness gauges (000.454), check whether the crankshaft
rests on the bottom bearing shells.
Important! If this is not the case, wrong results of crank web deflec-
tion will be obtained.
4. Place the measuring instrument (008.171) in measuring point (2) and
set the dial gauge to ”0” approx. in the middle of the measuring
range.
▲ Attention! The measuring points for taking measurements with
the running gear installed are located in the balance weights!
Exception: 58/64 engine, here they are in the crank webs!

Important! If measurements are taken with the engine still warm,

the measuring instrument must previously have been in the crankcase for
approx. 15 minutes to adapt to the temperature prevailing.
5. Turn the crankshaft in the normal sense of rotation up to the desired
measuring positions (refer to Figure 2 ). At every position, take read-
ings of the magnitude and direction (+ or --) of the dial gauge excur-
sion in comparison with the initial setting, and enter in a table (similar
to the example/table 1).
▲ Attention! On a Vee engine, take care that the measuring instru-
ment is not damaged by the slave connecting rod while turning the
engine!
6. Measure the other crank throws in the same way.

6682 000.10--03 E 09.06 32/40, L 40/54, 48/60, L 58/64 102/ 04

 1 Crank web
2 Measuring point
(punch mark)
3 Crank pin

A Distance between
measuring points

Figure 1. Measuring the crank web deflection

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

Figure 2. Designations of measuring points

Operating sequence 2 -- Note down the measured values

Apart from the data shown in Table 1, the following information should be
entered in the measuring log sheet:
- Assembly condition (e.g. pistons/connecting rods in place/removed),
- condition of coupling and bearings (e.g. vessel in drydock/afloat),
- temperatures of oil and cooling water if measurements are taken with
the engine at operating temperature, and
- main sense of rotation of the engine if measurements are taken with
running gear components in place.

6682 000.10--03 E 09.06 32/40, L 40/54, 48/60, L 58/64 103/ 04

 Cylinder No.
C k web
Crank b position
iti 1 2 3
Crank web at BDCR 0 0
Crank web at RTDC -2 +1
Crank web at TDC -5 +3
Crank web at LTDC +1 +2
Crank web at BDCL +2 0
Crank web deflection TDC-BDC -6 +3
Crank web deflection RTDC-LTDC -3 -1

Difference in TDC values of

neighbouring cylinders 8
Table 1. Measuring log sheet (example) - Dimensions in 1/100 mm

Operating sequence 3 -- Evaluation/valuation

Crank web deflection is the maximum difference of measurements of two

crank web positions at an angle of 180• . The reference position for verti-
cal deflection is the BDC, that for horizontal deflection is LTDC. If crank
web deflection is to be measured with the running gear components in
place, the value for BDC is obtained from 0.5 (BDCL + BDCR), which then
permits to calculate the difference between TDC and BDC.
If the crank web distance increases as compared with the reference posi-
tion, plus values (+) are to be entered in the table; if the distance becomes
smaller, minus values ( -- ) are entered.
Table 2 contains the maximum deflection values and the measuring point
distances (A). The maximum values apply to all cylinders with the engine
either cold or at operating temperature, and whether rigidly or flexibly
coupled (exception for 32/40 engine; see below). In case the actual deflec-
tion values exceed the ones stated in the table, the crankshaft has to be
newly aligned.
Please also note the following:
The difference of TDC measurements of neighbouring cylinders should not
be larger than the maximum admissible deflection.

Engine type 32/40 40/54 L 48/60 V 48/60 58/64

L 48/60 B V 48/60 B
With the engine in Deflection in 1/100 mm á14 1) á18 á23 á26 á23
cold condition
With the engine at Deflection in 1/100 mm 14 á18 á23 á26 á23
operating tempera- 20
ture
Measuring point distance (A) 460 505 580 580 560
in mm
1) Applicable to crank No. 1 (coupling end) with rigid coupling and to all the other cranks in all cases.
For crank No. 1 (coupling end) the maximum value is -- 20 if the connection to the driving flange is by flexible coupling.
Table 2. Maximum admissible crank web deflections (differentials) and relevant measuring point distances

6682 000.10--03 E 09.06 32/40, L 40/54, 48/60, L 58/64 104/ 04

Balance weight bolts
Checking, untightening and tightening 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 be checked for correct tension, according to the maintenance
schedule.
The work/steps include:
Establishing and evaluating the loosening pressure and
tensioning the connection at nominal pressure.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.306 Standard
2 Thrust pad 009.055 Standard
2 Hydraulic tensioning tool 009.053 Standard
2 Measuring device 009.052 Standard
2 Dial gauge (measuring device) 009.052--1 Standard
2 Extension 009.052--2 Standard
2 Extension 009.052--3 Standard
2 Threaded piece 009.052--4 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Screw drivers (set) -- Standard

6701 020.01--01 E 10.01 L 40/54 101/ 06

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.13
009.15

1 Nut
2 Balance weigth bolt
3 Crankshaft
4 Balance weigt
5 Crankcase

Figure 1. Balance-weight

Operating sequence 1 -- Checking the balance-weight bolts

Starting condition Crankcase is open, running gear turned so that the balance-weight bolts
are easily accessible (balance weight facing crankcase opening). See
Figure 1 .

▲▲ Caution! When the tensioning tools are mounted on the bal-

ance-weight bolts, the crankshaft must not be turned.

Steps 1. Clean the thread of the balance-weight bolts (2).

2. Place the pressure pads (009.055) over the nuts (1).
3. Screw the hydraulic tensioning tools (009.053) onto the balance-
weight bolts; make sure that the pressure pads are centred by the
hydraulic tensioning tools. See Figure 2 and 3 .
4. Back off the hydraulic tensioning tools by the back-off angle (see
000.30).
Work Card 000.30
5. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and the high-pressure pump (009.338).
009.03) and close
6. Switch on the high-pressure pump (see Work Card 009.03
the gap created by backing off.
▲▲▲ Danger! Make sure that nobody is near the projected axis of
the balance-weight bolts!

6701 020.01--01 E 10.01 L 40/54 102/ 06

 7. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened.
▲ Attention! The pressure must not be more than 7% below or 5%
above the tensioning pressure (see Work Card 000.30).
000.30

▲▲ Caution! During pumping, watch the stroke gauge (6) of the hy-
draulic tensioning tools. Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (7). Otherwise, the hydraulic
tensioning tools will be damaged.
Note the loosening pressure, and compare it to the tensioning pres-
sure.
8. Adjust the high-pressure pump to the prescribed tensioning pressure
000.30).
(see Work Card 000.30
9. Using the tommy bar (000.262), screw down both nuts through the
opening in the pressure pads, hand-tight.
10. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (time of reset aprox.
2 to 3 minutes). But for this purpose, the high-pressure pump must be
connected.
11. Remove the hydraulic tensioning tools.

2 Balance-weight bolt
3 Crankshaft
4 Balance weight

Figure 2. Balance weight with tensioning tools mounted

6701 020.01--01 E 10.01 L 40/54 103/ 06

 1 Nut
2 Balance weight bolt
4 Balance weight
6 Stroke gauge
7 Threaded stop ring

M Marking

Figure 3. Balance weight bolt with tensioning tool mounted

Operating sequence 2 -- Untensioning the balance-weight bolts

Starting condition Crankcase is open, running gear turned so that the balance-weight bolts
are easily accessible (balance weight facing crankcase opening). See
Figure 1 .

▲▲ Caution! When the tensioning tools are mounted on the bal-

ance-weight bolts, the crankshaft must not be turned.

Steps 1. Clean the thread of the balance-weight bolts (2).

2. Place the pressure pads (009.055) over the nuts (1).
3. Screw the hydraulic tensioning tools (009.053) onto the balance-
weight bolts; make sure that the pressure pads are centred by the
hydraulic tensioning tools. See Figure 2 and 3 .
4. Back off the hydraulic tensioning tools by the back-off angle (see
000.30).
Work Card 000.30
5. Connect the high-pressure hoses (009.306) to the hydraulic
tensioning tools and the high-pressure pump (009.338).
009.03) and close
6. Switch on the high-pressure pump (see Work Card 009.03
the gap created by backing off.
▲▲▲ Danger! Make sure that nobody is near the projected axis of
the balance-weight bolts!
7. Pump up the hydraulic tensioning tools until the nuts can be
loosened.
▲ Attention! The pressure must not be more than 7% below or 5%
above the tensioning pressure (see Work Card 000.30).
000.30

▲▲ Caution! During pumping, watch the stroke gauge (6) of the hy-
draulic tensioning tools. Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (7). Otherwise, the hydraulic
tensioning tools will be damaged.
8. Note the loosening pressure, and compare it to the tensioning
pressure.
9. Using the tommy bar (000.262), back off both nuts through the
opening in the pressure pads (for angle of back-off, see Work Card
000.30).
000.30

6701 020.01--01 E 10.01 L 40/54 104/ 06

 10. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (time of reset aprox. 2
to 3 minutes). But for this purpose, the high-pressure pump must be con-
nected.
11. Remove the tensioning tools

Operating sequence 3 -- Tensioning the balance-weight bolts

Starting condition Nuts (1) are screwed on and tightened hand-tight. Threads of the balance-
weight bolts are cleaned.

▲ Attention! A correctly indicating pressure gauge is essential for

tensioning a screw connection properly. If in doubt, check the
pressure gauge against a reference pressure gauge.

Steps 1. Check that the gap of the joint between the balance weight (4) and
the crankshaft (3) is the same size on both sides.
2. Unscrew the screw plug on the hydraulic tensioning tools (009.053).
Screw the threaded piece (009.052-4) into the threaded stop ring (7).
See Figure 4 .
3. Slip the pressure pads (009.055) over the nuts (1).
4. Screw the hydraulic tensioning tools onto the balance-weight bolts;
make sure that the pressure pads are centred by the hydraulic ten-
sioning tools. See Figure 2 and 3 .
5. Screw the extension pieces needed (009.052-2 or -3) onto the dial
gauges (009.052-1).
6. Insert the dial gauges into the threaded pieces, and fasten them with
the cylindrical screws (8). See Figure 4 .
▲ Attention! Make sure that the feeler pin of the dial gauges touches
the piston of the hydraulic tensioning tools
7. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and the high-pressure pump (009.338).
009.03), and ten-
8. Switch on the high-pressure pump (see Work Card 009.03
sion the balance-weight bolts with an initial pressure of 50 bars.
▲▲▲ Danger! Make sure that nobody is near the projected axis of
the balance-weight bolts during tensioning!

▲▲ Caution! During pumping, watch the stroke gauge (6) of the hy-
draulic tensioning tools. Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (7). Otherwise, the hydraulic
tensioning tools will be damaged.
9. Set the dial gauges to zero.
10. Tension the balance-weight bolts with the prescribed tensioning pres-
000.30).
sure (see Work Card 000.30
11. Using the tommy bar (000.262), tighten the two nuts hand-tight
through the opening in the pressure pads.
12. Release the pressure.
13. Tension the balance-weight bolts with an initial pressure of 50 bars
again. Read off the bolt elongation Dl from the dial gauges, note it
000.30).
down, and compare it with the desired value (see Work Card 000.30
▲ Attention! The bolt must be tensioned with the prescribed initial
tension pressure, not according to the elongation Dl! Measurement
of the bolt elongation Dl only serves as a check!

6701 020.01--01 E 10.01 L 40/54 105/ 06

 Important! If there are substantial deviations from the desired value,
repeat the tensioning procedure, and, if necessary, check the hydraulic
tensioning tools, the screw connections, and the pressure gauge.
14. Release the pressure, and disconnect the high-pressure hoses from
the hydraulic tensioning tools and the high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (time of reset 2 to 3
minutes). But for this purpose, the high-pressure pump must be con-
nected.
15. Remove the dial gauges.
16. Remove the tensioning tools.
17. Unscrew the threaded pieces from the threaded stop ring, and close
the tapped holes with a screw plug.

7 Threaded stop ring

8 Cylindrical screw,
M5x12

Figure 4. Hydraulic tensioning tool with measuring instrument mounted

6701 020.01--01 E 10.01 L 40/54 106/ 06

Coupling bolts
Checking, untightening and tightening 020.02

Purpose of jobs to be done

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

ensure operational reliability of bolted connections.

Brief description

Coupling bolts are to be checked at regular intervals.

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

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.341 Standard
2 High--pressure hose 009.306 Standard
2 Thrust pad 009.055 Standard
2 Hydraulic tensioning tool 009.053 Standard
1 Torque wrench 008.017 Standard
1 Screw driver insert 19x20 001.868 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Lifting tackle -- Inventory
1 Hexagon screw drivers (set) -- Inventory
1 Rope -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.13
071.01

6701 020.02--03 E 12.05 L 40/54 101/ 06

Operating sequence 1 -- Check the coupling bolts

Starting condition Coupling bolts are accessible.

Steps 1. Remove oil pipe (10) and covering (8) - see work card 071.01.
071.01
2. Clean the threads of the coupling bolts (6).
3. Put the thrust pads (009.055) over the two nuts (5) positioned
opposite each other.
4. Screw the hydraulic tensioning tools (009.053) onto both coupling
bolts (6), taking care that the thrust pads are centered by the
hydraulic tensioning tools. See to Figures 2 and 3 .
5. Turn the hydraulic tensioning tools back by the angular amount of
turning back (see work card 000.30).
000.30
6. Connect the high-pressure hoses (009.306) to hydraulic tensioning
tools and high-pressure pump (009.341).
009.03) and close
7. Switch on the high-pressure pump (see work card 009.03
the gap resulting from turning back.
▲▲▲ Danger! Make sure that there is no one in the area of the axis
of the coupling bolts!
8. Pump up the hydraulic tensioning tools until the nuts (5) can be
loosened.
▲ Attention! The pressure is allowed to be max. 7% below and
000.30)!
max. 5% above the tensioning pressure (see work card 000.30

▲▲ Caution! While pumping, watch the stroke gauges (13) of the

hydraulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauges reaches the
upper edge of the threaded stop ring (12)! Otherwise the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the tensioning
pressure.
9. Adjust the high-pressure pump to the specified tensioning pressure
000.30).
(see work card 000.30
10. Using the tommy bar (000.262), screw down both nuts (5) through
the opening in the thrust pad, hand-tight.
11. Release the pressure, disconnect the high-pressure hoses from the
hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx.
2 to 3 minutes). For this purpose, however, the high-pressure pump has
to be connected and its relief valve has to be open (see Work
009.03).
Card 009.03
12. Remove the tensioning tools.
13. Reposition the tensioning tools onto the next pair of bolts and repeat
the process until all coupling bolts (6) have been checked. See items
3 to 12.
14. After completion of the checks, disconnect the high-pressure hoses
from the high-pressure pump.
071.01.
15. Mount covering (8) and oil pipe (10) - see work card 071.01
16. Check the hexagon socket bolts (2) with the specified torque (see
flywheel arrangement drawing and/or coupling attachement drawing
of the respective plant in Volume E1); retighten the hexagon socket
bolts if necessary.

6701 020.02--03 E 12.05 L 40/54 102/ 06

Operating sequence 2 -- Untension the coupling bolts

Starting condition Coupling is removed (refer to the documentation of the coupling

manufacturer included in Volume E1), coupling bolts are accessible,
flywheel is fastened to the crankshaft by means of two hexagon socket
bolts (11).

Steps 071.01.
1. Remove oil pipe (10) and covering (8) - see work card 071.01
2. Clean the threads of the coupling bolts (6).
3. Put the thrust pads (009.055) over the two nuts (5) positioned
opposite each other.
4. Screw hydraulic tensioning tools (009.053) onto both coupling bolts
(6), taking care that the thrust pads are centered by the hydraulic
tensioning tools. See to Figures 2 and 3 .
5. Turn back the hydraulic tensioning tools by the angular amount of
turning back (see work card 000.30).
000.30
6. Connect the high-pressure hoses (009.306) to hydraulic tensioning
tools and high-pressure pump (009.341).
009.03) and close
7. Switch on the high-pressure pump (see work card 009.03
the gap resulting from turning back.
▲▲▲ Danger! During untensioning, make sure that there is no one
in the area of the axis of the coupling bolts to be untensioned!
8. Pump up the hydraulic tensioning tools until the nuts (5) can be
loosened.
▲ Attention! The pressure is allowed to be max. 7% below and
000.30)!
max. 5% above the tensioning pressure (see work card 000.30

▲▲ Caution! While pumping, watch the stroke gauges (13) of the

hydraulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauges reaches the
upper edge of the threaded stop ring (12)! Otherwise the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the tensioning
pressure.
9. Using the tommy bar (000.262), turn back both nuts (5) through the
opening in the thrust pad (for the angular amount of turning back, see
000.30).
work card 000.30
10. Release the pressure, disconnect the high-pressure hoses from the
hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx.
2 to 3 minutes). For this purpose, however, the high-pressure pump has
to be connected and its relief valve has to be open (see Work
009.03).
Card 009.03
11. Remove the tensioning tools.
12. Reposition the tensioning tools onto the next pair of bolts and repeat
the process until all coupling bolts (6) have been untensioned. See
items 3 to 11.
13. When all coupling bolts (6) have been untensioned, disconnect the
high-pressure hoses from the high-pressure pump.
Important! Prior to flywheel removal, verify whether the position
flywheel - crankshaft flange has been marked, if not, do it now.

6701 020.02--03 E 12.05 L 40/54 103/ 06

Operating sequence 3 -- Tension the coupling bolts

Starting condition Flywheel is fastened to the crankshaft by means of two hexagon socket
bolts (11), coupling bolts are cleaned and inserted into the bores.

Important! Take care that the coupling bolts are installed correctly
(number and position of coupling bolts).

Nuts screwed on and driven home to contact, hand-tight. Works No. and
marking of engine and/or crankshaft flange and flywheel coincide.

Important! Always tighten a pair of bolts (two coupling bolts

positioned opposite each other) at a time.

▲ Attention! Prerequisite for the correct tightening of a bolted

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

Steps 1. Put the thrust pads (009.055) over the nuts (5).
2. Screw the hydraulic tensioning tools (009.053) onto both coupling
bolts (6), taking care that the thrust pads are centered by the
hydraulic tensioning tools. See to Figures 2 and 3 .
3. Connect the high-pressure hoses (009.306) to hydraulic tensioning
tools and high-pressure pump (009.341).
009.03) and
4. Switch on the high-pressure pump (see work card 009.03
tension the coupling bolts (6) to the specified tensioning pressure
(see work card 000.30).
000.30
▲▲▲ Danger! During tensioning, make sure that there is no one in
the area of the axis of the coupling bolts to be tensioned!

▲▲ Caution! While pumping, watch the stroke gauges (13) of the

hydraulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauges reaches the
upper edge of the threaded stop ring (12)! Otherwise the hydraulic
tensioning tools will be damaged!
5. Using the tommy bar (000.262), screw down both nuts (5) through
the opening in the thrust pad, hand-tight.
6. Release the pressure, disconnect the high-pressure hoses from the
hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx.
2 to 3 minutes). For this purpose, however, the high-pressure pump has
to be connected and its relief valve has to be open (see Work
009.03).
Card 009.03
7. Remove the tensioning tools.
8. Reposition the tensioning tools onto the next pair of bolts and repeat
the process until all coupling bolts (6) have been tensioned. See
items 1 to 7.
9. When all coupling bolts (6) have been tensioned, disconnect the
high-pressure hoses from the high-pressure pump.
10. Attach covering (8) and oil pipe (10) - see work card 071.01.
071.01
11. While mounting of the coupling (refer to the documentation of the
coupling manufacturer in Volume E1), take care that the threads and
the head contact face of the hexagon socket bolts (2) have been
coated with clean lube oil and that the bolts have been screwed in,
hand-tight, and tightened to the specified torque (see flywheel
arrangement drawing and/or coupling attachement drawing of the
respective plant in Volume E1).

6701 020.02--03 E 12.05 L 40/54 104/ 06

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

Figure 1. Connection between crankshaft, flywheel and coupling

* Shape and size of coupling and flywheel may differ from that shown in the Figures.

6701 020.02--03 E 12.05 L 40/54 105/ 06

 6 Coupling bolt

Figure 2. Coupling bolts with tensioning tools attached

5 Nut
6 Coupling bolt
7 Crankshaft
12 Threaded stop ring
13 Stroke gauge

M Marking on the stroke

gauge

Figure 3. Coupling bolt with tensioning tool attached

6701 020.02--03 E 12.05 L 40/54 106/ 06

Crankshaft gear wheel
Installing 020.03

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

If damage should be found on the gear wheel on the crankshaft, the gear
rim is to be replaced or renewed.
The work includes:
Installing components.

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 Sliding caliper 009.059 Standard
1 Torque wrench 008.017 Standard
1 Socket wrench insert 41x20 001.772 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.32 100.01

Preliminary remarks

We recommend having overhauls of the camshaft drive carried out in an

MAN Service Centre.

6701 020.03--01 E 02.00 L 40/54 101/ 02

Operating sequence 1 -- Installing the crankshaft gear-wheel

▲ Attention! Do not turn the running gear unless the push-rods of

the inlet and outlet valves have been removed; otherwise, the
opened valves may be damaged by rising pistons!

Starting condition The lower double spur wheel of the camshaft drive and the old crankshaft
gear-wheel have been removed.

Steps 1. Insert the feather (5), and mount both gear-wheel halves on the
crankshaft (8); be careful that the cylindrical pins (9) are correctly
positioned.
2. Insert bolts (7).
3. Coat the threads and bearing surfaces of the castle nuts (10) with
MoS2 lubricant, screw them on and tighten hand-tight.
4. Measure the length of all the bolts with the sliding calipers (009.059)
and note down the readings.
Important! This dimension is required as the basis for the bolt
elongation ol after tightening.
5. Tighten the castle nuts of bolts 1 and 2 with an initial torque of 750
Nm, steadying with the bolts.
6. Tighten the castle nuts of bolts 3 and 4 in the same way, with an
initial torque of 750 Nm.
7. Continue turning the castle nuts of bolts 3 and 4 until the specified
bolt elongation ol (see Work Card 000.30
000.30) is reached.
▲ Attention! If necessary, turn to the next cotter-pin hole!

Important! The difference between the measurement in Item 4 and

the measurement during tightening (Item 7 or 8) gives the bolt elongation
ol.
8. Continue turning the castle nuts of bolts 1 and 2 until the specified
bolt elongation ol (see Work Card 000.30
000.30) is reached. If necessary,
turn to the next cotter-pin hole.
9. Secure all castle nuts with cotter pins (11).
10. Re-install the lower double spur wheel of the camshaft drive; make
sure the markings are in the correct position (see Work Card 100.01).
100.01

1-4 Tightening sequence

5 Feather
6 Crankshaft gear-wheel
7 Bolt
8 Crankshaft
9 Cylindrical pin
10 Castle nut
11 Cotter pin

Figure 1. Crankshaft gear-wheel

6701 020.03--01 E 02.00 L 40/54 102/ 02

Oil bore of the crankshaft
Blocking 020.04

Purpose of jobs to be done

Ensure correct execution of work,

enable emergency operation.

Brief description

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

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

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 Blocking tool 020.043 Standard
1 Sealing plug 020.043--1 Standard
1 Threaded rod with sealing plug 020.043--2 Standard
1 Open--jaw and ring wrenches (set) -- Standard

Related work cards

Work card Work card Work card

030.05 034.01 055.02
112.01 200.02

Operating sequence 1 -- Blocking the oil bores (emergency operation)

Starting condition Piston and connecting rod of one cylinder removed, engine must be kept
running.

6701 020.04--01 E 02.00 L 40/45 101/ 02

 ▲ Attention! The engine should only be operated with running gear
removed in an emergency, and even then at reduced power and
speed (note the directions in the Operating instruction manual).
Emergency operation with running gear removed is not possible for
flexibly-mounted engines.

Steps 1. Insert threaded rod with sealing plug (020.043-2) into oil bore (2).
2. Mount the sealing plug (020.043-1), screw on the hexagon nut (3),
tighten it, and secure it with the split pin (4).
3. Fit the complete cylinder head, but do not insert the push rods.
4. Put inlet and exhaust cam followers out of operation (fix them in place
outside the range of the cams) and close the lubrication bores.
5. Put the fuel injection pump of the cylinder concerned out of operation
(pull control rod to zero-admission position and fix it in this position with
200.02).
a clamp - see Work Card 200.02
6. Block oil pipe for rocker arm lubrication.
7. Block pilot air distributing pipe leading to the cylinder which has been
put out of operation.

1 Crank pin
2 Oil bore
3 Hexagon nut
4 Split pin

Figure 1. Blocking tool mounted

6701 020.04--01 E 02.00 L 40/45 102/ 02

Main bearing/Thrust bearing

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

6682 021--06 E 07.99 101/ 01

Main bearing shell
Checking 021.01

Purpose of jobs to be done

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

ensure operational reliability of bearings.

Brief description

Bearing shells must be checked at regular intervals. From the state of

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

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Centring template 021.154 Standard
1 Lifting/lowering device 021.153 Standard
2 Guide tube 021.153--2 Standard
4 Tommy bar, 12 mm 021.153--18 Standard
1 Cross tie 021.153--34 Standard
2 Support 021.153--38 Standard
1 Turning stone 021.152 Standard
1 Turning stone 021.151 Standard
1 Guide tube 021.032 Standard
1 Foot board (for oil sump) 011.006 Standard
1 Scissor--type jack 009.077 Standard
1 Adapter 20x12.5 001.923 Standard
1 Extension piece 12.5x125 001.911 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 36x20 001.771 Standard
1 Ratchet 001.521 Standard

6701 021.01--01 E 05.05 L 40/54 101/ 14

 Qty Designation No. Availability
1 Thickness gauges 0.05--1 000.454 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Eye bolt M6 000.023 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Securing compound Loctite 243 -- Inventory

Related work cards

Work card Work card Work card

000.10 000.11 000.19
012.02

Operating sequence 1 -- Removing and checking the lower bearing shell

▲ Attention! It is recommended to carry out the work mentioned

below with the engine at operating temperature!

Starting condition Crankcase opened, running gear turned to a position permitting easy ac-
cess to the main bearing cap.

Steps 1. Place the foot board (011.006) in the oil sump (12).
2. Remove the temperature sensor (30) from the main bearing cap (11)
and put it down in a safe place, outside of the crankcase.
Important! It might be necessary to remove some clamps serving
for fastening the temperature-sensor lines in place.
3. Untighten the main bearing bolts (10) and the cross tierods (7) of the
012.02).
respective main bearing (see Work Card 012.02
4. Unscrew the nuts (6) and take off the rings (15) including the O-ring
seals (16). Refer to Figure 1 .
5. Remove both cross tierods (7).
6. Untighten the cross tierods of the neighbouring main bearings (see
012.02), and loosen the nuts.
Work Card 012.02
7. Screw the guide tubes (021.153-2) into the main bearing bolts (10),
hand-tight. Refer to Figure 2 .
8. Slip the cross tie (021.153-34) onto the guide tubes from below, and
fix them in place by inserting two tommy bars (021.153-18) into the
bore holes (4) of the guide tubes. Refer to Figure 3 .
9. Place two supports (021.153-38) onto the cross tie, and fasten them
in the crankcase by turning the hexagon nuts (15). The cross tie is
thereby forced against the tommy bars. Refer to Figure 3 .
10. Place the scissor-type jack (009.077) on the cross tie, and fix it in
place by means of the hexagon bolt (17). Refer to Figure 3 .
▲ Attention! Tighten the hexagon bolt only to such an extent, hand-
tight, that the scissor-type jack remains movable enabling it to align
independently for further work!
11. Turn the scissor-type jack upwards until it contacts the main bearing
cap (11), and attach it to the main bearing cap by means of two hexa-
gon bolts (16). Refer to Figure 3 .
12. Unscrew both nuts (9), and put them down onto the cross tie.

6701 021.01--01 E 05.05 L 40/54 102/ 14

 13. Insert two more tommy bars (021.153-18) into the bore holes (2) of
the guide tubes. Refer to Figure 4 .
▲ Attention! Before lowering the main bearing cap (inner locating
bearing) positioned between the camshaft drive and cylinder 1, se-
cure the locating bearing ring in place! Otherwise there is the risk
that, when turning the crankshaft, the locating bearing ring, too, is
turned and falls down!
14. Using the scissor-type jack, lower the main bearing cap (11) down to
the tommy bars. Refer to Figure 5 .
15. Remove both supports (021.153-38).
16. Slightly lift the cross tie by means of the scissor-type jack, and re-
move both tommy bars from the lower bore holes (4).
17. Lower the cross tie all the way down to the bottom of the oil sump.
18. Slip two tommy bars (021.153-18) into the bore holes (3) of the guide
tubes. Refer to Figure 6 .
19. Slightly lift the main bearing cap (11), and remove the tommy bars
from the bore holes (2).
20. Lower the main bearing cap (11) down to the tommy bars. Refer to
Figure 7 .
21. Remove the bearing shell (18).
22. Carefully clean the running surface of the bearing shell (18), taking
care not to damage it.
23. Check the condition of the running surface (see Work Card 000.11000.11).
▲▲ Caution! Do not rework the bearing shell in any way!

▲ Attention! Replace bearing shells that have been damaged or

heavily scored by dirt particles!
In case dirt scores are found on the bearing shell, the shaft journal
must be checked and, if necessary, repolished (polishing cloth with
grain <15m)!

Operating sequence 2 -- Removing and checking the upper bearing shell

Starting condition The main bearing cap has been lowered, the lower bearing shell has been
removed.

Steps 1. Insert the turning stone (021.151) into the oil bore of the crankshaft
(13), slightly turn the crankshaft if necessary. Refer to Figure 8 .
▲ Attention! The turning stone must fully contact the crankshaft!
2. Carefully turn the bearing shell (20) out, do not damage it in the pro-
cess.
3. Pull the turning stone out by means of the eye bolt (000.023).
4. Carefully clean the running surface of the bearing shell (20), taking
care not to damage it.
000.11).
5. Check the condition of the running surface (see Work Card 000.11
▲▲ Caution! Do not rework the bearing shell in any way!

▲ Attention! Replace bearing shells that have been damaged or

heavily scored by dirt particles!
In case dirt scores are found on the bearing shell, the shaft journal
must be checked and, if necessary, repolished (polishing cloth with
grain <15m)!

6701 021.01--01 E 05.05 L 40/54 103/ 14

Operating sequence 3 -- Installing the upper bearing shell

▲ Attention! The new bearing shells supplied are ready to be fitted,

scraping or any other touching up is not permitted!

Starting condition The bearing shell has been cleaned.

Steps 1. Place the centring template (021.154) against the cylinder crankcase
(8). For this purpose, insert the centring bolt of the centring template
into the bore hole provided for bearing cap fixation (centring template
is held by magnetic force). Refer to Figure 9 .
2. Thoroughly oil the running surface of the bearing shell (20) - back of
the bearing shell to remain dry.
3. Place the bearing shell (20) against the centring template, and push it
in by hand as far as possible.
▲ Attention! Already prior to pushing the bearing shell in, pay
attention to the position of the groove for bearing shell fixation (C)!
4. Turn the crankshaft (13) until the turning stone (021.152) can be in-
serted into the oil bore of the crankshaft through one of the bore
holes in the bearing shell (20). Refer to Figure 9 .
▲ Attention! To avoid deformation of the thin bearing shell in the
process of turning it in, place the turning stone as closely as pos-
sible to the joint of the main bearing!
5. Turn in the bearing shell (20) in several stages (corresponding to the
pitch of bore holes). For this purpose, pull the turning stone out after
the first turning step, turn the crankshaft (13) back by one pitch of
bore holes and reinsert the turning stone. Repeat this step up to the
last bore. Refer to Figure 9 .
6. Pull the turning stone out, and turn the crankshaft (13) back until the
oil bore comes free.
7. Insert the turning stone (021.151) directly into the oil bore of the
crankshaft (13), and turn the bearing shell (20) completely in.
▲ Attention! Make sure that the joint faces of bearing shells are in
uniform end position!
8. Take the centring template off, and pull the turning stone out by
means of the eye bolt (000.023).

Operating sequence 4 -- Installing the lower bearing shell

▲ Attention! The new bearing shells supplied are ready to be fitted,

scraping or any other touching up is not permitted!

Starting condition The bearing shell and the cross tierods has/have been cleaned.

Steps 1. Thoroughly oil the running surface of the bearing shell (18) - back of
the bearing shell to remain dry.
2. Insert the bearing shell (18) into the main bearing cap (11). Refer to
Figure 7 .
▲ Attention! During installation of the bearing shell, take note of the
position of the groove for bearing shell fixation!
3. Lift the main bearing cap (11) by means of the scissor-type jack
(009.077), insert the tommy bars (021.153-18) into the bore holes (2)
of the guide tubes, and lower the main bearing cap down to the
tommy bars. Refer to Figure 6 .

6701 021.01--01 E 05.05 L 40/54 104/ 14

 ▲ Attention! When lifting the main bearing cap, make sure that it
does not become tilted!
4. Remove the tommy bars from the bore holes (3).
5. Lift the cross tie (021.153-34) by means of the scissor-type jack until
the tommy bars can be inserted into the bore holes (4) of the guide
tubes. Insert the tommy bars into the bore holes.
6. Lower the cross tie down to the tommy bars.
7. Place two supports (021.153-38) on the cross tie, and fasten them in
the crankcase by turning the hexagon nuts (15). The cross tie is
thereby forced against the tommy bars. Refer to Figure 5 .
8. Lift the main bearing cap (11) until it contacts the cylinder crankcase
(8). Refer to Figure 4 .
9. Remove the tommy bars from the upper bore holes (2).
10. Screw the nuts (9) onto the main bearing bolts (10) until they contact
the main bearing cap (11), and tighten them, hand-tight. Refer to Fig-
ure 3 .
▲ Attention! Take note of the specified projection of the main bear-
012.02)!
ing bolts (see Work Card 012.02
11. Remove the complete lifting/lowering device (021.153).
▲ Attention! Remove the fastening for locating bearing ring (main
bearing between camshaft drive and cylinder 1)!
12. Apply MoS2 lubricant to the screw-in threads of the cross tierods (7),
and screw them into the main bearing cap (11), hand-tight, down to
contact.
13. Slip new O-ring seals (16) and rings (15) over the cross tierods (7).
Screw the nuts (6) on, hand-tight, until they are seated.
14. Tighten the main bearing bolts (10) and the cross tierods (7) - see
012.02.
Work Card 012.02
15. Screw down the nuts of the cross tierods of the neighbouring main
bearings, hand-tight. Tighten the cross tierods of the neighbouring
012.02.
main bearings - see Work Card 012.02
16. Check the main bearing clearance using thickness gauges (000.454),
inserting the thickness gauges approx. 10 mm deep from the coup-
ling end and free engine end.
000.10), and enter
17. Measure the crank web deflection (see Work Card 000.10
the measured value into the engine log book.
18. Install the temperature sensor (30) into the main bearing cap (11).
Important! In case clamps serving for fastening the temperature
sensor lines in place have been removed, the hexagon bolts used for refit-
ting them have to be secured by Loctite 243 securing compound.
19. Remove the foot board (011.006) from the oil sump (12).
▲ Attention! Regarding running-in of new bearing shells, please
refer to the running-in instructions in Volume B1/Operating Instruc-
tions!

6701 021.01--01 E 05.05 L 40/54 105/ 14

 5 Balance weight 11 Main bearing cap ST Control side
6 Nut 12 Oil sump
7 Cross tierod 13 Crankshaft
8 Cylinder crankcase 14 Connecting rod
9 Nut 15 Ring
10 Main bearing bolt 16 O-ring seal
30 Temperature sensor

Figure 1. Main bearing

6701 021.01--01 E 05.05 L 40/54 106/ 14

 1-4 Bore hole in the guide tube ST Control side
10 Main bearing bolt

Figure 2. Main bearing and attached lifting/lowering device

6701 021.01--01 E 05.05 L 40/54 107/ 14

 8 Cylinder crankcase 16 Hexagon bolt M20x35 ST Control side
11 Main bearing cap 17 Hexagon bolt M12x16
12 Oil sump
15 Hexagon nut M20

Figure 3. Main bearing and attached lifting/lowering device

6701 021.01--01 E 05.05 L 40/54 108/ 14

 9 Nut ST Control side
10 Main bearing bolt

Figure 4. Main bearing and attached lifting/lowering device

6701 021.01--01 E 05.05 L 40/54 109/ 14

 11 Main bearing cap ST Control side

Figure 5. Main bearing and attached lifting/lowering device

6701 021.01--01 E 05.05 L 40/54 110 / 14

 12 Oil sump ST Control side

Figure 6. Main bearing and attached lifting/lowering device

6701 021.01--01 E 05.05 L 40/54 111 / 14

 11 Main bearing cap ST Control side
18 Lower bearing shell
19 Locating piece

Figure 7. Main bearing and attached lifting/lowering device

6701 021.01--01 E 05.05 L 40/54 112 / 14

 8 Cylinder crankcase
13 Crankshaft
20 Upper bearing shell
21 O-ring seal

ST Control side
I - II Steps

Figure 8. Main bearing - removal of the upper bearing shell

6701 021.01--01 E 05.05 L 40/54 113 / 14

 8 Cylinder crankcase C Groove for bearing shell fixation
13 Crankshaft ST Control side
20 Upper bearing shell I - III Steps
21 O-ring seal

Figure 9. Main bearing - installation of the upper bearing shell

6701 021.01--01 E 05.05 L 40/54 114 / 14

Main bearing shell (outer bearing)
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

Bearing shells must be checked at regular intervals. From the state of

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

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Centring template 021.154 Standard
1 Lifting/lowering device 021.153 Standard
6 Tommy bar, 12 mm 021.153--18 Standard
2 Guide tube 021.153--20 Standard
1 Cross tie 021.153--34 Standard
1 Turning stone 021.152 Standard
1 Turning stone 021.151 Standard
1 Guide tube 021.032 Standard
1 Foot board (for oil sump) 011.006 Standard
1 Scissor--type jack 009.077 Standard
1 Adapter 20x12.5 001.923 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 36x20 001.771 Standard
1 Ratchet 001.521 Standard
1 Thickness gauges 0.05--1 000.454 Standard
1 Tommy bar, 8 mm 000.262 Standard

6701 021.02--01 E 06.05 L 40/54 101/ 12

 Qty Designation No. Availability
1 Eye bolt M6 000.023 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Securing compound Loctite 243 -- Inventory

Related work cards

Work card Work card Work card

000.10 000.11 000.19
012.02 012.03

Operating sequence 1 -- Removing and checking the lower bearing shell

▲ Attention! It is recommended to carry out the work mentioned

below with the engine at operating temperature!

Starting condition Casing cover on the camshaft drive, as well as on the crankcase of the
neighbouring cylinder have been removed.

Steps 1. Place the foot board (011.006) in the oil sump (15).
2. Remove the temperature sensor (30) from the main bearing cap (8)
and put it down in a safe place, outside of the camshaft drive.
Important! It might be necessary to remove some clamps serving
for fastening the temperature-sensor lines in place.
3. Untighten the main bearing bolts (14) and the cross tierods (11) - see
012.03.
Work Card 012.03
4. Unscrew the nuts (10), and take off the rings (16) including O-ring
seals (17). Refer to Figure 1 .
5. Remove both of the cross tierods (11).
6. Untighten the cross tierods of the neighbouring main bearing (see
012.02), and loosen the nuts.
Work Card 012.02
7. Screw the guide tubes (021.153-20) into the main bearing bolts (14),
hand-tight. Refer to Figure 2 .
8. Push the cross tie (021.153-34) onto the guide tubes from below, and
fix them in place by inserting two tommy bars (021.153-18) into the
bore holes (5) of the guide tubes. Refer to Figure 3 .
9. Insert another tommy bar (021.153-18) each into the bore holes (4) of
the guide tubes. Refer to Figure 3 .
10. Place the scissor-type jack (009.077) on the cross tie, and fasten it in
place by means of hexagon bolt (19). Refer to Figure 3 .
▲ Attention! Tighten the hexagon bolt only to such an extent, hand-
tight, that the scissor-type jack remains movable enabling it to align
independently for further work !
11. Turn the scissor-type jack up until it contacts the main bearing
cap (8), and fasten it to the main bearing cap by means of two hexa-
gon bolts (18). Refer to Figure 3 .
12. Unscrew both nuts (13), and put them down. Refer to Figure 4 .
13. Insert two further tommy bars (021.153-18) into the bore holes (2) of
the guide tubes.
14. Fasten the locating bearing ring (7) in place.

6701 021.02--01 E 06.05 L 40/54 102/ 12

 ▲ Attention! In case the locating bearing ring is not fastened in
place prior to lowering the main bearing cap, there is the risk that,
when turning the crankshaft, the locating bearing ring, too, is turned
and falls down!
15. Using the scissor-type jack, lower the main bearing cap (8) onto the
tommy bars. Refer to Figure 5 .
16. Remove the bearing shell (21).
17. Carefully clean the running surface of the bearing shell (21). Do not
damage it in the process.
000.11).
18. Check the condition of the running surface (see Work Card 000.11
▲▲ Caution! Do not rework the bearing shell in any way!

▲ Attention! Replace bearing shells that have been damaged or

heavily scored by dirt particles!
In case dirt scores are found on the bearing shell, the crank journal
must be checked and, if necessary, repolished (polishing cloth with
grain <15mm)!

Operating sequence 2 -- Removing and checking the upper bearing shell

Starting condition The main bearing cap has been lowered, the lower bearing shell has been
removed.

Steps 1. Insert the turning stone (021.151) into the oil bore of the crank-
shaft (6), slightly turn the crankshaft. Please refer to Figure 6 .
▲ Attention! The turning stone must fully contact the crankshaft!
2. Carefully turn the bearing shell (23) out. Do not damage it in the pro-
cess.
3. Pull out the turning stone by means of the eye bolt (000.023).
4. Carefully clean the running surface of the bearing shell (23), taking
care not to damage it.
000.11).
5. Check the condition of the running surface (see Work Card 000.11
▲▲ Caution! Do not rework the bearing shell in any way!

▲ Attention! Replace bearing shells that have been damaged or

heavily scored by dirt particles!
In case dirt scores are found on the bearing shell, the crank journal
must be checked and, if necessary, repolished (polishing cloth with
grain <15mm)!

Operating sequence 3 -- Installing the upper bearing shell

▲ Attention! The new bearing shells supplied are ready to be fitted,

scraping or any other touching up is not permitted!

Starting condition The bearing shell has been cleaned.

Steps 1. Place the centring template (021.154) against the cylinder crank-
case (12). For this purpose, insert the centring bolt of the centring
template into the bore for bearing shell fixation (centring template is
held by magnetic force). Refer to Figure 7 .
2. Thoroughly oil the running surface of the bearing shell (23) - back of
the bearing shell to remain dry.
3. Place the bearing shell (23) against the centring template, and push it
in by hand as far as possible.

6701 021.02--01 E 06.05 L 40/54 103/ 12

 ▲ Attention! Already prior to pushing the bearing shell in, pay
attention to the position of the groove for bearing shell fixation (C)!
4. Turn the crankshaft (6) until the turning stone (021.152) can be in-
serted into the oil bore of the crankshaft through one of the bore
holes in the bearing shell (23). Refer to Figure 7 .
▲ Attention! To avoid deformation of the thin bearing shell in the
process of turning it in, place the turning stone as closely as
possible to the joint of the main bearing!
5. Turn in the bearing shell (23) in several stages (corresponding to the
pitch of bore holes). For this purpose, pull the turning stone out after
the first turning step, turn the crankshaft (6) back by one pitch of bore
holes and reinsert the turning stone. Repeat this step up to the last
bore. Refer to Figure 7 .
6. Pull the turning stone out, and turn the crankshaft (6) back until the
oil bore is exposed.
7. Insert the turning stone (021.151) directly into the oil bore of the
crankshaft (6), and turn the bearing shell (23) completely in.
▲ Attention! Make sure that the joint faces of bearing shells are in
uniform end position!
8. Take the centring template off, and pull the turning stone out by
means of the eye bolt (000.023).

Operating sequence 4 -- Installing the lower bearing shell

▲ Attention! The new bearing shells supplied are ready to be fitted,

scraping or any other touching up is not permitted!

Starting condition The bearing shell and the cross tierods has/have been cleaned.

Steps 1. Thoroughly oil the running surface of the bearing shell (21) - back of
the bearing shell to remain dry.
2. Insert the bearing shell (21) into the main bearing cap (8). Refer to
Figure 5 .
▲ Attention! During installation of the bearing shell, take note of the
position of the groove for bearing shell fixation!
3. Using the scissor-type jack (009.077), lift the main bearing cap (8)
until it contacts the cylinder crankcase (12). Refer to Figure 4 .
▲ Attention! When lifting the main bearing cap, make sure that it
does not become tilted!
4. Remove the tommy bars (021.153-18) from the bore holes (4).
5. Screw the nuts (13) onto the main bearing bolts (14) until they con-
tact the main bearing cap (8), and tighten them, hand-tight. Refer to
Figure 3 .
6. Remove the complete lifting/lowering device (021.153).
7. Remove the fastening for the locating bearing ring (7).
8. Coat the screw-in thread of the cross tierods (11) with MoS2 lubricant,
and screw them into the main bearing cap (8), hand-tight, down to
contact.
9. Slip new O-ring seals (17) and rings (16) over the cross tierods (11).
Screw the nuts (10) on, hand-tight, until they are seated.
10. Tighten the main bearing bolts (14) and cross tierods (11) - see Work
012.03.
Card 012.03
11. Screw down the nuts of the cross tierods of the neighbouring main
bearing, hand-tight. Tighten the cross tierods of the neighbouring
012.02).
main bearing (see Work Card 012.02

6701 021.02--01 E 06.05 L 40/54 104/ 12

 12. Using the thickness gauges (000.454), check the main bearing clear-
ance, inserting the thickness gauges approx. 10 mm deep from the
coupling end and free engine end.
000.10), and enter
13. Measure the crank web deflection (see Work Card 000.10
the measured values in the engine log book.
14. Install the temperature sensor (30) into the main bearing cap (8).
Important! In case clamps serving for fastening the temperature
sensor lines in place have been removed, the hexagon bolts used for refit-
ting them have to be secured by Loctite 243 securing compound.
15. Remove the foot board (011.006) from the oil sump (15).
▲ Attention! Regarding running-in of new bearing shells, please
refer to the running-in instructions in Volume B1/Operating Instruc-
tions!

6701 021.02--01 E 06.05 L 40/54 105/ 12

 6 Crankshaft 11 Cross tierod 16 Ring
7 Locating bearing ring 12 Cylinder crankcase 17 O-ring seal
8 Main bearing cap 13 Nut 30 Temperature sensor
9 Crankshaft gearwheel 14 Main bearing bolt
10 Nut 15 Oil sump ST Control side

Figure 1. Main bearing (outer bearing)

6701 021.02--01 E 06.05 L 40/54 106/ 12

 1-5 Bore hole in the guide tube ST Control side
14 Main bearing bolt

Figure 2. Main bearing (outer bearing) and attached lifting/lowering device

6701 021.02--01 E 06.05 L 40/54 107/ 12

 8 Main bearing cap 19 Hexagon bolt M12x16
12 Cylinder crankcase
15 Oil sump ST Control side
18 Hexagon bolt M20x35

Figure 3. Main bearing (outer bearing) and attached lifting/lowering device

6701 021.02--01 E 06.05 L 40/54 108/ 12

 13 Nut ST Control side
14 Main bearing

Figure 4. Main bearing (outer bearing) and attached lifting/lowering device

6701 021.02--01 E 06.05 L 40/54 109/ 12

 8 Main bearing cap ST Control side
21 Lower bearing shell
22 Locating piece

Figure 5. Main bearing (outer bearing) and attached lifting/lowering device

6701 021.02--01 E 06.05 L 40/54 110 / 12

 6 Crankshaft
12 Cylinder crankcase
23 Upper bearing shell
24 O-ring seal

ST Control side
I - II Steps

Figure 6. Main bearing (outer bearing) - Removal of the upper bearing shell

6701 021.02--01 E 06.05 L 40/54 111 / 12

 6 Crankshaft C Groove for bearing shell fixation
12 Cylinder crankcase ST Control side
23 Upper bearing shell I - III Steps
24 O-ring seal

Figure 7. Main bearing (outer bearing) - Installation of the upper bearing shell

6701 021.02--01 E 06.05 L 40/54 112 / 12

Main thrust bearing
Measuring axial clearance/
checking locating bearing rings 021.03

Purpose of jobs to be done

Carry out work in time according to maintenance schedule,

measure components,
assess contact pattern/wear.

Brief description

The axial clearance as well as the locating bearing rings are to be checked
at regular intervals.
Carry out work in time according to maintenance schedule,
measure components,
assess contact pattern/wear.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.306 Standard
2 Hydraulic cylinder 009.075 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hammer -- Inventory
1 Wooden wedge -- Inventory
1 Dial gauge with retainer -- Inventory

Related work cards

Work card Work card Work card

000.33 009.03 009.05

Technical details

Term Information
Checking dimension (A) 1 mm

6701 021.03--01 E 02.02 L 40/54 101/ 03

Operating sequence 1 -- Measuring the axial clearance of the crankshaft

Starting condition Crankcase window opened in the area of the camshaft drive and on two
cylinders.

Steps 1. Place two hyraulic cylinders (009.075) between crankcase wall and
balance weight so as to be able to move crankshaft (4) axially in one
direction.
▲ Attention! Hydraulic cylinders must be placed onto different cyl-
inders!
2. Connect high-pressure hoses (009.306) to hydraulic cylinders and
high-pressure pump (009.338).
009.03) and move
3. Switch on the high-pressure pump (see Work Card 009.03
the crankshaft, cautiously proportioning the amount of pressure ap-
plied, until contact is established.
▲ Attention! The pressure may not exceed 500 bar! Reduce pres-
sure when reaching end position!
4. Place dial gauge at the coupling flange or some other accessible
position and set it to “ZERO”.
5. Release pressure.
6. Relocate the hydraulic cylinder.
7. Switch on high-pressure pump and move the crankshaft into opposite
direction until contact is established, cautiously proportioning the
amount of pressure applied.
▲ Attention! The pressure may not exceed 500 bar! Reduce pres-
sure when reaching end position!
8. Read the distance covered by the displacement from the dial gauge.
9. Note down the axial clearance and compare it with the admissible
clearance (see Volume B1). Record axial clearance in engine operat-
ing log.
Important! If the admissible clearance is exceeded, remove the
crankshaft locating bearing rings (2), check and replace them, if necessary
(see operating sequence 2).
10. Release pressure and remove hydraulic cylinders, magnetic stand
and dial gauge.

Operating sequence 2 -- Removing and installing the locating bearing rings

Important! Assessment of the condition of the locating bearing rings

(2) can only be made when dismantled, by evaluating the running surface
appearance.

Steps 1. Detach one ledge (8) per locating bearing ring.

2. Using two wooden wedges, fix crankshaft (4) axially so that locating
bearing rings (2) are free.
3. Turn out both of the locating bearing rings in direction of rotation. Do
not turn crankshaft while performing this work.
4. Carefully clean the locating bearing rings. Do not damage them while
performing this work.
5. Check the condition of the locating bearing rings.
6. Prior to installation, slightly oil the locating bearing rings.
7. Turn the locating bearing rings in, placing them onto the crankshaft.

6701 021.03--01 E 02.02 L 40/54 102/ 03

 8. Attach ledge (8), in doing so, watch checking dimension A on both
sides. When screwing the hexagon bolt (9) in, do not forget lock
washer (10).
9. Remove both of the wooden wedges.
10. Measure the axial clearance (refer to operating sequence 1) and re-
cord it in the engine operation log.

1 Cylinder crankcase 6 Ledge 10 Spring pin

2 Locating bearing ring 7 Hexagon bolt
3 Crankshaft gearwheel 8 Lock washer A Checking dimension
4 Crankshaft 9 Main bearing cap
5 Main bearing cap (external bearing)

Figure 1. Main bearing with locating bearing

6701 021.03--01 E 02.02 L 40/54 103/ 03

Torsional vibration damper

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

6682 027--06 E 07.99 101/ 01

Torsional vibration damper
Checking 027.01

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

Torsional vibration dampers and their sleeve spring assemblies are to be

checked at regular intervals. Signs of wear should be recognised in time,
and parts affected should be replaced.
The work/steps include:
Dismounting components,
checking components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 027.029 Standard
2 Support 027.029--1 Standard
1 Plate (with bolt) 027.029--5 Standard
1 Butt strap (with bolt) 027.029--15 Standard
1 Driving mandrel 027.026 Standard
1 Removing tool 027.024 Standard
1 Clamp 027.014 Standard
1 Torque wrench 750--2000 Nm 008.005 Standard
1 Shackle A1.0 002.453 Standard
1 Shackle A0.6 002.452 Standard
1 Extension piece 25x200 001.915 Standard
1 Socket wrench insert 46x25 001.785 Standard
1 Inpact ring spanner 60 000.732 Standard
1 Lifting eye bolt M20 000.155 Standard
1 Lifting eye bolt M10 000.141 Standard
1 Power amplifier -- Standard
1 Open--jaw and ring wrenches (set) -- Standard

6701 027.01--02 E 02.02 L 40/54 101/ 11

 Qty Designation No. Availability
1 Inpact ring spanner 46 -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Hammer -- Inventory
1 Lifting tackle with rope -- Inventory
1 Marking pencil -- Inventory
1 Depth gauge -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory
1 Securing compound -- Inventory
(Loctite 243)

Related work cards

Work card Work card Work card

000.19 000.30 000.31
000.32

Technical details

Term Information
Bolt projection (A) 66 mm
Cover 30 kg
Side disc, two--part 480 kg
Gearwheel 240 kg

Operating sequence 1 -- Checking the torsional vibration damper

Important! Check the torsional vibration damper at the intervals

specified in the maintenance schedule and on the occasion of major en-
gine overhaul work.
Hard pounding noises during operation are an indication of broken sleeve
springs.

Starting condition The attached pumps and covering on the free end, as well as the crank-
case covering in the vicinity of the torsional vibration damper have been
removed. The torsional vibration damper is accessible.

Steps 1. Screw the lifting eye bolt (000.141) into the cover (9).
2. Attach the rope (27) to the lifting eye bolt by means of the shackle
(002.452) and suspend the rope from the lifting tackle. Tighten the
rope.
3. Unscrew the hexagon socket bolts (7); remove the cover (9).
4. Remove the tool.
5. Fasten the supports (027.029-1) to the cylinder crankcase (1). Refer
to Figure 2 .
6. Mark/note down the number and arrangement of the studs (6).
7. Loosen the nuts (5); unscrew the nuts (5 and 18), and remove the
studs (6).

6701 027.01--02 E 02.02 L 40/54 102/ 11

 8. Slide the bolt (25) of the butt strap (027.029-15) into the bore hole,
and fasten the butt strap to the supports. Refer to Figure 3 .
9. Swivel the butt strap (24) back. Refer to Figure 3 .
10. Screw two hexagon bolts (26) diagonally into the gearwheel (11).
11. Unscrew two hexagon socket bolts (20).
12. Loosen the gearwheel (11) with the hexagon bolts (26), and pull it
forward. Refer to Figure 4 .
13. Swivel the butt strap (24) back, and tighten the hexagon bolt (23),
hand-tight. Refer to Figure 4 .
▲ Attention! The butt strap serves to secure the gearwheel in order
to avoid that the gearwheel slips off the bolt during transport!
14. Attach the rope (27) to the butt strap by means of the shackle
(002.453), and suspend the rope from the lifting tackle. Tighten the
rope. Refer to Figure 4 .
15. Unscrew the hexagon bolts (26).
16. Screw out the hexagon bolts (22); haul the gearwheel (11) out of the
way, and put it down onto a support.
17. Remove the shackle together with the rope.
18. Mark the position of the damper mass (14)/side disc (12).
19. Loosen the hexagon nuts (15).
▲ Attention! Only loosen the hexagon nuts, do not screw the off!
20. Unscrew two hexagon nuts (15), and remove both of the hexagon
bolts (13).
21. Insert the bolts (28) of the plate (027.029-5) into the bore holes, and
fasten the plate to the supports. Refer to Figure 6 .
22. Screw two hexagon bolts (26) into the side-disc half.
23. Unscrew four hexagon nuts (15), and remove the hexagon bolts (13).
Refer to Figure 7 .
24. Loosen the side-disc half with the hexagon bolts (26), and pull the
side disc forward. Refer to Figure 7 .
25. Screw the lifting eye bolt (000.155) into the side-disc half.
26. Attach the rope (27) to the lifting eye bolt by means of the shackle
(002.453), and suspend the rope from the lifting tackle. Tighten the
rope. Refer to Figure 8 .
27. Unscrew the hexagon bolts (26).
28. Screw out the hexagon bolts (22), remove the plate, and put the side-
disc half down onto a support.
29. Remove the tool.
30. Turn the torsional vibration damper by 180ƒ .
31. Dismantle the second side-disc half the same way (items 20 to 29).
32. Remove the sleeve spring assemblies (2) by means of the removing
tool (027.024). Refer to Figure 10 .
Important! Never remove all sleeve spring assemblies at the same
time, i.e., in every second bore hole, the sleeve spring assemblies remain
installed.
During installation, make sure that the sleeve spring assemblies are in-
stalled in the same bore hole from which they were removed.
33. Clean the sleeve spring assemblies using liquid cleanser. After-
wards, check them, replacing them if necessary.
Important! If springs are found broken, always replace the complete
sleeve spring assembly.
34. Purge the oil bore in the damper support (8) and in the stop piece (4)
using compressed air.
35. Coat the springs of a sleeve spring assembly (2) with clean lubricat-
ing oil individually.
36. Compress the sleeve spring assembly by means of the clamp
(027.014), and insert it into the bore hole. Refer to Figure 11 .

6701 027.01--02 E 02.02 L 40/54 103/ 11

 37. Loosen the clamp, and drive the sleeve spring assembly all the way
in using the driving mandrel (027.026). Refer to Figure 11 .
Important! Pay attention to the number of sleeve spring assemblies
inserted into one bore hole.
38. Remove, check and reinstall the sleeve spring assemblies of the re-
maining bore holes the same way (items 32 to 37).
39. Thoroughly clean the admission bore in the crankshaft (17).
40. Clean the contact faces between the side disc (12) and torsional
vibration damper, as well as between the damper support (8) and the
gearwheel (11).
41. Screw the lifting eye bolt (000.155) into the side-disc half. Attach the
rope (27) to the lifting eye bolt by means of the shackle (002.453),
and suspend the rope from the lifting tackle. Lift the side-disc half.
Refer to Figure 9 .
▲ Attention! Attach the side-disc half so as to ensure that, during
the further course of the fitting procedure, the marking on the side-
disc half (item 18) coincides with the marking on the damper mass.
Turn the torsional vibration damper into the correct position if
necessary!
42. Slip the bolts (28) of the plate (027.029-5) through the bore holes in
the side-disc half, and insert them into the bore holes on the torsional
vibration damper. Fasten the plate to the supports. Refer to Fig-
ure 8 .
43. Remove the shackle together with the rope, unscrew the lifting eye
bolt.
44. Attach the side-disc half to the torsional vibration damper. Refer to
Figure 6 .
▲ Attention! Verify that the markings (item 18) affixed between the
side-disc half and the damper mass coincide!
45. Insert the hexagon bolts (13) into the bore holes. Coat the threads
and seating faces of the hexagon nuts (15) with MoS2 lubricant,
screw the nuts on and tighten them, hand-tight. Refer to Figure 1 .
46. Remove the plate.
47. Insert the remaining two hexagon bolts (13) into the bore holes. Coat
the threads and seating faces of the hexagon nuts (15) with MoS2
lubricant, screw the nuts on and tighten them, hand-tight.
48. Turn the torsional vibration damper by 180ƒ .
49. Fit the second side-disc half the same way (items 41 to 47).
50. Tighten the hexagon nuts (15) crosswise to the specified torque (see
000.30).
Work Card 000.30
51. Tighten the hexagon nuts (15) crosswise applying the specified angle
of torsion (see Work Card 000.30).
000.30
52. Attach the rope (27) to the butt strap (027.029-15) by means of the
shackle (002.453), and suspend the rope from the lifting tackle. Lift
the gearwheel. Refer to Figure 5 .
▲ Attention! Verify that the gearwheel has been secured against
sliding down, using the bow!
53. Slip the bolt (25) of the butt strap (027.029-15) into the bore hole on
the torsional vibration damper, and fasten the butt strap to the sup-
ports, slightly turning the torsional vibration damper if necessary.
Refer to Figure 4 .
54. Loosen the hexagon bolt (23), and swivel back the bow (24). Refer
to Figure 3 .
55. Coat the threads and seating faces of the hexagon socket bolts (20)
with Loctite 243 securing compound, and tighten the bolts, hand-tight.
56. Remove the complete tool.

6701 027.01--02 E 02.02 L 40/54 104/ 11

 57. Insert the studs (6) in the bore holes. Coat the threads and seating
faces of the nuts (5 and 18) with MoS2 lubricant; screw the nuts on.
Refer to Figure 2 .
▲ Attention! Pay attention to the correct number and arrangement
of the studs (item 6)!
58. Adjust the bolt projection (A) of all studs (6). Screw the nuts (18)
down, hand-tight.
59. Tighten the nuts (5) crosswise to the specified torque (see Work Card
000.30).
000.30
60. Tighten the nuts (5) crosswise applying the specified angle of torsion
000.30).
(see Work Card 000.30
61. Clean the contact faces between cover (9) and damper support (8).
62. Screw the lifting eye bolt (000.141) into the cover (9). Attach the
rope (23) to the lifting eye bolt by means of shackle (002.452), and
suspend the rope from the lifting tackle.
63. Fit the cover (9). Coat the threads and seating faces of the hexagon
socket bolts (7) with Loctite 243 securing compound; screw the bolts
in and tighten them.
64. Remove the tool.
65. Fit the crankcase covering in the vicinity of the torsional vibration
damper and the covering on the free end, as well as pumps which
had previously been fitted.

Operating sequence 2 -- Removal of the torsional vibration damper

The torsional vibration damper need not be removed for any maintenance
work. In case of any damage, it is recommended to have repair work per-
formed by MAN B&W personnel, as a special tool is required for dismount-
ing the torsional vibration damper.

6701 027.01--02 E 02.02 L 40/54 105/ 11

 1 Cylinder crankcase 9 Cover 17 Crankshaft
2 Sleeve spring assembly 10 Hexagon socket bolt 18 Nut
3 Hexagon bolt 11 Gearwheel 19 Hexagon bolt
4 Stop piece 12 Side disc, two-part 20 Hexagon socket bolt
5 Nut 13 Hexagon bolt
6 Stud 14 Damper mass A Bolt projection
7 Hexagon socket bolt 15 Hexagon nut
8 Damper support 16 Side disc

Figure 1. Torsional vibration damper

6701 027.01--02 E 02.02 L 40/54 106/ 11

 1 Cylinder crankcase 11 Gearwheel
5 Nut 18 Nut
6 Stud 21 Hexagon bolt M16x35

Figure 2. Torsional vibration damper (Removal of the gearwheel)

8 Damper support 23 Hexagon bolt M12x40

11 Gearwheel 24 Bow
20 Hexagon socket bolt 25 Bolt
22 Hexagon bolt M16x35 26 Hexagon bolt M16x95

Figure 3. Torsional vibration damper (Removal of the gearwheel)

6701 027.01--02 E 02.02 L 40/54 107/ 11

 8 Damper support 24 Bow
11 Gearwheel 25 Bolt
22 Hexagon bolt M16x35 26 Hexagon bolt M16x95
23 Hexagon bolt M12x40 27 Rope

Figure 4. Torsional vibration damper (Removal of the gearwheel)

8 Damper support
11 Gearwheel
23 Hexagon bolt M12x40
24 Bow
25 Bolt
27 Rope

Figure 5. Torsional vibration damper (removal of the gearwheel)

6701 027.01--02 E 02.02 L 40/54 108/ 11

 12 Side disc, two-part 22 Hexagon bolt M16x35
13 Hexagon bolt 26 Hexagon bolt M16x95
15 Hexagon nut 28 Bolt

Figure 6. Torsional vibration damper (removal of a side-disc half)

11 Side disc, two-part 28 Bolt

Figure 7. Torsional vibration damper (removal of a side-disc half)

6701 027.01--02 E 02.02 L 40/54 109/ 11

 11 Side disc, two-part
22 Hexagon bolt M16x35
26 Hexagon bolt M16x95
27 Rope

Figure 8. Torsional vibration damper (removal of a side-disc half)

11 Side disc, two-part

27 Rope

Figure 9. Torsional vibration damper (removal of a side-disc half)

6701 027.01--02 E 02.02 L 40/54 110 / 11

 2 Sleeve spring assem-
bly

I-II Steps

Figure 10. Torsional vibration damper (removal of a sleeve spring assembly)

2 Sleeve spring assem-

bly

Figure 11. Torsional vibration damper (installation of a sleeve spring assembly)

6701 027.01--02 E 02.02 L 40/54 111 / 11

Torsional vibration damper
of the camshaft
Checking 027.02

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

Torsional vibration dampers and their sleeve spring assemblies are to be

checked at regular intervals. Signs of wear should be recognised in time,
and damaged parts should be replaced.
The work includes:
checking components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Driving mandrel 027.015 Standard
1 Clamp 027.013 Standard
1 Dismantling tool 027.012 Standard
1 Eye bolt 000.028 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lubricating oil, clean -- Inventory

Technical details

Term Information
Covering disc 8 kg
Side disc 30 kg

6701 027.02--02 E 05.03 L 40/54 101/ 03

Operating sequence 1 -- Checking the torsional vibration damper

Important! The torsional vibration damper is to be checked at the

intervals specified in the maintenance schedule and when major overhaul
work is done on the engine.

Pounding during operation indicates that sleeve springs are broken.

Starting condition The cover of the camshaft covering has been removed.

Steps 1. Remove the covering disc (4).

2. Unscrew the hexagon bolts (8), take off the side disc (7) and remove
it.
3. Pull the stroke-limiting bolt (2) out by means of the eye bolt
(000.028).
4. Pull the sleeve spring assembly (1) out using the dismantling tool
(027.012). Refer to Figure 2 .
5. Clean the sleeve spring assembly (1) with liquid cleaner, and check it
afterwards.
Important! If springs are broken, always replace the entire sleeve
spring assembly.
6. Clean the stroke-limiting bolt (2) and check it.
7. Thoroughly clean the oil bore in the damper support (6).
8. Coat the springs of the sleeve spring assembly with clean lubricating
oil individually.
9. Compress the sleeve spring assembly (1) by means of the clamp
(027.013), and insert it into the bore hole. Loosen the clamp, and
press the sleeve spring assembly all the way in using the driving
mandrel (027.015). Refer to Figure 3 .
10. Coat the stroke-limiting bolt (2) with clean lubricating oil, and install it.
11. Check the other sleeve spring assemblies in the same way (refer to
items 3 to 10).
12. Thoroughly clean the oil supply bore in the camshaft (3).
13. Attach the side disc (7) to the torsional vibration damper; screw the
hexagon bolts (8) in and tighten them.
▲ Attention! When fitting the side disc, make sure that the marking
(U, unhardened side) is located on the outside!
14. Attach the covering disc (4) to the torsional vibration damper; screw
the hexagon bolts (5) in and tighten them.

Operating sequence 2 -- Removal of the torsional vibration damper

Removal of the torsional vibration damper is not necessary for any main-
tenance work. In case any damage occurs, we recommend entrusting
MAN B&W personnel with the repair work, as a special tool is required for
the removal of the torsional vibration damper.

6701 027.02--02 E 05.03 L 40/54 102/ 03

 1 Sleeve spring assem-
bly
2 Stroke-limiting bolt
3 Camshaft
4 Covering disc
5 Hexagon bolt
6 Damper support
7 Side disc
8 Hexagon bolt
9 Damper mass
10 Hexagon socket bolt
11 Side disc

Figure 1. Torsional vibration damper on the camshaft

1 Sleeve spring assem-

bly

Figure 2. Removal of a sleeve spring assembly

1 Sleeve spring assem-

bly

Figure 3. Installation of a sleeve spring assembly

6701 027.02--02 E 05.03 L 40/54 103/ 03

Connecting rod/Big end bearing

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

6682 030--06 E 07.99 101/ 01

Con-- rod shank bolts
Loosening and tightening 030.01

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Conrod shank bolts must be loosened as part of maintenance work.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Measuring device 030.201 Standard
1 Gauge mandrel 030.201--1 Standard
1 Tightening device 030.194 Standard
1 Spanner 030.194--1 Standard
1 Clamping piece 030.194--6 Standard
2 Support 030.194--14 Standard
1 Torque wrench 008.017 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Angular screw driver 000.445 Standard
1 Open--jaw and ring wrenches (set) -- Standard

Related work cards

Work card Work card Work card

000.30

6701 030.01--01 E 02.00 L 40/54 101/ 04

 1-8 Tightening sequence
9 Balance weight
10 Con-rod big end
11 Con-rod shank bolt
12 Hexagon socket-head
screw, M8x75
13 Hexagon-head screw,
M16x20
14 Con-rod shank

Figure 1. Connecting rod with tool attached

Operating Sequence 1 -- Loosening the con-rod shank bolts

Starting condition Crankcase is opened, and running gear of cylinder concerned is at BDC.

Steps 1. Mount the clamping piece (030.194-6) loosely on the con-rod shank
(14) – see Figure 1 .
2. Place the wrench extension tube [“spanner”] (030.194-1) on a con-
rod shank bolt (11), align the clamping piece, and clamp it tight.
Remove the extension tube.
3. Fasten two supports (030.194-14) between balance weights (9).
▲ Attention! The running gear must not be turned after the supports
have been mounted!
4. Put the wrench extension tube (030.194-1) and torque wrench
(008.017) onto a con-rod shank bolt.
5. Loosen the con-rod shank bolt.
▲ Attention! Only loosen, do not unscrew the con-rod shank bolt!
6.

6701 030.01--01 E 02.00 L 40/54 102/ 04

 7. Remove the torque wrench and extension tube, and put them onto
the next con-rod shank bolt.
8. Loosen all the con-rod shank bolts in the same way.
9. Remove the tools.

Operating Sequence 2 -- Tightening the con-rod shank bolts

Starting condition Con-rod big end placed on con-rod shank; threads and bearing surfaces of
the con-rod bolts coated with MoS2 lubricant, and bolts screwed in all the way
hand-tight; running gear at TDC.

Steps 1. Check that the gap between the con-rod shank (14) and the big end
(10) is smaller than 0.05 mm over the entire circumference.
2. Clamp the feeler [“gauge mandrel”] (030.202-1) into the dial indicator
measuring device (030.202), and set the scale of the dial gauge (16)
to zero. Remove the feeler again.
3. Mount the dial indicator in the centre holes of a con-rod shank bolt
(11) – see Figure 2 .
Take the reading from the dial gauge, and note it down.
Tip! We recommend keeping a separate test record for the tightening
of the con-rod shank bolts.
4. Measure all the other con-rod shank bolts in the same way, and note
down the readings – see Item 3.
5. Mount the clamping piece (030.194-6) loosely on the con-rod shank –
see Figure 1 .
6. Place the extension tube (030.194-1) on a con-rod shank bolt, align
the clamping piece, and clamp it. Remove the extension tube again.
7. Fasten two supports (030.194-14) between balance weights (9).
▲ Attention! The running gear must not be turned after the supports
have been attached!
8. Stick the extension tube (030.194-1) and the torque wrench
(008.017) onto the first con-rod shank bolt.
Tightening sequence: 2 - 6 - 3 - 7 - 4 - 8 - 1 - 5.
9. Tighten the first con-rod shank bolt with the specified preliminary
torque (see Work Card 000.30).
000.30
10. Remove the torque wrench and extension tube, and place them on
the next con-rod shank bolt.
11. Tighten all the con-rod shank bolts with the specified preliminary
torque in the same way.
12. Shift the torque wrench and the extension tube to the first con-rod
shank bolt again.
Tightening sequence: 2 - 6 - 3 - 7 - 4 - 8 - 1 - 5.
13. Tighten the con-rod shank bolt with the specified final torque (see
000.30).
Work Card 000.30
14. Remove the torque wrench and extension tube, and place them on
the next con-rod shank bolt.
15. Tighten all the con-rod shank bolts with the specified final torque in
the same way.
16. Remove the tools.
17. Clamp the feeler [“gauge mandrel”] (030.202-1) into the dial indicator
measuring device (030.202), and set the scale of the dial gauge (16)
to zero. Remove the feeler again.
18. Mount the dial indicator in the centre holes of a con-rod shank bolt
(11) – see Figure 2 .
Take the reading from the dial gauge, and note it down.
19. Measure all the other con-rod shank bolts in the same way, and note
down the readings – see Item 18.
20. Calculate the differences for the individual con-rod shank bolts from
the readings of Items 3--4 and 18--19.

6701 030.01--01 E 02.00 L 40/54 103/ 04

 Important! These differences are the elongation values of the indi-
vidual con-rod shank bolts.
21. Compare the elongations Dl of the individual con-rod shank bolts
000.30).
with the desired value (see Work Card 000.30
▲ Attention! The con-rod shank bolts must be tightened with the
specified torque! Retighten any con-rod shank bolts whose
measured elongation Dl is less than the minimum specified value
000.30) to a value within the specified range of
(see Work Card 000.30
desired values.

10 Big end
11 Con-rod shank bolt
14 Con-rod shank
15 Piston
16 Dial gauge

Figure 2. Con-rod shank bolt with dial indicator mounted

6701 030.01--01 E 02.00 L 40/54 104/ 04

Big-- end bearing bolts
Checking, untightening and tightening 030.02

Purpose of jobs to be done

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

ensure operational reliability of bolted connections.

Brief description

Big--end bearing bolts are to be checked at regular intervals using

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

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Foot board (for oil sump) 011.006 Standard
1 Foot board (for oil sump) 011.002 Standard
1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.306 Standard
1 Sliding caliper 009.060 Standard
2 Thrust pad 009.055 Standard
2 Hydraulic tensioning tool 009.053 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar, 8 mm 000.262 Standard

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.13
030.03

6701 030.02--01 E 10.01 L 40/54 101/ 05

 1 Big-end bearing cap
2 Big-end bearing bolt
3 Nut

Figure 1. Connecting rod

Operating sequence 1 -- Checking the big-end bearing bolts

Starting condition Crankcase has been opened, running gear of the respective cylinder is in
TDC position.

Steps 1. Place foot board (011.002 for reinforced oil sump or 011.006 for
standard oil sump) in the oil sump.
2. Clean the thread of the big-end bearing bolts (2).
3. Slip the thrust pads (009.055) over the nuts (3), and screw the hy-
draulic tensioning tools (009.053) onto the big-end bearing bolts,
making sure that the thrust pads are centred by the hydraulic tension-
ing tools. Refer to Figures 2 and 3 .
4. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
5. Connect the high-pressure hoses (009.306) to hydraulic tensioning
tools and high-pressure pump (009.338).
009.03), and
6. Switch on the high-pressure pump (see Work Card 009.03
close the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the big-end bearing bolts!
7. Pump up the hydraulic tensioning tool until the nuts can be loosened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see Work Card 000.30)!
000.30

▲▲ Caution! During pumping, watch the stroke gauge (4) of the hy-
draulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (5)! Otherwise, the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the tensioning
pressure.
8. Adjust the high-pressure pump to the specified tensioning pressure
000.30).
(see Work Card 000.30
9. Using the tommy bar (000.262), screw down both nuts through the
opening in the thrust pads, hand-tight.

6701 030.02--01 E 10.01 L 40/54 102/ 05

 10. Release the pressure; disconnect the high-pressure hoses from hy-
draulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
11. Remove the tensioning tools.
12. Take the foot board out of the oil sump.

1 Big-end bearing cap

Figure 2. Big-end bearing bolts with tensioning tools attached

1 Big-end bearing cap

2 Big-end bearing bolt
3 Nut
4 Stroke gauge
5 Threaded stop ring

M Marking

Figure 3. Big-end bearing bolts with tensioning tools attached

6701 030.02--01 E 10.01 L 40/54 103/ 05

Operating sequence 2 -- Untensioning the big-end bearing bolts

Starting condition Crankcase has been opened, running gear of the respective cylinder is in
TDC position.

Steps 1. Place foot board (011.002 for reinforced oil sump or 011.006 for
standard oil sump) in the oil sump.
2. Clean the threads of the big-end bearing bolts (2).
3. Slip the thrust pads (009.055) over the nuts (3), and screw the hy-
draulic tensioning tools (009.053) onto the big-end bearing bolts,
making sure that the thrust pads are centred by the hydraulic tension-
ing tools. Refer to Figures 2 and 3 .
4. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
5. Connect the high-pressure hoses (009.306) to hydraulic tensioning
tools and high-pressure pump (009.338).
009.03), and
6. Switch on the high-pressure pump (see Work Card 009.03
close the gap produced by backing off.
▲▲▲ Danger! During untensioning, make sure that there is no one
along the extended axis of the big-end bearing bolt to be unten-
sioned!
7. Pump up the hydraulic tensioning tool until the nuts can be loosened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see Work Card 000.30)!
000.30

▲▲ Caution! During pumping, watch the stroke gauge (4) of the hy-
draulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (5)! Otherwise, the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the tensioning
pressure.
8. Using the tommy bar (000.262), screw down both nuts through the
opening in the thrust pads (for angle of back-off, see Work Card
000.30).
000.30
9. Release the pressure; disconnect the high-pressure hoses from hy-
draulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
10. Remove the tensioning tools.

Operating sequence 3 -- Tensioning the big-end bearing bolts

Starting condition Big-end bearing has been preassembled (see Work Card 030.03030.03). Run-
ning gear of the respective cylinder is in TDC position. Foot board has
been placed in the oil sump; threads of the big-end bearing bolts have
been cleaned.

▲ Attention! Correct tensioning of a bolted connection requires the

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

Steps 1. Verify that the parting line between big-end bearing cap (1) and con-
necting rod is equal on both sides.

6701 030.02--01 E 10.01 L 40/54 104/ 05

 2. Measure the length of both of the big-end bearing bolts (2) by means
of a sliding caliper (009.060), and note it down.
Important! The measured dimensions will be required as a basis for
determining the bolt elongation DI of the big-end bearing bolts after ten-
sioning.

Tip! It is recommended to prepare a separate measuring record for the

tensioning of the big-end bearing bolts.
3. Slip the thrust pads (009.055) over the nuts (3), and screw the hy-
draulic tensioning tools (009.053) onto the big-end bearing bolts,
making sure that the thrust pads are centred by the hydraulic tension-
ing tools. Refer to Figures 2 and 3 .
4. Connect the high-pressure hoses (009.306) to hydraulic tensioning
tools and high-pressure pump (009.338).
009.03), and ten-
5. Switch on the high-pressure pump (see Work Card 009.03
sion the big-end bearing bolts to the specified tensioning pressure
(see Work Card 000.30).
000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the axis of the big-end bearing bolts to be tensioned!

▲▲ Caution! During pumping, watch the stroke gauge (4) of the hy-
draulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (5)! Otherwise, the hydraulic
tensioning tools will be damaged!
6. Using the tommy bar (000.262), screw down both nuts through the
opening in the thrust pads, hand-tight.
7. Release the pressure; disconnect the high-pressure hoses from hy-
draulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
8. Remove the tensioning tools.
9. Measure the length of both of the big-end bearing bolts by means of
the sliding caliper, and not it down.
10. Determine the difference of the values measured under items 2
and 9.
Important! The differences are the elongation values of the individ-
ual big-end bearing bolts.
11. Compare the bolt elongation Dl of the individual big-end bearing bolts
000.30).
with the required value (see Work Card 000.30
▲ Attention! The big-end bearing bolts are to be tensioned to the
specified tensioning pressure, not according to bolt elongation Dl!
Measuring the bolt elongation Dl is only intended as a check!

Important! In the case of considerable deviations from the required

value, repeat the tensioning procedure. If neccesary, check the hydraulic
tensioning tools, the bolted connections, and the pressure gauges.
12. Remove the foot board from the oil sump.

6701 030.02--01 E 10.01 L 40/54 105/ 05

Big-- end bearing shell (lower)
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

Bearing shells must be checked at regular intervals. From the state of

wear and appearance of the bearing shell running surface, conclusions
can be drawn about the load conditions, lube oil care etc.
The work/steps include:
removing components,
checking the bearing shell and
fitting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 030.195 Standard
1 Rope guide 030.195--1 Standard
1 Rope guide 030.195--9 Standard
1 Wire rope 030.195--15 Standard
1 Rope clamp 030.195--26 Standard
2 Support 030.195--30 Standard
1 Guide tube 021.032 Standard
1 Sliding caliper 009.060 Standard
1 Ratchet hoist 002.552 Standard
2 Shackle A0.6 002.452 Standard
1 Thickness gauges 0.05--1 000.454 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Screw drivers (set) -- Standard
2 Wooden support -- Inventory

6701 030.03--01 E 03.02 L 40/54 101/ 09

Related work cards

Work card Work card Work card

000.11 030.02

Technical details

Term Information
Big--end bearing bolt with nut 15 kg
Big--end bearing cap 110 kg

Operating sequence 1 -- Removal of the lower big-end bearing shell

Starting condition The crankcase has been opened, the big-end bearing bolts of the
respective cylinder have been untensioned, the crank pin of the cylinder
concerned is in BDC position.

Steps 1. Fasten two supports (030.195-30) to the big-end bearing cap (2) and
connecting rod shank (7) using the hexagon bolts (9 and 10). Refer
to Figure 2 .
2. Turn the running gear until the crank pin is approx. 52.5ƒ before/after
BDC. Refer to Figure 3 .
3. Unscrew the nut (3), and remove the big-end bearing bolt (4) includ-
ing nut (6) in upward direction. Refer to Figure 3 .
4. Remove the second big-end bearing bolt in the same way (items 2
and 3). Refer to Figure 4 .
5. Turn the running gear until the crank pin is in BDC position.
6. Attach the rope guide (030.195-1) between the balance weights (8).
Refer to Figure 5 .
Important! The bolts of the rope guide have to be screwed into the
balance weights until they contact the latter.

▲▲▲ Danger! The running gear must not be turned after the rope
guide has been mounted!
7. Fasten the rope guide (030.195-9) to the balance weights (8) by
means of the hexagon bolts (11). Refer to Figure 5 .
▲ Attention! Fasten the rope guide to the balance weights so that
the rope guide can still be moved!
8. Attach the ratchet hoist (002.552) at an appropriate spot.
9. Place the wire rope (030.195-15) over the rope guides. Fasten the
rope ends to the supports by means of shackle (002.452).
10. Suspend the wire rope from the ratchet hoist, and fastem it in place
using the rope clamp (030.195-26). Tighten the rope. Refer to Fig-
ure 5 .
11. Place the wooden supports (14) under the big-end bearing cap (2) in
the oil sump (12).
12. Unscrew the hexagon bolts (9). Refer to Figure 6 .
13. Lower the big-end bearing cap (2) onto the wooden supports (14) by
actuating the ratchet hoist. Refer to Figure 7 .
14. Remove the big-end bearing shell (13).

6701 030.03--01 E 03.02 L 40/54 102/ 09

 15. Carefully clean the running surface of the big-end bearing shell (13);
do not damage it in the process.
16. Check the condition of the running surface (see Work Card 000.11).
000.11
▲▲ Caution! Do not rework the big-end bearing shell in any way!

▲ Attention! Replace big-end bearing shells that have been dam-

aged or heavily scored by dirt particles!
In case dirt scores are found on the big-end bearing shell, the crank
pin has to be checked and, if necessary, repolished (polishing cloth
with grain size <15mm)!

Operating sequence 2 -- Installation of the lower big-end bearing shell

▲ Attention! The new big-end bearing shells supplied are ready to

be fitted, scraping or any other touching up is not permitted!

Starting condition The crank pin of the respective cylinder is in BDC position, the big-end
bearing shell and the big-end bearing bolts has/have been cleaned.

Steps 1. Thoroughly oil the running surface of the big-end bearing shell (13) -
back of the big-end bearing shell to remain dry.
2. Insert the big-end bearing shell (13) into the big-end bearing cap (8).
▲ Attention! Take note of the position of the positioning pin (15) for
big-end bearing shell fixation! Refer to Figure 7 .
3. Lift the big-end bearing cap (8) by actuating the ratchet hoist
(002.552) until it contacts the connecting rod shank (7).
▲ Attention! When assembling the big-end bearing cap with the
connecting rod shank, pay attention to the positioning pins (5)!
Refer to Figure 1 .
4. Screw the hexagon bolts (9) through the supports (030.195-30) and
into the connecting rod shank (7), and tighten them. Refer to Fig-
ures 5 and 6 .
5. Remove the rope clamp (030.195-26) from the wire rope
(030.195-15), and detach it from the ratchet hoist.
6. Loosen the wire rope from the supports, and remove it.
7. Dismantle the ratchet hoist.
8. Remove the rope guides (030.195-1 and 030.195-9).
9. Take the wooden supports (14) out of the oil sump (12).
10. Turn the running gear until the crank pin is approx. 52.5ƒ before/after
TDC. Refer to Figure 3 .
11. Check the length of the big-end bearing bolt (4) using the sliding cali-
per (009.069).
▲ Attention! Permanent elongation of the big-end bearing bolt may
occur, due to irregular conditions! If the big-end bearing bolt be-
comes longer than 749.65 mm (in untensioned condition), the big-
end bearing bolt is to be replaced!
12. Install the big-end bearing bolt (4), including the nut (6), from above,
screwing the nut (3) all the way down, hand-tight. Refer to Fig-
ure 3 .
13. Install the second big-end bearing bolt the same way (items 10 to
12). Refer to Figure 4 .
14. Remove the supports (030.195-30).
15. Turn the running gear until the crank pin is in TDC position.
16. Tension the big-end bearing bolts (see Work Card 030.02).
030.02
17. Check the bearing clearance using the thickness gauges (000.454),
inserting the thickness gauges approx. 10 mm deep from the
coupling side and free engine end.

6701 030.03--01 E 03.02 L 40/54 103/ 09

 ▲ Attention! For running in new bearing shells, please refer to the
running-in instructions in Volume B1!

1 Crankshaft 5 Positioning pin ST Control side

2 Big-end bearing cap 6 Nut
3 Nut 7 Connecting rod shank
4 Big-end bearing bolt 8 Balance weight

Figure 1. Connecting rod

6701 030.03--01 E 03.02 L 40/54 104/ 09

 2 Big-end bearing cap 10 Hexagon bolt M16x25
7 Connecting rod shank
9 Hexagon bolt M16x25 ST Control side

Figure 2. Big-end bearing with supports attached

6701 030.03--01 E 03.02 L 40/54 105/ 09

 1 Crankshaft 4 Big-end bearing bolt ST Control side
2 Big-end bearing cap 6 Nut
3 Nut 7 Connecting rod shank

Figure 3. Removal/installation of the big-end bearing bolt (control side)

6701 030.03--01 E 03.02 L 40/54 106/ 09

 1 Crankshaft 4 Big-end bearing bolt ST Control side
2 Big-end bearing cap 6 Nut
3 Nut 7 Connecting rod shank

Figure 4. Removal/installation of the big-end bearing bolt (exhaust side)

6701 030.03--01 E 03.02 L 40/54 107/ 09

 8 Balance weight ST Control side
11 Hexagon bolt M16x25

Figure 5. Big-end bearing with completely attached fitting/unfitting tool

7 Connecting rod shank ST Control side

9 Hexagon bolt M16x25

Figure 6. Lowering/lifting the big-end bearing cap

6701 030.03--01 E 03.02 L 40/54 108/ 09

 2 Big-end bearing cap 12 Oil sump 15 Positioning pin
5 Positioning pin 13 Big-end bearing shell
7 Connecting rod shank 14 Wooden support ST Control side

Figure 7. Lowered big-end bearing cap (checking the big-end bearing shell)

6701 030.03--01 E 03.02 L 40/54 109/ 09

Big-- end bearing shell (upper)
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

Bearing shells must be checked at regular intervals. From the state of

wear and appearance of the bearing shell running surface, conclusions
can be drawn about the load conditions, lube oil care etc.
The work/steps include:
checking the bearing shell.

Safety requirements

- Engine secured against starting

- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

2 Supporting device 030.257 Standard
1 Strap 030.197 Standard
2 Support 030.192 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Screw drivers (set) -- Standard
1 Lifting tackle -- Inventory
1 Rope (nylon) -- Inventory

Related work cards

Work card Work card Work card

000.11 030.03

Operating sequence 1 -- Removal of the upper big-end bearing shell

Starting condition The crank pin of the respective cylinder is in BDC position.

Steps 1. Remove the rope clamp (030.195-26) from the wire rope
(030.195-15), and detach it from the ratchet hoist (002.552).

6701 030.04--01 E 03.02 L 40/54 101/ 09

 2. Loosen and remove the wire rope from the supports (030.195-30).
3. Remove the rope guides (030.195-1 and 030.195-9).
4. Fasten two supporting devices (030.192) to the connecting rod shank
(3). Refer to Figure 2 .
Important! The supporting devices serve to fix the big-end bearing
shell in place in the connecting rod shank.
5. Put the strap (030.197) around the crank pin, and fasten it to the con-
necting rod shank (3). Refer to Figure 2 .
Important! Mounting the strap secures the connecting rod shank
against slipping off the crank pin during turning.
6. Turn the running gear until the crank pin is approx. 60ƒ before/after
TDC.
7. Mount one supporting device (030.257) each on the coupling side
and free engine end of the cylinder liner (10). Refer to Figure 3 .
8. Carefully turn the piston (9) downwards until it rests on the supporting
devices. Refer to Figure 4 .
▲▲ Caution! Only turn the running gear until the piston rests on
the supporting devices!
9. Sling the nylon rope (12) around the connecting rod shank (3), and
suspend it from the lifting tackle. Fix the connecting rod shank in
place in this position. Refer to Figure 5 .
10. Remove the strap.
11. Turn the crank pin downwards, out of the connecting rod shank (3)
until the big-end bearing shell (4) is easily accessible. Refer to Fig-
ure 6 .
12. Hold the big-end bearing shell (4) in place by hand, and dismantle the
supporting devices. Take the big-end bearing shell out.
13. Carefully clean the running surface of the big-end bearing shell (4).
Do not damage it in the process.
14. Check the condition of the running surface (see Work Card 000.11).
000.11
▲▲ Caution! Do not rework the big-end bearing shell in any way!

▲ Attention! Replace big-end bearing shells that have been dam-

aged or heavily scored by dirt particles!
In case dirt scores are found on the big-end bearing shell, the crank
pin must be checked and, if necessary, repolished (polishing cloth
with grain size < 15mm)!

Operating sequence 2 -- Installation of the upper big-end bearing shell

▲ Attention! The new big-end bearing shells supplied are ready to

be fitted, scraping or any other touching up is not permitted!

Starting condition The crank pin has been turned out of the connecting rod shank, the big-
end bearing shell has been cleaned.

Steps 1. Thoroughly oil the running surface of the big-end bearing shell (4) -
back of the big-end bearing shell to remain dry.
2. Insert the big-end bearing shell (4) into the connecting rod shank (3).
Fasten two supporting devices (030.192) to the connecting rod
shank. Refer to Figure 6 .
Important! The supporting devices serve to fix the big-end bearing
shell in place in the connecting rod shank.

▲ Attention! Take note of the position of the positioning pin (13) for
big-end bearing shell fixation! Refer to Figure 6 .

6701 030.04--01 E 03.02 L 40/54 102/ 09

 3. Carefully turn the running gear until the crank pin contacts the con-
necting rod shank/big-end bearing shell (3/4). Refer to Figure 5 .
4. Put the strap (030.197) around the crank pin, and fasten it to the con-
necting rod shank. Refer to Figure 4 .
Important! Mounting the strap secures the connecting rod shank
against slipping off the crank pin during turning.
5. Remove the nylon rope (12).
6. Turn the running gear until the crank pin is approx. 60ƒ before/after
TDC. Refer to Figure 3 .
7. Remove the supporting devices (030.257).
8. Turn the running gear until the crank pin is in BDC position.
9. Remove the strap (030.197) and the supporting devices (030.192).
10. Attach the rope guide (030.195-1) between the balance weights (1).
Refer to Figure 1 .
Important! The bolts of the rope guide have to be screwed into the
balance weights so that they contact the latter.

▲▲▲ Danger! The running gear must not be turned after the rope
guide has been mounted!
11. Attach the rope guide (030.195-9) to the balance weights (1) by
means of hexagon bolts (2). Refer to Figure 1 .
▲ Attention! Fasten the rope guide to the balance weights so that
the rope guide can still be moved!
12. Place the wire rope (030.195-15) over the rope guides. Fasten the
rope ends to the supports (030.195-30) by means of shackle
(002.452). Refer to Figure 1 .
13. Suspend the wire rope from the ratchet hoist (002.552), and secure it
using the rope clamp (030.195-26). Tighten the wire rope. Refer to
Figure 1 .
▲ Attention! For running in new bearing shells, please refer to the
running-in instructions in Volume B1!

6701 030.04--01 E 03.02 L 40/54 103/ 09

 1 Balance weight 3 Connecting rod shank 6 Cylinder crankcase
2 Hexagon bolt M16x25 4 Big-end bearing shell
5 Crankshaft ST Control side

Figure 1. Lowered big-end bearing cap

6701 030.04--01 E 03.02 L 40/54 104/ 09

 3 Connecting rod shank 8 Hexagon bolt M16x25
5 Crankshaft
7 Hexagon bolt M10x20 ST Control side

Figure 2. Securing the connecting rod shank and the big-end bearing shell

6701 030.04--01 E 03.02 L 40/54 105/ 09

 3 Connecting rod shank 10 Cylinder liner ST Control side
5 Crankshaft 11 Hexagon bolt M12x45
9 Piston

Figure 3. Fastening the supporting device to the cylinder liner

6701 030.04--01 E 03.02 L 40/54 106/ 09

 3 Connecting rod shank 10 Cylinder liner
5 Crankshaft
8 Hexagon bolt M16x25 ST Control side
9 Piston

Figure 4. Lowering the piston onto the supporting device

6701 030.04--01 E 03.02 L 40/54 107/ 09

 3 Connecting rod shank ST Control side
5 Crankshaft
12 Nylon rope

Figure 5. Connecting rod shank fixed in place

6701 030.04--01 E 03.02 L 40/54 108/ 09

 3 Connecting rod shank 7 Hexagon bolt M10x20 ST Control side
4 Big-end bearing shell 12 Nylon rope
5 Crankshaft

Figure 6. Crank pin turned back (checking the big-end bearing shell)

6701 030.04--01 E 03.02 L 40/54 109/ 09

Piston/Piston rings/Top land ring

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

6682 034--06 E 07.99 101/ 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.

Safety requirements

- Engine shut--down
- Engine secured against starting
- Operating media system closed/depressurised

Tools/appliances required

Quant Denomination No. Availability

1 Fitting/unfitting tool 050.158 Standard
1 Support 050.158--1 Standard
3 Hexagon bolt 050.158--3 Standard
1 Angular screw driver 050.120 Standard
1 Tap wrench 034.098 Standard
1 Tapered sleeve for inserting the piston rings 034.093 Standard
1 Suspension device 034.081 Standard
1 Support 034.081--1 Standard
1 Tap 034.080 Standard
1 Pilot rod 034.006 Standard
1 Guide tube 030.198 Standard
1 Locating clamp 030.190 Standard
1 Support 030.190--1 Standard
1 Thrust pad 030.190--3 Standard
1 Foot board (for oil sump) 011.006 Standard
1 Foot board (for oil sump) 011.002 Standard
2 Shackle A1.0 002.453 Standard
1 Tommy bar 5 000.507 Standard
1 Thickness gauges 0.05--1 000.451 Standard

6621 034.01--03 E 06.98 L 40/54 101/ 09

 Quant Denomination No. Availability
1 Open--jaw and ring spanner (set) -- Standard
1 Grease (acid--free) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricant, clean -- Inventory

Related work cards

Work card Work card Work card

030.01 055.02

Technical details

Term Information
Piston with connecting rod big end 335 kg
Sealing ring 1.7 kg
Top land ring 60 kg

Operating sequence 1 -- Removal of the piston

▲ Attention! Prior to dismantling the piston, the top land ring (10) is
to be removed, since its diameter is smaller than that of the piston
(13).

Starting condition Cooling water completely drained.

▲ Attention! Do not discharge the cooling water into the bilge or

waste water. Instead, pump the water into a separate container for
further use (cooling water treatment agent).

Cylinder head dismantled, crankcase opened, piston at aprox. 60ƒ before/

after TDC.

Steps 1. Remove coke residues, if any, from the top land ring (10) and in the
upper area of the cylinder liner (12).
▲ Attention! Cover gap between piston (13) and cylinder liner to
avoid foreign particles from falling in between.
2. Clean three blind end bores at the inner diameter of the top land ring
and remove loose dirt particles on the piston upper side.
3. Place support (050.158-1) correctly on the top land ring. Refer to
Figure 1 .
Important! Make sure that the positioning pin (15) on the support is
inserted in bore (N) which is located on the backing ring (11).
4. Screw three hexagon bolts (050.158-3) into the blind end bores of the
top land ring, hand-tight.
5. Screw four hexagon bolts (7) into the support, hand-tight, until they
contact the the backing ring.
6. Screw pilot rod (034.006) into the support.

6621 034.01--03 E 06.98 L 40/54 102/ 09

 7. Attach rope (1) to the support by means of shackle (002.453) and
suspend the rope in the lifting tackle.
8. By evenly, alternately turning the hexagon bolts, pull the top land ring
out until it comes loose.
9. Cautiously pull the top land ring out in upward direction, guiding it by
means of the pilot rod.
10. Put top land ring onto a wooden support, remove the tool.
11. Loosen the sealing ring (8), for doing so, insert the angular screw
driver (050.120) into the groove on the outer diameter and lift the
sealing ring. Take the sealing ring out.
12. Turn the piston (13) to TDC.
13. Using the tap (034.080), clean the tap holes on the piston upper side.
14. Position the support (034.081-1) on the piston, screw two hexagon
bolts (16) into the piston until contact is established and brace the
support with the piston by means of the hexagon nuts (17). Refer to
Figure 2 .
15. Attach the rope (1) to the support by means of shackle (002.453).
16. Turn the piston exactly to BDC.
17. Suspend the rope in the lifting tackle.
▲ Attention! Secure the crankshaft against turning.
18. Deposit the foot board (011.002 in case of V-type oil sump and
011.006 in case of normal oil sump respectively) in the oil sump .
19. Loosen the conrod shank bolts (see work card 030.01),
030.01 however, do
not screw them out yet.
20. Slip the support (030.190-1) over the connecting rod shank (21) and
attach it to the balance weight (19). Place thrust pad (030.190-3) on
the support and fix the connecting rod shank to the balance weight by
turning the hexagon bolt (22). Refer to Figure 2 .
▲▲ Caution! Fixation of the connecting rod shaft to the balance
weight by means of locating bracket is only intended for stopped
engine or for turning the crankgear after the piston has been
removed.
In this condition, the engine must not be started!
21. Screw out conrod shank bolts.
22. Cautiously pull piston out of cylinder liner (12).
▲ Attention! Take care that the cylinder head bolts (6) are not
damaged during removal.
23. Deposit the piston on the wooden support.
24. Plug the lube oil bore in the connecting rod shank and the connecting
rod big end (18) to avoid penetration of dirt.
25. Cover the aperture at the cylinder liner.

6621 034.01--03 E 06.98 L 40/54 103/ 09

 5 Rope 10 Top land ring N Bore in the backing ring
6 Cylinder head bolt 11 Backing ring for the positioning pin
7 Hexagon bolt M20x2x140 12 Cylinder liner ST Control side
8 Sealing ring 13 Piston
9 O-ring seal 14 Crankcase
15 Positioning pin

Figure 1. Removal and installation of the top land ring

6621 034.01--03 E 06.98 L 40/54 104/ 09

 5 Rope 16 Hexagon bolt M16x80 20 Hexagon bolt M16x25
6 Cylinder head bolt 17 Hexagon nut M16 21 Connecting rod shank
11 Backing ring 18 Connecting rod big end 22 Hexagon bolt M12x25
12 Cylinder liner 19 Balance weight
13 Piston

Figure 2. Removal of the piston

6621 034.01--03 E 06.98 L 40/54 105/ 09

Operating sequence 2 -- Installation of the piston

Starting condition Piston cleaned, checked and overhauled, if necessary. Connecting rod big
end assembled with piston. Cylinder liner, top land ring as well as joint
face on connecting rod big end and connecting rod shank cleaned. Con-
necting rod shank attached to balance weight by means olf locating clamp
and turned exactly to BDC position. Foot board inserted in oil sump.

Steps 1. Remove the cover from the aperture on the cylinder liner.
2. Place the tapered sleeve for inserting the piston rings (034.093) on
the cylinder liner (12), apply an ample amount of oil to the inner
faces.
3. Position the support (034.081-1) on the piston (13), screw two
hexagon bolts (16) in until they contact the piston and brace the
support with the piston by means of the hexagon nuts (17).
4. Attach the rope (5) to the support by means of shackle (002.453) and
suspend the rope in the lifting tackle. Lift the piston.
5. Screw the guide tube (030.198) into the connecting rod big end (18)
until contact is established.
6. Oil piston rings and running face of the piston with clean lube oil.
7. Position the piston ring joints (1 to 4) towards the control side (ST).
Refer to Figure 3 .
8. Open the lube oil bore in the connecting rod big end and in the
connecting rod shank (21).
9. Move the piston over the cylinder liner by means of the lifting tackle.
10. Turn the piston in a way ensuring that the marking on the piston top
is directed to the control side.
11. Carefully lower the piston into the cylinder liner. Refer to Figure 4 .
Important! Guide the piston until the piston lower part slides into the
cylinder liner.

▲ Attention! When installing the piston make sure that the cylinder
head bolts (6) are not damaged.
12. Cautiously lower the piston further, while doing so, the piston rings
slide through the tapered sleeve for inserting the piston rings.
13. Check that the guide tube points towards the respective bore in the
connecting rod shank, slightly turn the piston if necessary.
14. Lower the piston until it contacts the connecting rod shank, paying
attention to the positioning pins (23) on the joint faces.
Tip! To facilitate the assembly of connecting rod big end and
connecting rod shank, slightly loosen the locating clamp (030.190).
15. Using the thickness gauge (000.451), check that parting line between
connecting rod big end and connecting rod shank is < 0.05 mm.
16. Apply MoS2 lubricant to the threads and head contact face of the
conrod shank bolts.
17. Screw four conrod shank bolts in, hand-tight. Unscrew the guide
tube and screw the remaining conrod shank bolts in, hand-tight.
18. Remove the locating clamp.
19. Tighten the conrod shank bolts (see work card 030.01).
030.01
20. Turn the piston to TDC position.
21. Remove the foot board from the oil sump. Dismantle the suspension
device and the tapered sleeve for inserting the piston rings.
22. Turn piston approx. 60ƒ before/after TDC.
23. Apply acid-free grease to new O-ring seals (9), insert them into the
ring grooves, paying attention that the O-ring seals are evenly
tensioned over the whole circumference and not distorted.
24. Place the support (050.158-1) on the top land ring (10), taking care
that it is positioned correctly.

6621 034.01--03 E 06.98 L 40/54 106/ 09

 25. Screw three hexagon bolts (050.158-3) into the blind end bores of the
top land ring, hand-tight.
26. Using the shackle (002.453), attach the rope (1) to the support and
suspend the rope in the lifting tackle.
27. Screw the pilot rod (034.006) into the support.
28. Move the top land ring over the cylinder, carefully insert it into the
backing ring (11) and lower it onto the cylinder liner.
▲ Attention! Make sure that the positioning pin (15) on the support
engages into the bore (N) located on the backing ring. Refer to
Figure 1 .
29. Remove the tool.
Important! For safety reasons, check that the markings (M) on the
backing ring and on the top land ring are on the same level. Refer to
Figure 5 .
30. Insert a new sealing ring (8) into the groove.
31. Mount the engine parts that had previously been removed, attach
pipes and screwed connections, fill cooling water in the engine.
32. With the engine running, examine check bore holes (K) for gas
leakage. Refer to Figure 6 .

1-4 Position of the piston

ring joints

St Control side

Figure 3. Sketch showing the position of the piston ring joints

6621 034.01--03 E 06.98 L 40/54 107/ 09

 5 Rope 13 Piston 18 Connecting rod big end
6 Cylinder head bolt 16 Hexagon bolt M16x80 19 Balance weight
11 Backing ring 17 Hexagon nut M16 21 Connecting rod shank
12 Cylinder liner 23 Positioning pin

Figure 4. Installation of the piston

6621 034.01--03 E 06.98 L 40/54 108/ 09

 10 Top land ring
11 Backing ring

M Marking
N Bore in the backing
ring for the positioning
pin

Figure 5. Marking backing ring -- top land ring

10 Top land ring

11 Backing ring
12 Cylinder liner
24 Cylinder head

K Check bore hole

ST Control side

Figure 6. Position of the bores for checking gas tightness

6621 034.01--03 E 06.98 L 40/54 109/ 09

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:
Measuring components and
assessing contact pattern/wear.

Tools/appliances required

Qty Designation No. Availability

1 Piston ring expander 034.084 Standard
1 Thickness gauges 0.05--1 000.451 Standard
1 Felt--tip pen/Marking pen -- Inventory
1 Dial gauge -- Inventory

Related work cards

Work card Work card Work card

034.01 034.05 034.07

Operating sequence 1 -- Checking the piston

Starting condition Piston has been removed and placed on an appropriate wooden support.

Steps 1. Check condition of piston and piston rings (17 to 20).

Important! The piston running surface should have a uniform wear
pattern and should be free from scores and other damage.
Deep scores or signs of seizing are an indication of engine overloading,
malfunctions of the cooling system, insufficient lubrication, or foreign
matter caught between the piston and cylinder liner.
2. Clean the piston of carbon residues; do not roughen the surface of
the piston crown in the process. Carefully clean the running surface.
▲ Attention! The graphitised layer on the piston skirt (8) must not
be damaged during cleaning treatment!

6701 034.02--01 E 02.03 L 40/54 101/ 05

 3. Measure the axial clearance of the piston rings (17 to 20) in the
grooves, note down the readings, compare them with the maximum
permissible clearance, and enter them in the engine log book.
Important! Using the thickness gauges (000.451), determine the
axial clearance at four points (control side/exhaust side/coupling end/free
engine end) at a quarter depth of the piston ring groove. See Figure 2 .

For evaluation of piston ring condition, see Work Cards 034.05

034.07.
and 034.07

5 Retaining ring
6 Nut
7 Thrust pad
8 Piston skirt
9 O-ring seal
10 Stud
11 Piston crown
12 Spring plate
13 Compression spring
14 Spring plate
15 Retaining ring
16 Guide shoe
17 Compression ring
18 Compression ring
19 Compression ring
20 Oil control ring
21 Retaining ring
22 Clamping sleeve
23 Sleeve

Figure 1. Piston (Figure shows piston without connecting rod small end and piston pin)

6701 034.02--01 E 02.03 L 40/54 102/ 05

 11 Piston crown A Depth of piston ring groove
17 Compression ring B Measuring point -
1/ depth of piston ring groove (A)
18 Compression ring 4
19 Compression ring

Figure 2. Measuring the axial clearance of the piston rings (Figure shows measuring the axial clearance of the compression
rings)

Operating sequence 2 -- Removing and installing the piston rings

Starting condition When checking pistons, the piston rings should normally not be removed,
as they are subjected to high stress during removal and installation.

In case piston rings are removed due to the wear condition or because of
contamination:

Steps 1. Take the piston rings (17 to 20) off one by one, using the piston ring
expander (034.084), clean them and mark them with a marking pen
(cylinder number and number of the piston ring groove).
▲ Attention! Marking the piston rings is necessary to prevent the
piston rings being mixed up (used piston rings must be refitted into
the same piston and ring grooves)!

Important! Always use the piston ring expander for removal and
installation of piston rings. Refer to Figure 3 .
For expanding a piston ring, press the locking lever (24) down by hand.
The lever is spring loaded and, for this reason, returns to its initial position
independently once it is released/the piston ring is no longer expanded?
2. Thoroughly clean the piston ring grooves, and check the wear.
Important! Using a suitable dial gauge (25), measure the height of
the piston ring groove at four points (control side/exhaust side/coupling
end/free engine end) at a quarter depth of the piston ring groove. Refer to
Figure 4 .
3. Check the piston rings (17 to 20) closely; replace them if necessary.
▲ Attention! Piston ring grooves that are tapered due to wear are an
indication of excessive cylinder liner wear!
Worn out piston ring grooves may be remachined! We recommend
to contact MAN B&W Diesel AG in this regard! Replacement piston

6701 034.02--01 E 02.03 L 40/54 103/ 05

 rings fitting the reconditioned ring grooves have to be installed, the
new ring height has to be entered in the engine log book!
4. Fit the piston rings (17 to 20) on the piston by means of the piston
ring expander, making sure that they are positioned in accordance
with the marking applied.
5. Measure the axial clearance of the piston rings (17 to 20) in the
grooves, and enter it in the engine log book.
Important! Using the thickness gauges (000.451), determine the
axial clearance at four points (control side/exhaust side/coupling end/free
engine end) at a quarter depth of the piston ring groove. See Figure 2 .

▲ Attention! If a used piston is installed in a different cylinder liner,

it is absolutely necessary to replace the compression rings (17 to 19)
and the oil control ring (20), and to rehone the cylinder liner (see
050.05)! New running in of the engine will then be
Work Card 050.05
necessary (refer to the running-in instructions in Volume B1)!

For piston ring dimensions and clearances, please refer to Volume B1.

17 Compression ring
18 Compression ring
19 Compression ring
24 Locking lever

Figure 3. Piston ring expander with piston ring inserted

11 Piston crown
25 Dial gauge

A Depth of piston ring

groove
B Measuring point -
1/ depth of piston ring
4
groove (A)

Figure 4. Measuring the height of the piston ring groove (in order to determine the wear)

6701 034.02--01 E 02.03 L 40/54 104/ 05

 Arrangement of the piston rings (refer to Figure 5 ):
- A compression ring (17) with chromium-ceramic coating is installed
into the topmost piston ring 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.
- Chromium-plated compression rings (18 and 19) are installed in the
second and third piston ring groove from the 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.
- An oil control ring (20) is installed in the fourth piston ring groove from
the top (ring groove 4). The oil control ring with the hose spring
always has to be inserted with the ring side marked “TOP” being up.

8 Piston skirt
11 Piston crown
17 Compression ring
18 Compression ring
19 Compression ring
20 Oil control ring

Figure 5. Arrangement of the piston rings

6701 034.02--01 E 02.03 L 40/54 105/ 05

Piston pin and piston pin bush
Removing and installing/checking 034.03

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Piston pin and piston pin bush are to be checked at regular intervals, and
are hence to be dismounted.
The work/steps include:
removal of components,
checking of components,
installation of components.

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 034.082 Optional
1 Shackle A1.0 002.453 Standard
1 Pliers for retaining ring 002.165 Standard
1 Lifting eye bolt M20 000.155 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lifting tackle -- Inventory
1 Rope (hemp) -- Inventory
1 Rope (nylon) -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

034.01

Technical details

Term Information
Piston pin 60 kg
Connecting rod small end 85 kg

6701 034.03--01 E 09.06 L 40/54 101/ 04

 5 Retaining ring
8 Piston skirt
11 Piston crown
16 Guide shoe
26 Connecting rod small
end
27 Piston pin

Figure 1. Piston with installed piston pin and connecting rod small end

Operating sequence 1 - Removal of the piston pin

Starting condition The piston has been removed, cleaned on the outside, and put down onto
a wooden support (piston skirt pointing up).

Steps 1. Screw the lifting eye bolt (000.155) into the connecting rod small end
(26).
2. Attach the rope (25) to the lifting eye bolt by means of shackle
(002.453), and suspend the rope from the lifting tackle. Refer to Fig-
ure 2 .
3. Slightly lift the connecting rod small end (25), thus relieving the piston
pin (27).
4. Remove the retaining rings (5), and push the piston pin (27) out to
the extent shown in Figure 2, securing the piston against tilting in the
process.
Important! The piston pin may easily be pushed out at a tempera-
ture difference of 30-40ƒ C compared with the piston. For doing so, care-
fully warm up the piston in the area of the pin, using, e.g., a gas torch.
Keep torch in circular motion, inner flame cone not too close to the piston.
5. Lift the connecting rod small end (26) out of the piston, and carefully
put it down.
6. Remove the tool.

6701 034.03--01 E 09.06 L 40/54 102/ 04

 7. Mount the fitting/unfitting tool (034.082) in the piston pin (27), and
fasten it in place by means of the hexagon bolt (28). Refer to Fig-
ure 3 .
8. Attach the rope (25) to the fitting/unfitting tool by means of shackle
(002.453), and suspend the rope from the lifting tackle.
9. Carefully move the piston pin (27) out completely, and put it down -
handling it with care.
10. Clean the piston pin (27) and piston pin bush in the connecting rod
small end (26), and check them for wear (for maximum permissible
clearance, please refer to Volume 1).
Important! If required, the piston pin bush should be replaced in a
Service Workshop, as the bush is to be cooled down before being in-
stalled. If necessary, install spare connecting rod small end for the interim
period. Respraping of the running surface must neither be done on new
nor on used piston pin bushes.

Operating sequence 2 - Installation of the piston pin

Starting condition Piston, piston pin and connecting rod small end have been cleaned and
checked. Piston has been put down onto a wooden support (pistin skirt
pointing up).

Steps 1. Check to ensure movability of the guide shoe (16).

2. Installing the piston pin (28) is a reversal of the removal procedure.
During installation, make sure that the piston is not damaged by the
fitting/unfitting tool (034.082) in the course of the insertion process.
Prior to installation, the running surface of the piston pin is to be oiled
slightly.

8 Piston skirt
16 Guide shoe
25 Rope
26 Connecting rod small
end
27 Piston pin

Figure 2. Removal/installation of the connecting rod small end

6701 034.03--01 E 09.06 L 40/54 103/ 04

 8 Piston skirt
16 Guide shoe
25 Rope
27 Piston pin
28 Hexagon bolt M8x30

Figure 3. Removal/installation of the piston pin

6701 034.03--01 E 09.06 L 40/54 104/ 04

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 Torque wrench 008.029 Standard
1 Torque wrench 008.016 Standard
1 Pliers for retaining rings C 19--60 002.162 Standard
1 Pliers for retaining rings A 19--60 002.122 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Standard
1 Adapter 12.5x10 001.922 Standard
1 Extension piece 20x400 001.914 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 30x12.5L 001.766 Standard
1 Socket wrench insert 14x12.5 001.753 Standard
1 Honing stone -- Optional
1 Lifting tackle -- Inventory
1 Oil stone -- Inventory
1 Emery paper -- Inventory
1 Rope (hemp) -- Inventory
1 Rope (nylon) -- Inventory
1 Molykote HSC -- Inventory
1 Lubricant (Copa Slip) -- Inventory
1 Lubricating oil, clean -- Inventory

6701 034.04--01 E 12.04 L 40/54 101/ 04

Related work cards

Work card Work card Work card

034.03

Technical details

Term Information
Piston crown 70 kg
Piston skirt 130 kg

Operating sequence 1 -- Disassembly of the piston

Starting condition The piston has been removed, cleaned on the outside, and put down onto
a wooden support (piston skirt pointing up).

Steps 1. Remove the piston pin and connecting rod small end (see Work Card
034.03).
034.03
2. Loosen and screw off four nuts (6), remove the thrust pads (7).
3. Suspend the piston skirt (8) from the lifting tackle by means of the
rope run through the piston pin bores, lift it carefully, and put it down
onto the wooden support.
▲ Attention! When lifting the piston skirt, take care not to damage
the studs (10)! Do not set the piston skirt down onto the guide shoe
(16)!
4. Remove the O-ring seal (9).
5. Verify that the guide shoe (16) moves easily, remove it if necessary.
6. Carefully clean the piston crown (11) and the piston skirt (8). 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).
7. If necessary, unscrew the studs (10) from the piston crown (11).
8. Check the contact face between piston crown (11) and piston
skirt (8), and smooth material elevations (see Operating Se-
quence 2).

Operating sequence 2 -- Smoothing the contact face between the piston crown and the piston skirt

Preliminary remark During engine operation, punctual welding may occur locally on the con-
tact faces between piston crown and piston skirt, which cause material
elevations on the contact faces when the piston is disassembled.
As the precise starting position cannot be reached when the piston is reas-
sembled, the material elevations are to be removed and smoothed re-
spectively.

Starting condition The piston has been disassembled and cleaned.

Steps 1. Check the contact face of piston crown (11) and piston skirt (8) for
material elevations.
2. Remove the material elevations in several stages using emery paper
with increasingly finer grain size every time (100 --180).
3. Smooth the contact faces by means of an oil stone or honing stone.

6701 034.04--01 E 12.04 L 40/54 102/ 04

 ▲ Attention! Particular care is to be taken in this connection that
the material elevations on the contact faces of the piston crown and
piston skirt are removed completely, as remaining elevations may
result in high compressive stresses at certain points.

Operating sequence 3 -- Assembly of the piston

Starting condition Piston components cleaned, checked, and replaced as far as necessary.
Piston crown has been put down onto an appropriate wooden support.

Important! Carry out items 1-10 if parts were replaced.

Execute items 1-6 and 9-10 as a general rule whenever the piston has
been disassembled.

Steps 1. Screw studs (10) into the piston crown (11) applying a torque of
35 Nm.
2. Insert a new O-ring seal (9), which has been coated with clean lubri-
cating oil, into the ring groove, taking care that the O-ring seal is
evenly tensioned over the entire circumference, and not distorted.
3. Check the contact face of the piston crown (11) and piston skirt (8);
they have to be absolutely clean and dry.
4. Suspend the piston skirt (8) from the lifting tackle by means of the
rope run through the piston pin bores, lift it, and carefully place it on
the piston crown (11).
▲ Attention! Prior to placing the piston skirt on the piston crown,
make sure that the bore hole in the piston skirt is positioned cor-
rectly relative to the clamping sleeve (22) in the piston crown!
Do not damage the studs (10) when placing the piston skirt on the
piston crown!
5. Put the thrust pads (7) over the studs (10) and into the bore holes.
6. Apply HSC Molykote paste or “Copa Slip” lubricant to the threads and
seating faces of the nuts (6), and screw them all the way down.
7. Tighten the nuts (6) applying a preliminary torque of 150 Nm, order
of tightening1-2-3-4, and loosen them again.
8. Applying a torque of 35 Nm, check whether the studs (10) have
been drawn in correctly.
9. Execute the final tightening in two steps:
- Tighten the nuts (6) to a preliminary torque of 50 Nm, order of
tightening 1-2-3-4.
- Continue turning down the nuts (6) with an angle of torsion of
90•, order of tightening 4-3-2-1.

Check: It must not be possible to continue turning down the

nuts when applying a torque of 120 Nm!

10. Verify that the guide shoe (16) moves easily.

11. Install the piston pin and the connecting rod small end (see Work
034.03).
Card 034.03

6701 034.04--01 E 12.04 L 40/54 103/ 04

 5 Retaining ring
6 Nut
7 Thrust pad
8 Piston skirt
9 O-ring seal
10 Stud
11 Piston crown
12 Spring plate
13 Compression spring
14 Spring plate
15 Retaining ring
16 Guide shoe
17 Compression ring
18 Compression ring
19 Compression ring
20 Oil control ring
21 Retaining ring
22 Clamping sleeve
23 Sleeve

Figure 1. Piston (illustration shows piston without connecting rod small end and piston pin)

1-4 Order of tightening

Figure 2. Order of studs/nuts tightening

6701 034.04--01 E 12.04 L 40/54 104/ 04

Piston rings
Assessing 034.05

Purpose of jobs to be done

Carry out work in time according to maintenance schedule,

measure components,
assess contact pattern/wear.

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 or
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 2/3 chromium-coated uniformly grey
Oil scraper ring
Groove 4 chromium-coated uniformly grey
Table 1. Piston rings/coating
On 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 network of cracks
will appear on the surface. This is the normal appearance.

6682 034.05--02 E 06.02 32/40 upw 101/ 03

 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 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 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
thickness of the coating will not safely endure the subsequent
maintenance interval.

6682 034.05--02 E 06.02 32/40 upw 102/ 03

 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.
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--02 E 06.02 32/40 upw 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

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

6682 050--06 E 07.99 101/ 01

Cylinder liner
Measuring 050.02

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Cylinder liners are to be checked within the scope of maintenance and

repair work.
The work/steps include:
Measuring components and
assessing contact pattern/wear.

Tools/appliances required

Qty Designation No. Availability

1 Gauge bar 32/40 050.097 Standard
1 Gauge bar 40/54 050.096 Optional
1 Gauge bar 48/60 050.095 Optional
1 Gauge bar 58/64 050.094 Standard
1 Micrometer (inside) 58/64 050.107 Standard
1 Micrometer (inside) 48/60 050.062 Optional
1 Micrometer (inside) 32/40 050.038 Optional
1 Micrometer (inside) 40/54 050.002 Optional

Preliminary remarks

Cylinder liners are not worn out completely evenly on the circumference
and along the running face. The wear values are limited and that for both
the ovality and the maximum wear. This way, sealing problems and over-
loading of the piston rings are to be avoided.
Regular checks provide a basis for optimising the operating conditions and
for decisions concerning a possible replacement of the cylinder liner.

Operating sequence 1 - Measure the cylinder liner

Starting condition Cylinder head, top land ring (if existing) as well as piston and connecting
rod removed. Cylinder liner thoroughly cleaned, especially in the upper
area and in the area of the gauge bar stop, on the top face.

6682 050.02--01 E 09.06 32/40, 40/54, 48/60, 58/64 101/ 03

Steps 1. Insert the gauge bar in the cylinder liner. See Figure 1. The measur-
ing bar is held magnetically on the running face and on the top face
of the collar. The number and positions of the measuring points are
fixed by means of the bores in the bar.
Important! Measuring point 1 is only relevant for cylinder liner de-
signs without top land ring. For measuring, the spacer (8) is to be re-
moved. For cylinder liner designs with top land ring, measuring is started
at measuring point 2.
2. Heat up the inside micrometer to the temperature of the cylinder liner
and insert it successively into all of the bores of the gauge bar. De-
termine the dimensions in longitudinal direction of the engine and
transversely to it and note them down.
3. Determine the temperature of the cylinder liner during measurement
and note it down.
4. Enter dimensions in engine log book and compare with the max. per-
missible values (refer to operating manual, Section 2.5).
▲ Attention! In case the values measured exceed the max. permis-
sible values for wear or ovality, the cylinder liner must be renewed.
The wear is the difference from the values measured minus nominal di-
mension. The ovality is the difference from the values measured (in trans-
verse and in longitudinal direction) of each plane.

1-6 Measuring point

7 Knurled screw
8 Spacer
9 Cylinder liner
10 Gauge bar
11 Inner screw gauge

Figure 1. Measuring the cylinder liner

6682 050.02--01 E 09.06 32/40, 40/54, 48/60, 58/64 102/ 03

 Cylinder diameter (mm)

Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

M
Measuring
i plane
l trans- longitu- trans- longitu- trans- longitu- trans- longitu- and
d so
verse dinal verse dinal verse dinal verse dinal on
1 -- --
2 580.82 580.75
3 580.76 580.60
4 580.30 580.30
5 580.20 580.20
6 580.83 580.75
Cylinder liner
temperature during 30ƒ &
measuring
Condition of running perfect
surface
Table 1. Measuring log (example: L 58/64 engine)

6682 050.02--01 E 09.06 32/40, 40/54, 48/60, 58/64 103/ 03

Sealing face on cylinder head
and sealing groove in top land ring
Grinding 050.03

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

The sealing face on the cylinder head and the sealing groove in the top
land ring are to be checked every time the cylinder head is removed, and
remachined if necessary.
The work includes:
grinding the sealing face and the sealing groove.

Tools/appliances required

Qty Designation No. Availability

1 Angular screw driver 050.120 Standard
1 Grinding tool 050.110 Optional
1 Disk support 050.110--1 Optional
1 Grinding wheel 050.110--5 Optional
1 Sliding caliper -- Inventory
1 Depth gauge -- Inventory
1 Grinding paste (silicon--free) -- Inventory

Related work cards

Work card Work card Work card

055.02 055.05

Technical details

Term Information
Gap dimension B min. 0.5 mm

6701 050.03--01 E 05.03 L 40/54 101/ 03

 1 Backing ring 3 Top land ring M Sealing groove
2 Cylinder liner 4 Cylinder head N Sealing face

Figure 1. Grinding the sealing groove in the top land ring (illustration on the left) and/or the sealing face on the cylinder head
(illustration on the right)

1 Backing ring
3 Top land ring
4 Cylinder head
5 Sealing ring

B Gap

Figure 2. Gap between top land ring and cylinder head

6701 050.03--01 E 05.03 L 40/54 102/ 03

Operating sequence -- Grinding the sealing face on the cylinder head and/or
the sealing groove in the top land ring

Important! The grinding tool (050.110) can be used for both the top
land ring and the cylinder head. The correct side to be used in each case
can be gathered from Figure 1 .

Starting condition The cylinder head has been clamped into the cylinder head turnover stand
055.05). The combustion chamber side is facing up-
(see Work Card 055.05
wards.

Steps 1. Loosen the sealing ring (5). For this purpose, insert the angular
screw driver (050.120) into the groove at the outer diameter. Take
the sealing ring out.
2. Face-grind the sealing groove (M) in the top land ring (3) and/or the
sealing face (N) on the cylinder head (4), using grinding paste and
grinding tool (050.110).
For this purpose, move the grinding tool back and forth, lifting it from
time to time to allow the abrasive to distribute evenly.
Important! Do not put on too much grinding paste. Grinding should
be kept to the necessary minimum, as it is difficult to obtain a plain surface
by grinding. If necessary, the cylinder head and/or the top land ring have
to be machined on a turning lathe.
3. After completion of the work, thoroughly remove all remains of
abrasive.
Important! In case the sealing faces have been remachined, the
gap (B) between top land ring and cylinder head has to be at least
0.5 mm. Refer to Figure 2 .
4. Insert a new sealing ring (5) into the sealing groove.

6701 050.03--01 E 05.03 L 40/54 103/ 03

Cylinder liner
Honing 050.05

Purpose of jobs to be done

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

check state/wear condition of components,
restore running face,
ensure correct execution of work.

Brief description

Cylinder liners are to be checked at regular intervals, and the original

running face geometry is to be restored.
The work/steps include:
honing of the reversing zone of the piston rings,
honing of the complete running face.

Tools/appliances required

Qty Designation No. Availability

1 Honing device 050.115 Optional
1 Rope tackle with remote control 050.115--1 Optional
1 Cross tie 050.115--2 Optional
2 Extension pipe 050.115--4 Optional
2 Adapter 050.115--5 Optional
4 Stop for stroke limit 050.115--6 Optional
1 Guide arm with control valve 050.115--7 Optional
1 Extension 050.115--8 Optional
1 Drive unit 050.115--9 Optional
1 Air connection with universal joint 050.115--10 Optional
1 Honing head 050.115--11 Optional
1 Tank 050.115--12 Optional
1 Funnel 050.115.13 Optional
2 Tension spring strip 050.115--16 Optional
1 Air supply station 050.115--17 Optional
1 Spray nozzle 050.115--20 Optional
3 Cleaning brush 050.115--21 Optional
1 Oil for air oiler 050.115--23 Optional
1 Support 050.115--24 Optional
1 Honing stone (set) for laser--hardened cylinder -- Optional
liners
1 Honing stone (set) for unhardened cylinder liners -- Optional
1 Collecting tank -- Inventory

6701 050.05--01 E 03.02 L 40/54 101/ 08

 Qty Designation No. Availability
1 Lifting tackle with rope -- Inventory
1 Cleaning agent (diesel oil/kerosene) -- Inventory

Related work cards

Work card Work card Work card

034.01 050.02

Preliminary remark

Cylinder liners require rehoning when piston rings are replaced or after the
maintenance interval has expired. Honing will restore the original state of
roughness of the cylinder liner running surface. This roughness is
necessary to ensure a sufficiently thick and properly adhering lubricating
film. While the original microgeometry can largely be restored, the wear
profile, i.e. the macrogeometry of the cylinder liner, cannot be altered.
The usual procedure is to hone the TDC zone of piston rings in a first
pass, and in a second pass the entire running surface of piston rings.
Honing of the cylinder liner is not very time-consuming. However, the use
of the device and the job itself, and judging the results require care and a
certain amount of experience. We therefore recommend that MAN B&W
Diesel AG personnel be entrusted with this job, at least the first time for
instruction.

Technical/functional description

The honing device essentially consists of:

- the rope tackle (1) -- refer to Figure 1
- the drive unit (15)
- the honing head (20)
- the lubricator (17 and 24)
- the guide elements (2 to 4, 6 to 10), and
- the portable air supply station (23).

The honing device is driven and controlled by means of compressed air

(pmax = 18 bar).
The fittings of the air supply station (23) serve the purposes of filtering air,
draining water, and adding oil. Refer to Figure 2 .
The regulating valves at the compressed air outlets serve to preset the
reciprocating and rotational speed of the honing head (20), and the contact
pressure of the honing sticks (18). The hoisting motor for lifting and
lowering is operated by pushbuttons on the remote control (5).
The ball cock on the guide arm (7) serves to switch the drive unit (15) on
and off. The slide valve next to it is used to control the contact force of the
honing sticks.
The lubricator consisting of tank (24) and spray nozzles (17) is used to
lubricate the grinding zone and to clean the grinding dust away. The
lubricant/cleanser is collected in a funnel (22) attached to the lower rim of
the cylinder liner (14), and disposed. Exchanging the honing sticks for

6701 050.05--01 E 03.02 L 40/54 102/ 08

 cleaning brushes (19) permits mechanical cleaning of the cylinder liner
(14).
The device can be adjusted to various diameters, and matched to different
stroke lengths by means of extension tubes and adapters.

1 Rope tackle
2 Cross tie
4 Stop for stroke
limitation
5 Remote control
6 Extension tube
7 Guide arm with control
valves
10 Adapter
11 Extension
12 Support
13 Cylinder head bolt
14 Cylinder liner
15 Drive unit
16 Air connection with
universal joint
17 Spray nozzles
18 Honing stick with
honing stones
19 Cleaning brush
20 Honing head
21 Tension spring strip
22 Funnel
23 Air supply station
24 Tank

Figure 1. Pneumatic honing device in mounted condition

6701 050.05--01 E 03.02 L 40/54 103/ 08

 23 Air supply station
26 Filter/Water separator
27 Oiler
28 Pressure regulating
valve
29 Pressure gauge

A Compressed air supply

B Compressed air to the
hoisting motor
(reciprocating speed)
C Compressed air to the
drive unit (rotational
speed)
D Compressed air to the
guide arm/honing head
(contact pressure)

Figure 2. Air supply station (side view and top view)

Operating sequence 1 -- Honing the zone of piston ring reversal, TDC (nip area)

Starting condition Cylinder head dismantled, piston with connecting rod big end removed,
connecting rod shank fastened to the balance weight by means of locating
clamp and turned sidewards far enough to permit the funnel (22) to be
mounted. Refer to Figure 3 .
Cylinder liner cleaned (free of carbon deposits and lube oil) and measured
precisely (cylinder liner has not yet reached the limits of maximum wear; for
limit values, refer to Volume B1). Outlet holes for cylinder lubrication plugged
by means of plasticine or pasty grease.
Crank gear covered by appropriate means. Funnel fastened to lower end of
cylinder liner, and hose (31) connected outward into the collecting tank (32).
Honing device mounted and adjusted according to separate description.

Important! Hone the zone of piston ring reversal in a first pass

using the short honing stones, then hone the entire running surface
contacted by the piston rings.

Steps 1. Mount the honing stones (approx. 20 mm long) to each of the honing
sticks (18) at the same level, near the middle of the honing sticks.
Tip! Short honing stones can be prepared by breaking long honing
stones. For this purpose, cut a notch into the stone using a steel saw
blade, mount the stone in a vice and break it off.
2. Carefully introduce the honing head (20) into the cylinder liner (14).
3. Using the stops (4), limit the reciprocating movement of the honing
head in the cylinder liner so that the top edge of the honing stones
projects approx. 10 mm beyond the top dead centre of the top piston
ring, and a stroke length of 65-85 mm results.
4. Adjust the spray nozzles (17) so that the issuing lubricant is
distributed over the honing area.
5. Close the stop cock on the tank (24) and fill the tank with lubricant
(Diesel oil, gas oil or kerosene).
▲▲ Caution! Do not smoke, do not use open flames - fire hazard!
6. Open the stop cock on the tank. Verify that the lubricant issues from
the spray nozzles and wets the honing area. Check that the lubricant
is collected in the funnel (22) and passed to the collecting tank (32)
without leakage losses.

6701 050.05--01 E 03.02 L 40/54 104/ 08

 Important! Approx 4-6 litres of lubricant are required for honing one
cylinder liner. Make sure to use an adequate amount of lubricant for
honing, because it is desirable to wash off the grinding dust immediately.
The lubricant can be used several times if it is passed into the collecting
tank through a fine-meshed fleece mat.
For final cleaning of the cylinder liner after the honing process, use clean
lube oil or cleanser.
7. Start the honing device with a previously tested setting, and bring the
honing stones into contact with the liner wall.
Hone by short, up-and-down strokes (20-30 double strokes each)
until the short honing stones have been used up, which takes about
1-1.5 minutes. During the honing process, the speed of the honing
head is about 35 r.p.m., and the contact pressure is 2.5 bar. The
short stroke results in a narrow honing angle.
When honing marks become visible in the TDC zone of the top piston
ring, stop honing. A rounded step that may have been left at the point
of top piston ring reversal is acceptable. If necessary, use a second
set of short honing stones and repeat the process.
8. Stop honing as soon as a satisfactory grinding pattern has been
produced, and shut off the supply of lubricant.
9. Move the honing head out of the cylinder liner and secure it in the top
position.

Operating sequence 2 -- Honing the entire cylinder liner running surface

Starting condition Zone of reversal of piston rings at TDC honed, or cylinder liner shows but
slight incipient wear in the TDC zone.

Important! The purpose of this operating sequence is the

roughening of the upper cylinder liner area, where the honing marks have
disappeared in the course of time. Honing in the lower area should be
kept to the minimum possible; but at the end of this operating sequence,
two double strokes should be made over the entire running surface
contacted by the piston rings. On laser-hardened cylinder liners, make
sure that there is a gradual transition from the hardened parts of the
cylinder liner to the soft section below.

Steps 1. Mount six long honing stones on the honing head (20).
2. Carefully introduce the honing head into the cylinder liner (14).
3. Adjust the reciprocation of the honing head by means of stops (4) so
that the honing stones work in the upper half of the piston stroke
zone (the zone contacted by the piston rings), i.e. the tops and
bottoms of the honing stones should move approx. 100 mm beyond
these limits.
4. Adjust the spray nozzles (17) so that the lubricant issuing from them
wets the honing area. Fill the tank (24) with lubricant (diesel oil, gas
oil or kerosene).
▲▲ Caution! Do not smoke, do not use open flames - fire hazard!
5. Open the stop cock on the tank. Verify that the lubricant issues from the
spray nozzles and wets the honing area. Check that the lubricant is
collected in the funnel (22) and passed to the collecting tank (32) without
leakage losses.
Important! Approx. 10 litres of lubricant are required for the honing
of one cylinder liner. Make sure to use enough lubricant for the honing
process. The grinding dust should preferably be washed away
immediately.
6. Start the honing device with a previously tested setting, and bring the
the honing stones into contact with the liner surface.
65-70 up-and-down strokes are required to hone one cylinder liner at

6701 050.05--01 E 03.02 L 40/54 105/ 08

 a reciprocating speed of about 12 double strokes per minute. Refer
to Table 2. The entire honing time for one cylinder liner is normally
4-8 minutes, the longer times being required for laser-hardened
cylinder liners. Speed of the honing head -- see Table 2; contact
pressure 2.5 bar. Control the reciprocating motion so that a honing
angle (§) of 45•-60• (22.5•-30• relative to the horizontal) is reached.
See template Figure 4 . The desirable surface roughness Rz is
10-15 ³m, both for laser-hardened and standard-type cylinder liners.
7. Stop the honing device. Assess the surface roughness, the honing
angle and the honing pattern (refer to Table 1).
If this assessment is satisfactory, then make two double strokes
covering the full zone of piston ring contact. Adjust the stops (4) for
this purpose so that the honing stones partly emerge from the
cylinder liner. But the honing head must not hit the funnel (22).
8. After honing, measure the cylinder liner (see Work Card 050.02
050.02).
If the maximum permissible wear in the TDC zone of the top piston
ring or the maximum permissible out-of-roundness has been
exceeded (for limit values, see the Volume B1), the cylinder liner
must be replaced.
9. Exchange the honing sticks for hard cleaning brushes (19).
10. Introduce the honing head and carefully remove (loosen/wash off)
any grinding residues at a reduced contact pressure of 0.5-1.0 bar,
with unchanged rotating and reciprocating speeds. Repeat the
procedure with soft cleaning brushes, if necessary. An ample amount
of lubricant should be used for cleaning. A total of about 50 double
strokes is necessary. Fresh lubricant should be used for the last
pass. No grinding particles must be left. Check with your finger tips!
11. Detach the honing device.
12. Attach it to the next cylinder, or, when cleaning is finished, store it in
a safe place or in the shipping box.
13. Remove the wads of grease or plasticine from the cylinder-lubrication
holes.
14. Disconnect the lube-oil pipe of the cylinder-lubrication system from
the cylinder crankcase, and clear the cylinder-lubrication holes with
compressed air. Reconnect the lube-oil pipes.
15. Remove the funnel (22), taking care that no contaminating matter
gets into the running gear.
16. Finally, clean the cylinder liner by hand.
▲ Attention! After the pistons have been installed and the cylinder
covers mounted in place, follow the instructions for running in the
engine (see Volume B1) when starting up the engine again!

6701 050.05--01 E 03.02 L 40/54 106/ 08

 14 Cylinder liner
22 Funnel
31 Hose
32 Collecting tank

§ Honing angle

Figure 3. Honing the cylinder liner (initial state)

Alternatively
F t
Feature Ch ki /M
Checking/Measuring
i 1 2
Surface roughness Rz, Measuring instrument Technovit impression Fingernail test and visual
measured in the TDC (self-curing plastic) inspection
zone for the top piston ring - permits later evaluation
and the middle of top of all three parameters
piston ring lift
Honing angle Goniometer Angle template
Honing pattern, i.e. profile Evaluation of “faxfilm” Examination using a
and distribution of honing impressions (cellulose pocket lens, visual
lines, occurrence of acetate film) under the assessment -- requires
glazing and pitting along microscope (50-power experience
the honing lines, unhoned magnification)
“pits” remaining
Table 1. Evaluation of the running surface of cylinder liners after honing

Number of Time per Number of

Engine model Stroke Velocity double strokes double stroke * double strokes
[mm] [r.p.m.] per min. [s] required
40/54 600 28 12 5 65-70
Table 2. Parameters for the honing of cylinder liners

* Valid for a honing angle (§) of 45ƒ

6701 050.05--01 E 03.02 L 40/54 107/ 08

 X 135ƒ 45ƒ Honing angle Y 120ƒ 60ƒ Honing angle

Figure 4. Aid for making a honing-angle template

6701 050.05--01 E 03.02 L 40/54 108/ 08

Cylinder head

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

6682 055--02 E 07.99 101/ 01

Cylinder head bolts
Checking, untightening and tightening 055.01

Purpose of jobs to be done

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

ensure operational reliability of bolted connections.

Brief description

Cylinder head bolts are to be checked at regular intervals by means of

hydraulic tensioning tools.
The work/steps include:
checking bolted connection,
untightening,
tightening.

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

2 Thrust pad 055.112 Standard
2 Tension screw 055.111 Standard
1 High--pressure pump 009.338 Standard
4 High--pressure hose 009.306 Standard
2 Thrust pad 009.055 Standard
4 Hydraulic tensioning tool 009.053 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Open--jaw and ring wrenches (set) -- Standard

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.13

Operating sequence 1 -- Check the cylinder head bolts

Starting condition Rocker arm casing removed.

6701 055.01--01 E 10.01 L 40/54 101/ 06

Steps 1. Remove the protecting caps (9) from the cylinder head bolts (1-8).
2. Clean the threads of the cylinder head bolts.
3. Screw the tension screws (055.111) all the way onto the cylinder
head bolts (4 and 8).
4. Slip the thrust pads (055.112) over tension screws and nuts (10).
5. Screw the hydraulic tensioning tools (009.053) onto the cylinder head
bolts. Refer to Figures 3 and 4 .
6. Slip the thrust pads (009.055) over the cylinder head bolts (2
and 6) and the nuts.
7. Screw the hydraulic tensioning tools (009.053) onto the cylinder head
bolts, making sure that the thrust pads are centred by the hydraulic
tensioning tools. Refer to Figures 3 and 4 .
8. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
9. Connect the high-pressure hoses (009.306) to hydraulic tensioning
tools and high-pressure pump (009.338).
009.03) and close
10. Switch on the high-pressure pump (see Work Card 009.03
the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the cylinder head bolts!
11. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below
000.30!
or 5% above the control pressure (600 bar) - see Work Card 000.30

In case the loosening pressure is more than 7% lower than the con-
trol pressure, all cylinder head bolts (1-8) are to be untensioned and
afterwards to be tensioned again (see operating sequences 2 and 3)!

▲▲ Caution! During pumping, watch the stroke gauge (13) of the

hydraulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (14)! Otherwise, the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the control
pressure (600 bar).
12. Adjust the high-pressure pump to the specified pressure (600 bar).
13. Using the tommy bar (000.262), screw down the nuts through the
opening in the thrust pads, hand-tight.
14. Release the pressure. Disconnect the high-pressure hoses from the
hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
15. Remove the tensioning tools.
16. Reposition the tension screws (055.111), thrust pads (055.112) and
hydraulic tensioning tools (009.053) onto the cylinder head bolts
(1 and 5). See items 3 to 5. Refer to Figures 2 and 4 .
17. Reposition the thrust pads (009.055) and hydraulic tensioning tools
(009.053) onto the cylinder head bolts (3 and 7). See items 6 and
7. Refer to Figures 2 and 4 .
18. Check the cylinder head bolts (1, 3, 5, and 7) the same way. See
items 8 to 13.
19. Release the pressure. Disconnect the high-pressure hoses from hy-
draulic tensioning tools and high-pressure pump.
20. Remove the tensioning tools.
21. Slip the protecting caps onto the cylinder head bolts.

6701 055.01--01 E 10.01 L 40/54 102/ 06

 1-8 Cylinder head bolt
9 Protecting cap
10 Nut
11 Cylinder head
12 Backing ring

Figure 1. Cylinder head and cylinder head bolts

1 Cylinder head bolt

3 Cylinder head bolt
5 Cylinder head bolt
7 Cylinder head bolt

Figure 2. Cylinder head bolts (1-3-5-7) with tensioning tools attached

6701 055.01--01 E 10.01 L 40/54 103/ 06

 2 Cylinder head bolt
4 Cylinder head bolt
6 Cylinder head bolt
8 Cylinder head bolt

Figure 3. Cylinder head bolts (2-4-6-8) with tensioning tools attached

1 Cylinder head bolt 6 Cylinder head bolt 13 Stroke gauge

2 Cylinder head bolt 7 Cylinder head bolt 14 Threaded stop ring
3 Cylinder head bolt 8 Cylinder head bolt
4 Cylinder head bolt 10 Nut M Marking
5 Cylinder head bolt 11 Cylinder head

Figure 4. Cylinder head bolts with tensioning tools attached

6701 055.01--01 E 10.01 L 40/54 104/ 06

Operating sequence 2 - Untension the cylinder head bolts

Starting condition Rocker arm casing has been removed.

Steps 1. Remove the protecting caps (9) of the cylinder head bolts (1-8).
2. Clean the threads of the cylinder head bolts.
3. Screw the tension screws (055.111) all the way onto the cylinder
head bolts (4 and 8).
4. Slip the thrust pads (055.112) over the tension screws and nuts (10).
5. Screw the hydraulic tensioning tools (009.053) onto the cylinder head
bolts. Refer to Figures 3 and 4 .
6. Slip the thrust pads (009.055) over cylinder head bolts (2 and 6)
and the nuts.
7. Screw the hydraulic tensioning tools (009.053) onto the cylinder head
bolts, making sure that the thrust pads are centred by the hydraulic
tensioning tools. Refer to Figures 3 and 4 .
8. Back off the hydraulic tensioning tools by the angle of back-off (see
000.30).
Work Card 000.30
9. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and the high-pressure pump (009.338).
009.03), and
10. Switch on the high-pressure pump (see Work Card 009.03
close the gap produced by backing off.
▲▲▲ Danger! During untensioning, make sure that there is no one
along the extended axis of the cylinder head bolts to be unten-
sioned!
11. Pump up the hydraulic tensioning tools until the nuts can be loos-
ened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the control pressure (600 bar) - see Work Card 000.30!
000.30

▲▲ Caution! During pumping, watch the stroke gauge (13) of the

hydraulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (14)! Otherwise, the hydraulic
tensioning tools will be damaged!
Note down the loosening pressure and compare it with the control
pressure (600 bar).
12. Using the tommy bar (000.262) back off the nuts through the opening
000.30).
in the thrust pads (for angle of back-off, see Work Card 000.30
13. Release the pressure. Disconnect the high-pressure hoses from the
hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
14. Remove the tensioning tools.
15. Reposition the tension screws (055.111), thrust pads (055.112), and
hydraulic tensioning tools (009.053) onto the cylinder head bolts
(1 and 5). See items 3 to 5. Refer to Figures 2 and 4 .
16. Reposition the thrust pads (009.055) and hydraulic tensioning tools
(009.053) onto the cylinder head bolts (3 and 7). See items 6 and
7. Refer to Figures 2 and 4 .
17. Untension the cylinder head bolts (1, 3, 5, and 7) the same way. See
items 8 to 12.
18. Release the pressure. Disconnect the high-pressure hoses from the
hydraulic tensioning tools and high-pressure pump.
19. Remove the tensioning tools.

6701 055.01--01 E 10.01 L 40/54 105/ 06

Operating sequence 3 - Tension the cylinder head bolts

Starting condition The nuts have been screwed on and tightened, hand-tight. The threads of
the cylinder head bolts have been cleaned.
▲ Attention! Correct tensioning of a bolted connection requires the
pressure gauge indication to be correct! In case of doubt, check the
pressure gauge against a reference pressure gauge!
Steps 1. Screw the tension screws (055.111) all the way onto the cylinder
head bolts (1 and 5).
2. Slip the thrust pads (055.112) over the tension screws and nuts (10).
3. Screw the hydraulic tensioning tools (009.053) onto the cylinder head
bolts. Refer to Figures 2 and 4 .
4. Slip the thrust pads (009.055) over the cylinder head bolts (3
and 7) and the nuts.
5. Screw the hydraulic tensioning tools (009.053) onto the cylinder head
bolts, making sure that the thrust pads are centred by the hydraulic
tensioning tools. Refer to Figures 2 and 4 .
6. Connect the high-pressure hoses (009.306) to the hydraulic tension-
ing tools and high-pressure pump (009.338).
009.03), and ten-
7. Switch on the high-pressure pump (see Work Card 009.03
sion the cylinder head bolts to tensioning pressure (650 bar).
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the cylinder head bolts to be tensioned!
▲▲ Caution! During pumping, watch the stroke gauge (13) of the
hydraulic tensioning tools! Hydraulic tensioning tools may only be
pumped up until the marking (M) on the stroke gauge reaches the
upper edge of the threaded stop ring (14)! Otherwise, the hydraulic
tensioning tools will be damaged!
8. Using the tommy bar (000.262), screw down the nuts through the
opening in the thrust pads, hand-tight.
9. Release the pressure. Disconnect the high-pressure hoses from the
hydraulic tensioning tools.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
10. Remove the tensioning tools.
11. Reposition the tension screws (055.111), thrust pads (055.112), and
hydraulic tensioning tools (009.053) onto the cylinder head bolts
(4 and 8). See items 1 to 3. Refer to Figures 3 and 4 .
12. Reposition the thrust pads (009.055) and hydraulic tensioning tools
(009.053) onto the cylinder head bolts (2 and 6). See items 4 and
5. Refer to Figures 3 and 4 .
13. Connect the high-pressure hoses to the hydraulic tensioning tools.
009.03), and ten-
14. Switch on the high-pressure pump (see Work Card 009.03
sion the cylinder head bolts to tensioning pressure (600 bar).
Important! The cylinder head bolts (1, 3, 5, and 7) do not have to be
tensioned again. By tensioning the cylinder head bolts (2, 4, 6, and 8),
they are unloaded to the extent that all cylinder head bolts are evenly ten-
sioned.
15. Using the tommy bar, screw down the nuts through the opening in the
thrust pads, hand-tight.
16. Release the pressure. Disconnect the high-pressure hoses from the
hydraulic tensioning tools and high-pressure pump.
17. Remove the tensioning tools.
18. Slip the protecting caps (9) onto the cylinder head bolts.

6701 055.01--01 E 10.01 L 40/54 106/ 06

Cylinder head
Removing and refitting 055.02

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Cylinder heads are to be disassembled within the scope of maintenance

and repair work.
The work/steps include:
dismounting components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems drained
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Suspension device 055.118 Standard
1 Angular screw driver 050.120 Standard
1 Pilot rod 034.006 Standard
1 Torque wrench 008.017 Standard
1 Shackle A1.6 002.454 Standard
1 Shackle A1.0 002.453 Standard
1 Extension piece 20x400 001.914 Standard
1 Socket wrench insert 36x20 001.779 Optional
1 Lifting eye bolt M16 000.143 Standard
1 Lifting tackle -- Inventory
1 Open--jaw and ring wrenches (set) -- Inventory
2 Hexagon bolt (M16) with pin -- Inventory
1 Rope -- Inventory
1 Molykote HSC -- Inventory
1 Lubricating oil, clean -- Inventory

6701 055.02--01 E 12.06 L 40/54 101/ 10

Related work cards

Work card Work card Work card

000.08 000.30 055.01
113.01 114.01 434.01

Technical details

Term Information
Cylinder head with valves 1270 kg

Operating sequence 1 -- Removal of the cylinder head

Starting condition The cooling water has been drained completely and the cooling water for
the injection valve cooling system (if fitted) has been drained.

▲ Attention! Do not drain cooling water into the bilge or into the
sewage system! Pump cooling water into a separate tank and reuse
it (cooling water reconditioning agent)!

The running gear has been turned so that the piston of the cylinder con-
cerned is in the ignition-TDC position (all valves closed). The rocker arm
casing has been dismantled, and the push-rods have been removed.

Steps 1. Loosen or remove all pipes and pipe unions from the cylinder head
(3) concerned.
2. Partly remove the covering of the exhaust pipe.
3. Loosen the nuts (26) and unscrew them alternately.
4. Screw the lifting eye bolt (000.143) into the upper part of the quick-
acting coupling (19). Refer to Figure 2 /II.
5. Attach the rope (28) to the lifting eye bolt by means of the shackle
(002.453) and suspend it from the lifting tackle. Slightly tighten the
rope.
6. Screw two hexagon bolts (27) into the upper part of the quick-acting
coupling (19). By tightening the hexagon bolts alternately, loosen the
upper part of the quick-acting coupling. Refer to Figure 2 /II.
7. Remove the upper part of the quick-acting coupling (19) and place it
on a clean support. Refer to Figure 2 /III.
▲ Attention! Do not damage the studs (25) during removal!
8. Detach the rope (28) from the lifting eye bolt, unscrew the hexagon
bolts (27).
9. Dismantle the fuel injection pipe (see Work Card 434.01).
10. Untighten the cylinder head bolts (1) - see Work Card 055.01.
11. Unscrew the nuts (2).
12. Place the suspension device (055.118) on the cylinder head (3) and
attach it by means of the hexagon bolts (29). Refer to Figure 3 .
13. Screw the pilot rod (034.006) into the suspension device. Refer to
Figure 4 .
14. Attach the rope (28) to the suspension device by means of the
shackle (002.454).
15. Remove the cylinder head (3) carefully, guiding it by means of the
pilot rod. Refer to Figure 5 .

6701 055.02--01 E 12.06 L 40/54 102/ 10

 ▲ Attention! Do not damage the cylinder head bolts (1) and the cyl-
inder head sealing face during removal!
16. Place the cylinder head (3) on a clean support.
17. Remove the tools.
18. Remove the sealing ring (10) using the angular screw driver
(050.120). Refer to Figure 6 .
19. Remove the sealing rings (23) from the sleeves (22).
20. Cover all openings on the engine by suitable means, including the
openings of the push-rod coverings (11).
21. Close the opening on the exhaust pipe section (20) by means of the
closing cover.
22. Remove the O-ring seals (5, 8 and 9).
23. Clean the cylinder head (3) - see operating sequence 2.

Operating sequence 2 -- Cleaning the cylinder head

Starting condition The cylinder head has been removed.

Steps 1. Remove the inlet and exhaust valves (see Work Cards 113.01
and 114.01).
2. Check the inlet and exhaust ducts and the side facing the combustion
chamber with regard to deposits and, if necessary, remove deposits
adhering to them, but do not damage the surface in the process.
3. Check the cooling spaces for deposits, and remove the deposits if
necessary (see Work Card 000.08).
4. Clean the cylinder head from oil sludge.
5. Install the inlet and exhaust valves (see Work Cards 113.01
and 114.01).

Operating sequence 3 -- Fitting the cylinder head

Starting condition The cylinder head has been cleaned, the sealing faces between cylinder
head and top land ring as well as between cylinder head and exhaust pipe
section have been cleaned.

Steps 1. Insert a new sealing ring (10) into the groove.

2. Oil new O-ring seals (23) with clean lubricating oil and insert them
into the ring grooves, making sure that they are uniformly tensioned
over the entire circumference and are not twisted. Refer to Fig-
ure 1 .
3. Place the suspension device (055.118) on the cylinder head (3) and
attach it by means of the hexagon bolts (29). Refer to Figure 3 .
4. Screw the pilot rod (034.006) into the suspension device.
5. Attach the rope (28) to the suspension device by means of the
shackle (002.454) and suspend it from the lifting tackle.
6. Raise the cylinder head (3).
7. Oil new O-ring seals (5, 8 and 9) with clean lubricating oil and insert
them into the ring grooves, making sure that they are uniformly ten-
sioned over the entire circumference and are not twisted. Refer to
Figures 1 and 5 .
8. Position the cylinder head (3) over the centre of the cylinder. Refer to
Figure 5 .
9. Loosen the hexagon bolts (7) from the push-rod coverings (11).
Refer to Figure 1 .
Important! This permits the sleeves (6) to align themselves with the
cylinder head (3).
10. Fit the cylinder head (3) carefully, guiding it by means of the pilot rod.

6701 055.02--01 E 12.06 L 40/54 103/ 10

 ▲ Attention! When fitting the cylinder head, observe the following:
: Do not damage the cylinder head bolts (1),
: pay attention to the parallel pin (21) and the sleeves (22),
: pay attention to the alignment of sleeve (4)/push-rod covering
(11),
: pay attention to the alignment of the pipe section (18)/lower
part of quick-acting coupling (17)!
11. Remove the tools.
12. Screw the nuts (2) onto the cylinder head bolts (1) and tighten them
firmly by hand. Refer to Figure 1 .
13. Tighten the cylinder head bolts (1) - see Work Card 055.01.
14. Tighten the hexagon bolts (7) of the push-rod covering (11). Refer to
Figure 1 .
15. Fit the fuel injection pipe (see Work Card 434.01).
16. Screw the lifting eye bolt (000.143) into the upper part of the quick-
acting coupling (19).
17. Attach the rope (28) to the lifting eye bolt by means of the shackle
(002.453) and suspend it from the lifting tackle.
18. Position the upper part of the quick-acting coupling (19) over the
centre of the cylinder.
19. Attach the upper part of the quick-acting coupling (19) carefully.
▲ Attention! Do not damage the studs (25) during the fitting pro-
cess!
20. Remove the tools.
21. Apply Molykote HSC lubricant to the thread and contact face of the
nuts (26), screw the nuts onto the studs (25) and tighten them to the
specified torque (see Work Card 000.30).
22. Fit the covering of the exhaust pipe.
23. Fit all the pipes and pipe unions to the cylinder head (3) concerned.
24. After installing/fitting all engine components (push-rods, rocker arm
casing etc.), fill cooling water into the engine and vent the cooling
water pipe and injection valve cooling system.
25. After completion of the assembly work, check at operational cooling
water pressure whether the O-ring seals are in order and no water is
leaking from the check bore holes (A and B). Refer to Figure 1 .
26. With the engine running, check the cylinder at the check bore holes
(A) to verify that no gas is leaking. Refer to Figure 1 .
▲ Attention! If the cylinder head leaks despite the fact that the cylin-
der head screws have been tightened correctly, it must be detached
again and the sealing ring (10) has to be checked!

6701 055.02--01 E 12.06 L 40/54 104/ 10

 1 Cylinder head bolt
2 Nut
3 Cylinder head
4 Sleeve
5 O-ring seal
6 Sleeve
7 Hexagon bolt
8 O-ring seal
9 O-ring seal
10 Sealing ring
11 Push-rod covering
12 Backing ring
13 Cylinder crankcase
14 Piston
15 Cylinder liner
16 Top land ring
17 Quick-acting coupling,
lower part
18 Pipe section
19 Quick-acting coupling,
upper part
20 Exhaust pipe section
21 Parallel pin
22 Sleeve
23 O-ring seal

A Check bore hole

B Check bore hole
ST Control side

Figure 1. Cylinder head

6701 055.02--01 E 12.06 L 40/54 105/ 10

 17 Quick-acting coupling, lower part 26 Nutr
18 Pipe section 27 Hexagon bolt with pin M16x80
19 Quick-acting coupling, upper part 28 Rope
20 Exhaust pipe section
24 Nut I-III Steps
25 Stud

Figure 2. Cylinder head - Removing and fitting the upper part of the quick-acting coupling

6701 055.02--01 E 12.06 L 40/54 106/ 10

 3 Cylinder head
29 Hexagon bolt M24x180

ST Control side

Figure 3. Cylinder head - Fitting the suspension device

6701 055.02--01 E 12.06 L 40/54 107/ 10

 1 Cylinder head bolt
3 Cylinder head
4 Sleeve
6 Sleeve
18 Pipe section
20 Exhaust pipe section
28 Rope

ST Control side

Figure 4. Cylinder head - Removing/fitting

6701 055.02--01 E 12.06 L 40/54 108/ 10

 1 Cylinder head bolt 9 O-ring seal 17 Quick-acting coupling,
3 Cylinder head 10 Sealing ring lower part
4 Sleeve 11 Push-rod covering 18 Pipe section
5 O-ring seal 12 Backing ring 20 Exhaust pipe section
6 Sleeve 15 Cylinder liner 28 Rope
7 Hexagon bolt 16 Top land ring
8 O-ring seal ST Control side

Figure 5. Cylinder head - Removing/fitting

6701 055.02--01 E 12.06 L 40/54 109/ 10

 10 Sealing ring ST Control side
16 Top land ring I-II Steps

Figure 6. Removal of the sealing ring

6701 055.02--01 E 12.06 L 40/54 110 / 10

Cylinder head
Grinding of seating faces 055.03

Purpose of jobs to be done

Ensure correct execution of work,

assess wear pattern/condition,
restore contact pattern.

Brief description

In case the wear pattern of a valve seat is incorrect, the seat is to be

regenerated (continuos bearing area) by grinding.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Qty Designation No. Availability

1 Grinding tool 055.171 Standard
1 Tool rod 055.171--1 Standard
1 Guide tube 055.171--2 Standard
1 Stop plate 055.171--3 Standard
1 Extension 055.171--6 Standard
1 Grinding wheel 055.171--9 Standard
1 Grinding wheel 055.171--10 Standard
1 Tap wrench 055.171--31 Standard
1 Cleaning device 055.121 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Grinding paste (silicon--free) -- Inventory
1 Torch -- Inventory
1 Depth gauge -- Inventory

Related work cards

Work card Work card Work card

161.01 221.01

Preliminary remark

Important! Whenever valves are removed, the valve seating face

in the cylinder head is to be checked by an inking test. This test must

6621 055.03--04 E 12.00 L 40/54 101/ 04

 show a continuous bearing area on the valve seat. If this is not so, the
valve seat requires regrinding.

Operating sequence 1 -- Grinding of the valve seating faces

Starting condition The respective valve (injection or starting valve) resp. both valves re-
moved.

Steps 1. Take the parts for grinding the valve seating face out of the wooden
box and assemble them. Refer to Figure 1 or 3 .
Important! Do not forget the stop plate (055.171-3). It prevents
tilting of the grinding wheel.
2. Apply grinding paste to the grinding wheel.
3. Introduce the grinding tool in the cylinder head (1) resp. insert (2),
mount the extension (055.171-6) and tap wrench (055.171-31).
4. Move the grinding tool to and fro in a rotating movement, lift it in be-
tween so that the grinding paste can redistribute.
▲ Attention! Do not grind more material away than necessary to
obtain a seating face (A) that is bright and free from defects over the
full width. Therefore, check the seating face from time to time during
the grinding process.
5. When the grinding has been finished, take the grinding tool out and
carefully clean the seating face using the cleaning device (055.121).
6. Clean the grinding tool, disassemble it and put the parts back into the
wooden box.
7. After repetitive grinding of a seating face, determine and note down
dimension (B) (cylinder head being removed). Refer to Figure 2
or 4 .
Important! Admissible minimum dimensions:
injection valve seat .............. 53 mm,
starting valve seat ............... 63 mm.

In case a measured dimension is smaller than the permissible dimension,

the cylinder head resp. insert must be replaced.

6621 055.03--04 E 12.00 L 40/54 102/ 04

 1 Cylinder head
2 Insert
3 Feather key
4 Washer
5 Hexagon nut M 10

A Seating face

Figure 1. Grinding (on the left) and cleaning (on the right) of injection valve seating face in the cylinder head

2 Insert

B Admissible minimum
dimension
C Cylinder head bottom
edge

Figure 2. Admissible minimum dimension for grinding the injection valve seating
face

6621 055.03--04 E 12.00 L 40/54 103/ 04

 1 Cylinder head
3 Feather key
4 Washer
5 Hexagon nut M 10

A Seating face

Figure 3. Grinding (on the left) and cleaning (on the right) of starting valve seating face in the cylinder head

1 Cylinder head

B Admissible minimum
dimension
C Cylinder head bottom
edge

Figure 4. Admissible minimum dimension for grinding the starting valve seating face

6621 055.03--04 E 12.00 L 40/54 104/ 04

Valve seat rings
Removing and installing 055.04

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Removal and installation of valve seat rings are not part of the work
specified in the maintenance schedule.
The work/steps include:
removal of components,
installation of components.

Tools/appliances required

Qty Designation No. Availability

1 Extractor 113.193 Standard
1 Fitting/unfitting tool 113.137 Standard
1 Thrust pad 113.137--1 Standard
1 Guide piece 113.137--3 Standard
1 Ring 113.137--5 Standard
1 Clamping piece 113.137--7 Standard
1 High--pressure pump 009.341/(009.338) Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning device (hollow piston) 009.022 Standard
1 Counterbrace 002.525 Standard
1 Extractor 002.513 Standard
1 Gloves (neoprene) -- Inventory
1 Open--jaw and ring wrenches (set) -- Inventory
1 Micrometer (inside) -- Inventory
1 Sliding caliper -- Inventory
1 Welding apparatus (autogenous) -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

000.21 009.03 009.05
055.02 113.01 113.03
113.04 114.01

6701 055.04--01 E 09.06 L 40/54 101/ 10

Preliminary remark

Inlet and exhaust valve seat rings have to be removed and replaced
: if there are corrosion or pounding marks, which cannot be
machined away by grinding or turning,
: if spalling or blow-by or stress cracks have been found, and
: if the remachining limit has been reached (see Work Card 113.04
113.04).

Operating sequence 1 -- Removal of an inlet and/or exhaust valve seat ring

Starting condition The cylinder head has been removed and clamped into the cylinder head
turnover stand and carefully cleaned from oil and fuel. The valve con-
cerned has been removed. The combustion chamber side points up-
wards.

Attention / Danger! Removing an exhaust valve seat ring (4):

If the working instructions are not observed, the impact of severe
heat may cause decomposition of the O-ring seals (6 and 7) which
results in the development of highly toxic and caustic vapours (hy-
000.21!
drofluoric acid) - see Work Card 000.21

Steps 1. Using the welding torch (1), heat the inlet valve seat ring (3) and/or
the exhaust valve seat ring (4) at the valve seat at four points, stag-
gered by approx. 90ƒ , until the material starts melting. Refer to Fig-
ure 1 .
▲ Attention! The removal of inlet or exhaust valve seat rings with-
out prior heating and cooling down is not possible!
2. Let the cylinder head (2) together with the valve seat ring cool down.
Important! The tangential tension in the heated zone is reduced
because the yield point is exceeded.
3. Slacken the expanding solid (15) far enough to permit the extractor
(002.513) to be inserted into the inlet and/or exhaust valve seat ring
(3 and/or 4). Refer to Figure 2 /I and 3 /I respectively.
4. Place the complete extractor (113.193, consisting of counter support
and extractor) over the valve seat ring.
Important! The bolt (11) with the attached plate (14) has to be posi-
tioned towards the interior of the cylinder head so as to ensure that the
extractor is placed vertically to the valve seat.
5. After loosening the hexagon nuts (10), align the bolts (11) so as to
ensure that they fully rest on the cylinder head (2). Afterwards, re-
tighten the hexagon nuts.
6. Lower the shells (13) by turning the spindle (8) until they are posi-
tioned before the gap (D) between the inlet and/or exhaust valve seat
rings (3 and/or 4) and the cylinder head (2). Refer to Figure 2 /II
and 3 /II respectively.
7. Hold the crown (12) in place, and expand the extractor as far as
possible by turning the spindle (8). Refer to Figure 2 /III and 3 /III
respectively.
▲ Attention! Make sure that the shells engage in the gap between
valve seat ring and cylinder head!
8. Pull the inlet and/or exhaust valve seat ring (3 and/or 4) out by uni-
formly turning the setting nut (9). Refer to Figure 2 /IV and 3 /IV
respectively.

6701 055.04--01 E 09.06 L 40/54 102/ 10

 ▲ Attention! Make sure that the valve seat ring is pulled out uni-
formly, i.e., that it is not tilted!
9. Remove the valve seat ring including tool from the cylinder head.
10. Take the tool off.
11. When removing an exhaust valve seat ring (4), take off the O-ring
seals (6 and 7).
▲ Attention! In case decomposition or brown discolouration is de-
tected on the O-ring seals, neoprene gloves must be worn when
handling them!
12. Check the locating bore in the cylinder head (2) for damage and
check the dimension (B) at several points. Refer to Figure 4
and 5 respectively.

Max. admissible dimension (B): Inlet valve .... 138.026 mm

Exhaust valve .... 152.026 mm.

▲ Attention! In case the dimension (B) is exceeded, MAN Diesel SE

has oversize valve seat rings available, for which the locating bore
has to be remachined!

Operating sequence 2 -- Installation of an inlet valve seat ring

Starting condition The cylinder head has been clamped into the cylinder head turnover stand
(combustion chamber side pointing upwards). The locating bore in the
cylinder head has been cleaned and measured.

Steps 1. Slip the guide piece (113.137-3) into the valve guide (16). Slip the
clamping piece (113.137-7) on, and screw the hexagon nut (17) all
the way on by hand until it is seated (do not use the open-jaw/ring
wrench to do so).
2. Place the thrust pad (113.137-1) on the new inlet valve seat ring (3),
slip them over the guide piece together, and centre them in the
locating bore by hand. Refer to Figure 6 /I.
3. Slip the hydraulic hollow-piston tensioning device (009.022) over the
guide piece, slip the ring (113.137-5) on, and screw the hexagon nut
(18) on, hand-tight. Refer to Figure 6 /II.
4. Connect the high-pressure hose (009.306) to the hydraulic hollow-
piston tensioning device and high-pressure pump (009.338 or
009.341). Connect the oil pressure gauge (0 - 400 bar) to the high-
pressure pump.
009.03),
5. Take the high-pressure pump into operation (see Work Card 009.03
and slowly pump up the hydraulic hollow-piston tensioning device.
▲ Attention! While pumping, watch the oil pressure gauge! A
sudden pressure increase during the forcing-in process indicates
that the inlet valve seat ring has become tilted!
6. Pump the hydraulic hollow-piston tensioning device up until the inlet
valve seat ring (3) is seated. Refer to Figure 6 /III.
▲ Attention! Shortly before the inlet valve seat ring becomes
seated, watch the oil pressure gauge carefully! Seating is indicated
by an intense pressure rise!
7. Release the pressure.
8. Disconnect the high-pressure hose from the hydraulic hollow-piston
tensioning device and high-pressure pump.
9. Remove the tools.
10. Check the gap (D) for uniform width at several points.
11. Grind the inlet valve seat ring (3) using the valve seat grinder, or turn
it by means of the valve seat turning machine, and carry out an ink

6701 055.04--01 E 09.06 L 40/54 103/ 10

 contact (”touching”) test using a new valve cone (see Work Cards
113.04).
113.03 and 113.04
12. Install the inlet valve together with a new or remachined valve cone
(see Work Card 113.01).
113.01

Operating sequence 3 -- Installation of an exhaust valve seat ring

Starting condition The cylinder head has been clamped into the cylinder-head turnover stand
(combustion chamber facing upwards). The locating bore in the cylinder
head and the bush have been cleaned. The locating bore has been
measured.

Steps 1. Slip the guide piece (113.137-3) into the valve guide (16). Slip the
clamping piece (113.137-7) on, and screw the hexagon nut (17) all
the way on by hand until it is seated (do not use an open-jaw or ring
wrench to do so).
2. Coat a new O-ring seal (7) with clean lubricating oil and insert it into
the groove, making sure that it is not twisted.
3. Coat a new O-ring seal (6) with clean lubricating oil and insert it into
the groove, making sure that it is evenly tensioned over the entire
circumference and not twisted.
4. Place the thrust pad (113.137-1) on a new exhaust valve seat ring
(4), slip them over the guide piece together, and centre them in the
locating bore by hand. Refer to Figure 7 /I.
5. Slip the hydraulic hollow-piston tensioning device (009.022) over the
guide piece, slip the ring (113.137-5) on, and screw the hexagon nut
(18) on, hand-tight. Refer to Figure 7 /II.
6. Connect the high-pressure hose (009.306) to the hydraulic hollow-
piston tensioning device and high-pressure pump (009.338 or
009.341). Connect the oil pressure gauge (0 - 400 bar) to the high-
pressure pump.
009.03)
7. Take the high-pressure pump into operation (see Work Card 009.03
and slowly pump up the hydraulic hollow-piston tensioning device.
▲ Attention! While pumping, watch the oil pressure gauge! A
sudden pressure increase during the forcing-in process indicates
that the exhaust valve seat ring has become tilted!
8. Pump the hydraulic hollow-piston tensioning device up until the ex-
haust valve seat ring (4) is seated. Refer to Figure 7 /III.
▲ Attention! Shortly before the exhaust valve seat ring becomes
seated, watch the oil pressure gauge carefully! Seating is indicated
by an intense pressure rise!
9. Release the pressure.
10. Disconnect the high-pressure hose from the hydraulic hollow-piston
tensioning device and high-pressure pump.
11. Remove the tools.
12. Check the gap (D) for uniform width at several points.
13. Grind the exhaust valve seat ring (4) using the valve seat grinder, or
turn it by means of the valve seat turning machine, and carry out an
ink contact (”touching”) test using a new valve cone (see Work Cards
113.04).
113.03 and 113.04
14. Install the exhaust valve together with a new or reground valve cone
114.01).
(see Work Card 114.01

6701 055.04--01 E 09.06 L 40/54 104/ 10

 1 Welding torch 5 Bush A Heating areas
2 Cylinder head 6 O-ring seal ST Control side
3 Inlet valve seat ring 7 O-ring seal
4 Exhaust valve seat ring

Figure 1. Heating the valve seat rings

6701 055.04--01 E 09.06 L 40/54 105/ 10

 2 Cylinder head 11 Bolt D Gap (cylinder head/inlet
3 Inlet valve seat ring 12 Crown valve seat ring)
8 Spindle 13 Shell I-IV Order of work steps
9 Setting nut 14 Plate
10 Hexagon nut 15 Expanding solid

Figure 2. Removal of an inlet valve seat ring

6701 055.04--01 E 09.06 L 40/54 106/ 10

 2 Cylinder head 10 Hexagon nut 15 Expanding solid
4 Exhaust valve seat ring 11 Bolt D Gap (cylinder head/
5 Bush 12 Crown exhaust valve seat ring)
8 Spindle 13 Shell I-IV Order of work steps
9 Setting nut 14 Plate

Figure 3. Removal of an exhaust valve seat ring

6701 055.04--01 E 09.06 L 40/54 107/ 10

 2 Cylinder head

B Maximum admissible
dimension of the
locating bore

Figure 4. Locating bore for the inlet valve seat ring in the cylinder head

2 Cylinder head

B Maximum admissible
dimension of the
locating bore

Figure 5. Locating bore for the exhaust valve seat ring in the cylinder head

6701 055.04--01 E 09.06 L 40/54 108/ 10

 2 Cylinder head C Contact face on the cylinder head
3 Inlet valve seat ring D Gap between the cylinder head and the inlet
16 Valve guide valve seat ring
17 Hexagon nut M24 I-III Order of work steps
18 Hexagon nut M24

Figure 6. Installation of the inlet valve seat ring

6701 055.04--01 E 09.06 L 40/54 109/ 10

 2 Cylinder head 18 Hexagon nut M24
4 Exhaust valve seat ring
5 Bush C Contact face on the cylinder head
6 O-ring seal D Gap between cylinder head and exhaust
7 O-ring seal valve seat ring
16 Valve guide I-III Order of work steps
17 Hexagon nut M24

Figure 7. Installation of an exhaust valve seat ring

6701 055.04--01 E 09.06 L 40/54 110 / 10

Cylinder head with turnover stand
Machining 055.05

Purpose of jobs to be done

Impart the necessary knowledge,

ensure proper application.

Brief description

On cylinder heads, various jobs are to be carried out at regular intervals.

For this purpose, the turnover stand is to be used.
The work includes:
clamping components.

Tools/appliances required

Qty Designation No. Availability

1 Turnover stand 055.130 Optional
1 Open--jaw and ring wrenches (set) -- Inventory

Related work cards

Work card Work card Work card

055.02 055.03 055.04
113.03

General

The turnover stand is suitable for:

- Thorough cleaning and checking of cylinder heads,
- Grinding the valve seat surfaces in the cylinder head (see work
055.03),
card 055.03
- Checking the valve seats (see work card 113.03
113.03),
- Measuring the inlet and exhaust valve seat surfaces,
- Removing and installing valve seat rings in cylinder head
(see work card 055.04).
055.04

Step -- Clamping cylinder head

Starting condition Cylinder head is suspended on lifting tackle by suspension device.

Steps 1. Attach adapter plates (2 and 9) securely to cylinder head (8).

6644 055.05--01 E 09.06 L 40/54, 48/60 101/ 02

 2. Adjust clamping head (4) by turning the hand wheel on the turnover
gear (3) so that the fastening bow (5) faces upwards.See Figure 1 .
3. Open fastening bow and locking bolt (10).
4. Put cylinder head in place and clamp with fastening bow. Close lok-
king bolt. See Figure 1 .
5. Remove suspension device.
Important! The cylinder head can now be brought into the required
position with the locking lever (7) folded up, by turning the hand wheel
(possibility of locking every 45•).

▲ Attention! When working on the cylinder head, it is essential to

engage locking lever in a groove in the clamping head (4).
6. For storage of the adapter plates, these can be attached to the
frame (1).

1 Frame for 6 Turnover shaft axis 11 Exhaust valve

turnover stand 7 Locking lever 12 Inlet valve
2 Adapter plate 8 Cylinder head 13 Collecting tank
3 Turnover gear 9 Adapter plate 14 Enveloping circle
4 Clamping head 10 Locking bolt (cylinder head with val-
5 Fastening bow ves)

Figure 1. Turnover stand with cylinder head clamped on

6644 055.05--01 E 09.06 L 40/54, 48/60 102/ 02

Cylinder head
Refacing of the injection valve
seating face 055.06

Purpose of jobs to be done

Ensure correct execution of work,

assess wear pattern/condition,
restore contact pattern.

Brief description

In case a correct contact pattern (continous bearing area) of the injection

valve seat could not be established by grinding, the valve seat is to be
regenerated by refacing.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Quant Denomination No. Availability

1 Cleaning device 055.121 Standard
1 Grinding tool 055.171 Standard
1 Tool rod 055.171--1 Standard
1 Guide tube 055.171--2 Standard
1 Stop plate 055.171--3 Standard
1 Facing head 055.171--4 Standard
1 Guide bush 055.171--5 Standard
1 Washer 055.171--7 Standard
1 Washer 055.171--8 Standard
1 Pot sleeve 055.171--14 Standard
1 Plate 055.171--16 Standard
1 Clamping piece 055.171--30 Standard
1 Tap wrench 055.171--31 Standard
1 Pliers for retaining rings A 19--60 002.122 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Hexagon screw driver (set) -- Inventory
1 Grease (acid--free) -- Inventory
1 Depth gauge -- Inventory

Related work cards

Work card Work card Work card

055.02 055.05 221.01

6621 055.06--02 E 01.98 40/54 101/ 04

 1 Hexagon nut 5 Insert 10 Hexagon nut M6
2 Hexagon socket screw 6 Locking ring
M8x25 7 Feather key A Injection valve seating
3 Stud bolt 8 Washer face
4 Cylinder head 9 Hexagon nut M10

Figure 1. Refacing (on the left) and cleaning (on the right) of injection valve seating face

6621 055.06--02 E 01.98 40/54 102/ 04

Preliminary remark

Refacing of the injection valve seating face in the cylinder head becomes
necessary in cases where a continuous face of at least half the seat width
cannot be obtained by grinding (work card 055.03).
055.03

▲ Attention! Unnecessary refacing will in each case reduce the

service life of the insert (5).

The starting valve seating face and the exhaust valve cage seating
face in the cylinder head can also be subjected to refacing. The MAN
B&W Service Bases have the facing tools required for this job in
possession. We have to point out that refacing of these valve seats
is only permitted to be done by service personnel because improper
refacing of these valve seats would entail replacement of the
complete cylinder head.

Operating sequence 1 -- Refacing of the injection valve seat

Starting condition The cylinder head is removed and clamped onto a reversing jig, the
injection valve is removed.

Steps 1. Take the corresponding parts for refacing the injection valve seating
face out of the wooden box and assemble them. Refer to Figure 1 .
2. Apply a thin film of grease on the facing head (055.171-4).
3. Introduce the facing tool in the insert (5), put the plate (055.171-16)
over stud screws (3) onto clamping piece (055.171-30) and secure it
by screwing the hexagon nut (1) on loosely.
Important! The weight of the plate serves to apply pressure to the
facing head. Normally, no additional pressure should be exerted during the
facing operation.
4. Stick tap wrench (055.171-31) onto tool rod (055.171-1).
5. Slightly remachine the injection valve seating face (A), only
smoothing it and removing as little material as possible.
6. Remove hexagon nuts and pull facing tool carefully out of the insert.
7. Clean injection valve seating face with cleaning device (055.121),
thoroughly removing any chips.
8. Clean facing tool, disassemble it and put the parts back into the
wooden box.
9. Determine measurement (B) and note down. Refer to Figure 2 .
Important! Admissible minimum dimension: ............... 53 mm.

In case the dimension measured is smaller than the admissible dimension,

the insert must be replaced.

6621 055.06--02 E 01.98 40/54 103/ 04

 5 Insert

B Admissible minimum
dimension
C Cylinder head bottom
edge

Figure 2. Minimum admissible dimension during refacing of the injection valve

seating face

6621 055.06--02 E 01.98 40/54 104/ 04

Crankcase cover

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

6682 073--05 E 07.99 101/ 01

Covering on the coupling side
Removing and refitting 071.01

Purpose of jobs to be done

Insert/replace components,
proper processing and installation.

Brief description

The covering on the coupling side is only to be dismantled for the purpose
of removing the outer main bearing cap.
The work/steps include:
dismounting components,
mounting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Torque wrench 008.017 Standard
2 Shackle A1.0 002.453 Standard
1 Adapter 12.5x20 001.927 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Screw driver insert 14x12.5 001.858 Standard
1 Ratchet 001.521 Standard
2 Lifting eye bolt M16 000.143 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Wood (for placing underneath) -- Inventory
1 Hexagon nut M10 -- Inventory
1 Securing compound -- Inventory
(Loctite 243)
1 Sealing compound (silicone) -- Inventory

6701 071.01--01 E 08.00 L 40/54, 48/60 101/ 05

Related work cards

Work card Work card Work card

000.19 000.30

Technical details

Term Information
Covering lower part L 40/54: 27 kg
L 48/60: 24.5 kg
V 48/60: 27.5 kg
Splash ring half L 40/54: 16 kg
L 48/60: 10.5 kg
V 48/60: 12.5 kg
Covering half L 40/54: 60 kg
L 48/60: 73.5 kg
V 48/60: 84 kg
Covering upper part L 40/54: 25 kg
L 48/60: 24.5 kg
V 48/60: 27.5 kg

Operating sequence 1 -- Removal

Steps 1. Remove all pipes which would be hindering when dismantling the
covering.
2. Dismantle the drain pipe (17) including seals (18).
3. Screw two lifting eye bolts (000.143) into the upper covering part (4),
attach the rope to the lifting eye bolts by means of shackle (002.453)
and suspend the rope from the lifting tackle.
4. Remove two taper pins (9).
5. Screw off hexagon nuts (1) and hexagon bolts (3), and remove
hexagon bolts (2). Dismantle the upper covering part.
6. Remove the tools.
7. Screw two lifting eye bolts (000.143) into the lower covering part (21),
attach the rope to the lifting eye bolts by means of shackle (002.453)
and suspend the rope from the lifting tackle. Tighten the rope.
8. Remove two taper pins (11).
9. Screw off the hexagon bolts (3) and remove the lower covering part.
10. Remove the tools.
11. Screw two lifting eye bolts (000.143) into the right-hand covering half
(22), attach the rope to the lifting eye bolts by means of shackle
(002.453) and suspend the rope from the lifting tackle.
12. Remove the taper pins (10, 20 and 23).
13. Screw off the hexagon nuts (5) and hexagon bolts (12 and 15) for the
right-hand covering half, and remove the hexagon bolts (6 and 19).
Dismantle the right-hand covering half.
14. Remove the tools.
15. Screw two lifting eye bolts (000.143) into the left-hand covering half
(13), attach the rope to the lifting eye bolts by means of shackle
(002.453) and suspend the rope from the lifting tackle.
16. Screw off the hexagon bolts (12 and 15) for the left-hand covering
half and remove the left--hand covering half.
17. Support the lower part of the splash ring using appropriate means
(e.g., a wooden block).

6701 071.01--01 E 08.00 L 40/54, 48/60 102/ 05

 18. Screw off the hexagon socket bolts (26), and take off the upper part
of the splash ring (24).
19. Remove the lower part of the splash ring (25), paying attention to the
parallel pin (27).
20. Clean all individual parts, check the upper and lower part of the
splash ring for damage.

1 Hexagon nut 10 Taper pin 19 Hexagon bolt

2 Hexagon bolt 11 Taper pin 20 Taper pin
3 Hexagon bolt 12 Hexagon bolt 21 Covering, lower part
4 Covering, upper part 13 Left-hand covering half 22 Right-hand covering half
5 Hexagon nut 14 Oil sump 23 Taper pin
6 Hexagon bolt 15 Hexagon bolt 24 Splash ring - upper part
7 Crankshaft 16 Hexagon bolt 25 Splash ring - lower part
8 Cylinder crankcase 17 Drain pipe
9 Taper pin 18 Seal

Figure 1. Covering on the coupling side (illustration shows 40/54 in-line engine)

6701 071.01--01 E 08.00 L 40/54, 48/60 103/ 05

 7 Crankshaft
24 Splash ring - upper
part
25 Splash ring - lower part
26 Hexagon socket bolt
27 Parallel pin

Figure 2. Splash ring (illustration shows 40/54 in-line engine)

Operating sequence 2 -- Fitting

Steps 1. Clean the contact face of the cylinder crankcase (8).

2. Clean the crankshaft (7) in the splash ring area.
3. Lay the lower part of the splash ring (25) against the crankshaft and
support it using appropriate means (e.g., a wooden block).
▲ Attention! When laying the lower part of the splash ring against
the crankshaft, pay attention to the position of the parallel pin (27)!
4. Put the upper part of the splash ring (24) onto crankshaft and lower
part of the splash ring.
5. Coat the thread of the hexagon socket bolts (26) with securing
compound Loctite 243, screw in the hexagon socket bolts and tighten
000.30).
them to the specified torque (see work card 000.30
6. Remove the support for the lower part of the splash ring.
7. Screw lifting eye bolts (000.143) into the left-hand covering half (13),
attach the rope to the lifting eye bolts by means of shackle (002.453),
and suspend the rope from the lifting tackle.
8. Apply sealing compound Silicone Rhodorsil to the contact faces of
the left-hand covering half.
9. Fit the left-hand covering half, loosely screw the hexagon bolts (12
and 15) down, all the way.
▲ Attention! When attaching the covering halves (13 and 21), make
sure that the splash ring is not damaged!
10. Remove the tools.
11. Attach the right-hand covering half (22) in the same way. Refer to
items 7 to 10.
12. Loosely connect the right-hand and the left-hand covering half by
means of hexagon nuts (5) and hexagon bolts (6 and 19).
13. By inserting two taper pins (20 and 23), fix the right-hand and the
left-hand covering half. Tighten the hexagon nuts.
14. Using two taper pins (10), fasten the covering halves to the cylinder
crank case (8), tighten the hexagon bolts (12 and 15).
15. Screw lifting eye bolts (000.143) into the lower covering part (21),
attach the rope to the lifting eye bolts by means of shackle (002.453),
and suspend the rope from the lifting tackle.
16. Cover the contact face of the lower covering part with sealing
compound Silicone Rhodorsil.

6701 071.01--01 E 08.00 L 40/54, 48/60 104/ 05

 17. Fit the lower covering part, loosely screw the hexagon bolts (3) in, all
the way.
18. Remove the tools.
19. Fit the upper covering part (4) in the same way. Refer to items 15 to
18.
20. Insert the hexagon bolts (2) and loosely screw the hexagon nuts (1)
on, all the way.
21. By inserting two taper pins (9), fix the upper and lower covering part.
Tighten the hexagon nuts.
22. Using two taper pins (11), fasten the covering halves to the cylinder
crank case. Tighten the hexagon bolts.
23. Fit the drain pipe (17) together with seals (18) and align it. Screw in
the hexagon bolts (16) and tighten them.

6701 071.01--01 E 08.00 L 40/54, 48/60 105/ 05

Safety valve on the crankcase cover
Checking, removing and refitting 073.01

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Safety valves on the crankcase covers are to be examined for ease of

motion at regular intervals.
The work/steps include:
checking of components,
removal and installation of components.

Safety requirements

- Engine shut down

Tools/appliances required

Qty Designation No. Availability

1 Torque wrench 008.029 Standard
1 Adapter 12.5x10 001.922 Standard
1 Socket wrench insert 19x12.5 001.755 Standard
1 Open--jaw and ring wrenches (set) -- Inventory
1 Metal adhesive (Loctite Adhaesiv 307) -- Inventory
1 Securing compound Loctite 270 -- Inventory

Related work cards

Work card Work card Work card

000.19

Technical details

Term Information
Crankcase cover with safety valve 24.5 kg
Safety valve 6.5 kg

6701 073.01--03 E 08.06 L 40/54 101/ 04

Preliminary remarks

Checking all the safety valves mounted on the crankcase for ease of mo-
tion is to ensure that pressure increases/pressure waves occurring, e.g.
after explosions, can be safely controlled.

▲▲ Caution! 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!

Operating sequence 1 -- Checking the safety valves

Steps 1. Loosen the hexagon nuts (5), and turn the retaining clamps (4) out of
the way.
2. Take the crankcase cover (2) off.
3. Verify that the safety valve (3) is in good condition and moves easily.
If necessary, remove it and replace it by a new safety valve (see Op-
erating Sequence 2).
4. Check the valve plate (9), the compression spring (10), and the O-
ring seal (8) for damage; if necessary, remove the safety valve (3)
and replace it by a new safety valve (see Operating Sequence 2).
Refer to Figure 2 .
5. Check the sealing ring (1) for damage, and replace it if necessary.
Important! Prior to installing a new sealing ring, the groove in the
crankcase cover has to be cleaned from adhering remainders of adhesive.
The new sealing ring is to be sticked in using metal adhesive (Loctite
000.19.
Adhaesiv 307) - see Work Card 000.19
6. Place the crankcase cover (2) on the spring pins (7), and attach it to
the cylinder crankcase (6).
7. Turn the retaining clamps (4) back and tighten the hexagon nuts (5).
8. Check the remaining safety valves in the same way.

Operating sequence 2 -- Removing and fitting the safety valve

Starting condition The crankcase cover with safety valve has been removed.

Steps 1. Unscrew the hexagon nuts (12), and take the safety valve (3) off the
crankcase cover (2).
2. Remove the seal (13).
3. Fit a new seal (13).
4. Check the new safety valve (3) to verify that it moves easily.
5. Slip the new safety valve (3) over the studs (11).
6. Coat the thread and seating face of the hexagon nuts (12) with secur-
ing compound Loctite 270, screw the hexagon nuts onto the
studs (11), and tighten them applying a torque of max. 44 Nm.

6701 073.01--03 E 08.06 L 40/54 102/ 04

 1 Sealing ring
2 Crankcase cover
3 Safety valve
4 Retaining clamp
5 Hexagon nut
6 Cylinder crankcase
7 Spring pin

Figure 1. Crankcase cover with safety valve attached

6701 073.01--03 E 08.06 L 40/54 103/ 04

 2 Crankcase cover
8 O-ring seal
9 Spring plate
10 Compression spring
11 Stud
12 Hexagon nut
13 Seal

Figure 2. Safety valve

6701 073.01--03 E 08.06 L 40/54 104/ 04

Camshaft drive

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

6682 100--06 E 07.99 101/ 01

Camshaft drive
Checking 100.01

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

The camshaft drive is to be inspected for changes at regular intervals, the

wear pattern is to be assessed so that sources of disturbances are
recognized and, if necessary, remedied in time.
The work includes:
checking components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Thickness gauges 0.05--1 000.451 Inventory
1 Open--jaw and ring wrenches (set) -- Inventory

Related work cards

Work card Work card Work card

020.03

Operating sequence 1 -- Checking the camshaft drive

Starting condition The cover on the camshaft drive has been removed.

Steps 1. Visually inspect all gear wheels (1, 3, 6 and 8).

2. Measure flank clearances with thickness gauges (000.451), note
down the values and compare them with the specified values
(see Volume B1 / Operating Instructions).
3. Determine the bearing and axial clearance of the double spur
wheel (3), note down the values and compare them with the specified
values (see Volume B1 / Operating Instructions).

6701 100.01--01 E 08.06 L 40/54 101/ 03

 4. Determine the bearing and axial clearance of the spur wheel (6), note
down the values and compare them with the specified values (see
Volume B1 / Operating Instructions).
5. Check the hexagon bolts (9 and 10) for firm tightening.
6. Check all spray nozzles to see if they work correctly.
Important! Purge clogged spray nozzles with compressed air.
7. Check all bolted connections (spray nozzles etc.) for firm tightening.

Operating sequence 2 -- Overhaul work on the camshaft drive

Recommendation You are advised to have overhaul work on the camshaft drive done at an
after-sales service centre or by MAN B&W Diesel personnel.

▲ Attention! During overhaul work that requires an interruption of

the drive from the crankshaft to the camshaft, turn the running gear
only if all push-rods of the inlet and outlet valves have been re-
moved (otherwise the opened inlet and outlet valves may be dam-
aged by rising pistons)!

Crankshaft gear wheel For details regarding checking the crankshaft gear wheel (1), see Work
020.03.
Card 020.03

6701 100.01--01 E 08.06 L 40/54 102/ 03

 1 Crankshaft gear wheel 6 Spur wheel
2 Crankshaft 7 Camshaft
3 Double spur wheel 8 Camshaft gear wheel
4 Axle 9 Hexagon bolt
5 Spacer 10 Hexagon bolt

Figure 1. Camshaft drive

6701 100.01--01 E 08.06 L 40/54 103/ 03

Camshaft bearing/
Camshaft thrust bearing

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

6682 102--03 E 07.99 101/ 01

Camshaft bearing bolts
Checking, untightening and tightening 102.01

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

Camshaft bearing 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

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 High--pressure pump 009.338 Standard
2 High--pressure hose 009.306 Standard
2 Hydraulic tensioning tool 009.057 Standard
1 Torque wrench 008.016 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 Thickness gauges 0.05--1 000.451 Standard
1 Tommy bar, 5 mm 000.272 Standard
1 Tommy bar, 6 mm 000.261 Standard
1 Depth gauge -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30 000.32 000.33
009.03 009.05 009.19

6701 102.01--01 E 11.01 L 40/54 101/ 05

Technical details

Term Information
Bolt projection (A) 66 mm

1 Hexagon nut
2 Camshaft bearing bolt
3 Cylinder crankcase
4 Bearing block
5 Hexagon bolt
6 Bearing body
7 Bearing cap
8 Hexagon nut

A Bolt projection

Figure 1. Camshaft bearing

Operating sequence 1 -- Check the camshaft bearing bolts

Starting condition Cover of camshaft covering has been removed.

Steps 1. Verify that the hexagon bolt (5) has been firmly tightened to the
000.30).
specified torque (see Work Card 000.30
2. Clean the thread of the camshaft bearing bolts (2).
3. Slip the supporting sleeve (10) of the hydraulic tensioning tool
(009.057) over the camshaft bearing bolt onto the hexagon nut (8),
paying attention to the inside socket wrench (9). Refer to Figure 3 .
4. Screw cylinder (11) of the hydraulic tensioning tool onto the camshaft
bearing bolt, making sure that the supporting sleeve is centred by the
cylinder. Refer to Figures 2 and 3 .
5. Mount the second hydraulic trensioning tool onto the camshaft bear-
ing bolt the same way. Refer to items 3 and 4.

6701 102.01--01 E 11.01 L 40/54 102/ 05

 6. Back off the cylinder of the tensioning tool by the angle of back-off
000.30).
(see Work Card 000.30
7. Connect the high-pressure hoses (009.306) to the cylinder of the ten-
sioning tool and the high-pressure pump (009.338).
8. Switch on the high-pressure pump (see Work Card 009.03009.03), and
close the gap produced by backing off.
▲▲▲ Danger! Make sure that there is no one along the extended
axis of the camshaft bearing bolt!
9. Pump up the hydraulic tensioning tools until the hexagon nuts (8) can
be loosened.
▲ Attention! The pressure applied must not be more than 7% below
or 5% above the tensioning pressure (see Work Card 000.30)!
000.30
Note down the loosening pressure and compare it with the tensioning
pressure.
10. Adjust the high-pressure pump to the specified tensioning pressure
000.30).
(see Work Card 000.30
11. Using the tommy bar (000.272), tighten the hexagon nuts (8) over the
inside socket wrench (9), hand-tight.
12. Release the pressure; disconnect the high-pressure hoses from the
hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
13. Remove the hydraulic tensioning tools.

2 Camshaft bearing bolt

7 Bearing cap

Figure 2. Camshaft bearing with tensioning tools attached to the camshaft bearing bolts

6701 102.01--01 E 11.01 L 40/54 103/ 05

 2Camshaft bearing bolt
7Bearing cap
8Hexagon nut
9Inside socket wrench
SW46
10 Supporting sleeve
11 Cylinder of the
tensioning tool

Figure 3. Camshaft bearing bolt with tensioning tool attached

Operating sequence 2 -- Untension the camshaft bearing bolts

Starting condition Cover of the camshaft covering has been removed.

▲ Attention! Never untension the camshaft bearing bolts of two ad-

jacent camshaft bearings at the same time! Every second camshaft
bearing has to remain fastened (the camshaft has to remain sup-
ported)!

Steps 1. Clean the threads of the camshaft bearing bolts (2).

2. Slip the supporting sleeve (10) of the hydraulic tensioning tool
(009.057) over the camshaft bearing bolt onto the hexagon nut (8),
paying attention to the inside socket wrench (9). Please refer to Fig-
ure 3 .
3. Screw the cylinder (11) of the hydraulic tensioning tool onto the cam-
shaft bearing bolt, making sure that the supporting sleeve is centred
by the cylinder of the tensioning tool. Refer to Figures 2 and 3 .
4. Mount the second hydraulic tensioning tool onto the camshaft bearing
bolt the same way. Please refer to items 2 and 3.
5. Back off the cylinder of the tensioning tool by the angle of back-off
000.30).
(see Work Card 000.30
6. Connect the high-pressure hoses (009.306) to the cylinder of the ten-
sioning tool and the high-pressure pump (009.338).
7. Switch on the high-pressure pump (see Work Card 009.03009.03), and
close the gap produced by backing off.
▲▲▲ Danger! During untensioning, please make sure that there is
no one along the extended axis of the camshaft bearing bolts to be
untensioned!
8. Pump up the hydraulic tensioning tools until the hexagon nuts (8) can
be loosened.
▲ Attention! The pressure applied must not be more than 7% below
or max. 5% above the tensioning pressure (see Work Card 000.30)!
000.30
Note down the loosening pressure, and compare it with the tension-
ing pressure.
9. Using the tommy bar (000.272), back off the hexagon nut (8) over the
inside socket wrench (9) - for angle of back-off, please refer to Work
000.30.
Card 000.30

6701 102.01--01 E 11.01 L 40/54 104/ 05

 10. Release the pressure. Disconnect the high-pressure hoses from hy-
draulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
11. Remove the hydraulic tensioning tools.
12. Loosen the hexagon bolt (5) and unscrew it.

Operating sequence 3 -- Tension the camshaft bearing bolts

Starting condition The hexagon nuts have been screwed on and tightened, hand-tight. The
threads of the camshaft bearing bolts have been cleaned.

▲ Attention! Correct tensioning of a bolted connection requires the

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

Steps 1. Verify that the parting lines between bearing cap (7) and bearing body
(6) as weel as between bearing body and cylinder crankcase (3) are
the same size.
2. Coat the threads and seating faces of the hexagon bolt (5) with MoS2
lubricant, screw the bolts in and tighten them to the specified torque
(see Work Card 000.30).
000.30
3. Check the bolt projection (A) of the camshaft bearing bolts (2).
Refer to Figure 1 .
4. Slip the supporting sleeve (10) of the hydraulic tensioning tool
(009.057) over the camshaft bearing bolt and onto hexagon nut (8),
paying attention to the inside socket wrench (9). Refer to Figure 3 .
5. Screw the cylinder (11) of the hydraulic tensioning tool onto the cam-
shaft bearing bolt, making sure that the supporting sleeve is centred
by the cylinder of the tensioning tool. Refer to Figures 2 and 3 .
6. Mount the second hydraulic tensioning tool on the camshaft bearing
bolt the same way. Refer to items 4 and 5.
7. Connect the high-pressure hoses (009.306) to the cylinder of the ten-
sioning tool and the high-pressure pump (009.338).
009.03), and ten-
8. Switch on the high-pressure pump (see Work Card 009.03
sion the camshaft bearing bolts applying the specified tensioning
000.30).
pressure (see Work Card 000.30
▲▲▲ Danger! During tensioning, make sure that there is no one
along the extended axis of the camshaft bearing bolt to be ten-
sioned!
9. Using the tommy bar (000.272), screw down the hexagon nuts (8)
over the inside socket wrench (9), hand-tight.
10. Release the pressure. Disconnect the high-pressure hoses from the
hydraulic tensioning tools and high-pressure pump.
Important! The hydraulic tensioning tools are automatically reset to
zero position by the integrated compression springs (this takes approx. 2
to 3 minutes). For this purpose, however, the high-pressure pump has to
be connected.
11. Remove the hydraulic tensioning tools.

6701 102.01--01 E 11.01 L 40/54 105/ 05

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 bearing of the camshaft is to be checked for damage at regular

intervals, the axial clearance is to be determined. In the process,
changes/sources of interferences are to be recognised and, if necessary,
eliminated in time.
The work/steps include:
checking of components,
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Torque wrench 008.017 Standard
2 Shackle A1.0 002.453 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Screw driver insert 19x20 001.868 Standard
1 Ratchet 001.521 Standard
1 Feeler gauge (set) 000.451 Standard
2 Lifting eye bolt M20 000.155 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
2 Forcing--off bolt M16x150 -- Inventory
1 Lifting tackle with rope -- Inventory
1 Marking pen -- Inventory
1 Depth gauge -- Inventory

6701 102.02--01 E 05.03 L 40/54 101/ 04

 Qty Designation No. Availability
1 Hylomar SQ/M -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory
1 Securing compound Loctite 243 -- Inventory

Related work cards

Work card Work card Work card

000.11 000.30

Technical details

Term Information
Cover 20.5 kg
Bearing body 85 kg

1 Cylinder crankcase
2 Screw plug
3 O-ring seal
4 Hexagon socket bolt
5 Hexagon bolt
6 Butting disk
7 Cover
8 Camshaft
9 Spring pin
10 Butting ring
11 Butting ring
12 Hexagon socket bolt
13 Bearing body
14 O-ring seal
15 Hexagon socket bolt
16 Bearing bush

Figure 1. Camshaft thrust bearing

Operating sequence 1 -- Removing and checking the camshaft thrust bearing

Starting condition The cover on the camshaft covering in the camshaft drive area has been
removed.

6701 102.02--01 E 05.03 L 40/54 102/ 04

Steps 1. Remove the lube oil admission pipe from the camshaft thrust bearing.
2. Mark the position of cover (7) - bearing body (13).
3. Unscrew the hexagon socket bolts (12), and take the cover (7) off.
4. Clean the contact faces. Measure the projection cover (7) - butting
ring (10) at several points and note down the measured values.
5. Clean the contact face on the bearing body (13) and on the butting
disk (6). Measure the projection at several points and note down the
measured values.
6. Unscrew the hexagon bolts (5), and take off the butting disk (6).
7. Clean the contact face on the camshaft (8) and on the butting ring
(11). Measure the projection at several points and note down the
measured values.
8. Calculate the axial clearance from the values measured under
steps 4, 5 and 7, and compare it with the permissible clearance (refer
to Volume B1 / Operating Manual).
9. Unscrew the hexagon socket bolts (15).
10. Unscrew the screw plugs (2), screw the forcing-off bolts M16x150
into the bearing body (13), and force the latter off. Remove the
forcing-off bolts.
11. Screw the lifting eye bolts (000.155) into the bearing body (13), at-
tach the rope to the lifting eye bolts by means of the shackle
(002.453), and suspend the rope from the lifting tackle.
12. Remove the bearing body (13) and put it down onto a wooden sup-
port.
13. Remove the tools.
14. Carefully clean the running surface of the bearing bush (14), taking
care not to damage it in the process. Check the condition of the run-
000.11).
ning surface (see Work Card 000.11
15. Remove the O-ring seals (3 and 14).
16. Clean all the individual parts, check them for damage and remove
them if necessary. Purge the oil bores by means of compressed air.
Important! If a butting ring (10 or 11) has to be replaced, the thread
and contact face of the hexagon socket bolts (2) is to be coated with
Loctite 243 securing compound, and afterwards screwed in and tightened
hand-tight when the butting ring is fitted.

Operating sequence 2 -- Installing the camshaft thrust bearing

Starting condition All individual parts have been cleaned and checked.

Steps 1. Coat a new O-ring seal (14) with clean lubricating oil and insert it into
the ring groove, making sure that it is evenly tensioned over the en-
tire circumference and not twisted.
2. Screw the lifting eye bolts (000.155) into the bearing body (13). At-
tach the rope to the lifting eye bolts by means of shackle (002.453),
and suspend the rope from the lifting tackle.
3. Thoroughly oil the running surface of the bearing bush (16) and the
camshaft (8).
4. Install the bearing body (13).
5. Remove the tools.
6. Coat the thread and contact face of the hexagon socket bolts (15)
with MoS2 lubricant, screw them in hand-tight, and tighten them to
000.30).
the specified torque (see Work Card 000.30
7. Coat the thread of the screw plugs (2) with Loctite 243 securing
compound, and screw the screw plugs into the bearing body (13).
8. Thoroughly oil the running surface of the butting ring (11) and the but-
ting disk (6).
9. Attach the butting disk (6) to the camshaft (8), paying attention to the
position of the spring pin (9) - bore hole in the camshaft.
10. Coat the thread and contact face of the hexagon bolts (5) with
Loctite 243 securing compound, screw the bolts in and tighten them.

6701 102.02--01 E 05.03 L 40/54 103/ 04

 11. Oil a new O-ring seal (3) with clean lubricating oil and insert it into the
ring groove, making sure that it is not twisted.
12. Spread Hylomar SQ 32/M sealing compound onto the contact face
of the cover (7) towards the bearing body (13).
Important! The area around the O-ring seal (3) and the butting ring
(10) has to remain free from sealing compound.
13. Thoroughly oil the running surface of the butting disk (6) and the but-
ting ring (10).
14. Fit the cover (7), paying attention to the marking cover - bearing body
(13) - refer to operating sequence 1, item 2.
15. Screw the hexagon socket bolts (12) in and tighten them.
16. Fit the lube oil admission pipe to the camshaft thrust bearing.

6701 102.02--01 E 05.03 L 40/54 104/ 04

Camshaft bearing shell
Checking 102.03

Purpose of jobs to be done

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

ensure operational reliability of bearings.

Brief description

Bearing shells must be checked at regular intervals. From the state of

wear and appearance of the bearing shell running surface, conclusions
can be drawn about the load conditions, lube oil care etc.
The work/steps include:
removing components,
checking the bearing shell and
fitting components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Wood (for placing underneath) -- Inventory
1 Depth gauge -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

000.11 102.01

Technical details

Term Information
Bearing cap 13 kg
Camshaft bearing bolt 4 kg
Bolt projection (A) 66 mm

6701 102.03--01 E 11.01 L 40/54 101/ 04

 1 Hexagon nut
2 Camshaft bearing bolt
3 Cylinder crankcase
4 Bearing block
5 Hexagon bolt
6 Bearing body
7 Lubricating oil pipe
8 Bearing cap
9 Hexagon nut

A Bolt projection

Figure 1. Camshaft bearing

Operating sequence 1 -- Removing and checking the camshaft bearing shells

Starting condition Cover of the camshaft covering has been removed.

▲ Attention! Never check two adjacent camshaft bearings at the

same time! Every second camshaft bearing has to remain mounted
(the camshaft has to remain supported)!

Steps 1. Remove the lubricating oil pipe (7).

102.01.
2. Untension the camshaft bearing bolts (2) - see Work Card 102.01
3. Loosen the hexagon bolt (5) - see Work Card 102.01 - and unscrew
it.
4. Support the bearing cap (8) by means of wood.
5. Screw the hexagon nuts (9) off. Remove the camshaft bearing bolts
in upward direction.
6. Remove the wood. Take the bearing cap off and dismantle it.
7. Take the lower bearing shell (12) out, and deposit it on a clean sup-
port.
8. Turn the upper bearing shell (10) out (taking care not to damage it),
and deposit it on a clean support.
▲▲ Caution! When turning the upper bearing shell (10) out, pay
attention to the sense of rotation (position of the lug for bearing
shell fixation)! Refer to Figure 2 .

6701 102.03--01 E 11.01 L 40/54 102/ 04

 9. Carefully clean the running surface of the bearing shells, taking care
not to damage it.
10. Check the condition of the running surface (see Work Card 000.11).
000.11
▲▲ Caution! Do not rework the bearing shells in any way!

▲ Attention! Replace bearing shells that have been damaged or

heavily scored by dirt particles!
In case dirt scores have been found on the bearing shell, the cam-
shaft has to be checked and repolished, if necessary (polishing cloth
with a grain of < 15mm)!

2 Camshaft bearing bolt 6 Bearing body 12 Bearing shell, lower

3 Cylinder crankcase 8 Bearing cap
4 Bearing block 9 Hexagon nut B Lug for bearing shell
5 Hexagon bolt 10 Bearing shell, upper fixation
11 Camshaft ST Control side

Figure 2. Camshaft bearing

Operating sequence 2 -- Installing the camshaft bearing shells

▲ Attention! The new bearing shells delivered are ready for installa-
tion! They must not be rescraped or reworked in any other way!

Starting condition Bearing shells and camshaft bearing bolts have been cleaned.

Steps 1. Clean the contact faces between bearing cap (8) and bearing body
(6).

6701 102.03--01 E 11.01 L 40/54 103/ 04

 2. Thoroughly oil the running surface of the upper bearing shell (10) -
back of the bearing shell to remain dry.
3. Turn the upper bearing shell in.
▲ Attention! Note the position of the lug for bearing shell fixation!
Refer to Figure 2 .
4. Thoroughly oil the running surface of the lower bearing shell (12) -
back of the bearing shell to remain dry.
5. Insert the bearing shell into the bearing cap.
▲ Attention! Note the position of the lug for bearing shell fixation!
Refer to Figure 2 .
6. Place the bearing cap in the cylinder crankcase (3) and lift it until it
contacts the bearing body. Support the bearing cap by means of
wood.
▲ Attention! Make sure to install the bearing cap correctly! The
connection for the lubricating oil pipe (7) has to point towards the
control side (ST)! Refer to Figure 2 .
7. Screw the hexagon nuts (1) onto the camshaft bearing bolts (2).
8. Insert the camshaft bearing bolts; screw the hexagon nuts (9) on.
9. Adjust the bolt projection (A). Refer to Figure 1 .
10. Screw the hexagon nuts (1) down, hand-tight.
11. Remove the wood.
12. Tighten the hexagon bolt (5) to the specified torque (see Work Card
102.01).
102.01
102.01).
13. Tension the camshaft bearing bolts (see Work Card 102.01
14. Connect the lubricating oil pipe.

6701 102.03--01 E 11.01 L 40/54 104/ 04

Rocker arm casing/Rocker arm

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

6682 111--06 E 07.99 101/ 01

Rocker arm casing with rocker arms
Valve clearance
Removing, attaching, checking 111.01

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

Rocker arm casings are to be disassembled within the scope of

maintenance and repair work.
The work/steps include:
removal of components,
attachment of components,
checking/adjusting of valve clearance.

Safety requirements

- Engine shut--down
- Engine secured against starting
- Operating media system closed/depressurised

Tools/appliances required

Quant Denomination No. Availability

1 Setting gauge 0.8 113.130 Standard
1 Connecting link 111.111 Standard
1 Suspension device 111.110 Standard
1 Sealing cover 055.148 Standard
1 Pilot rod 034.006 Standard
1 Torque wrench 008.029 Standard
1 Torque wrench 008.017 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 20x12.5 001.923 Standard
1 Adapter 12.5x10 001.922 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Screw driver insert 19x20 001.868 Standard
1 Screw driver insert 8x12.5 001.854 Standard
1 Ratchet 001.521 Standard
1 Set of feeler gauges 0.2 000.455 Standard

6621 111.01--04 E 05.98 L 40/54 101/ 07

 Quant Denomination No. Availability
1 Thickness gauges 0.05--1 000.451 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Grease (acid--free) -- Inventory
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory

Related work cards

Work card Work card Work card

000.30

Technical details

Term Information
Rocker arm casing with cylinder head cover 485 kg
and charge air pipe section

Operating sequence 1 -- Checking

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Check valve clearance, screw connections and control lever lubrication
in the intervals specified in the maintenance schedule.
Whenever cylinder heads are removed and in the course of overhaul
work, check the individual parts for wear. In case the bearing clea-
rance is too large, renew the bearing bushes (11).
Blow the oil bores in the control levers (1, 4 and 8) and axles (13 and
15) through with compressed air.
Turn the engine by means of the turning gear, checking whether the
valves constantly follow the movements of the control levers or whether
they got stuck.

Operating sequence 2 -- Removing the rocker arm casing

Starting condition Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), lube oil pump (if available) turned off, cylinder head cover
opened.

Steps 1. Loosen pipe couplings (12) and shift them sideward onto the longer
end of the charge--air pipe sections, direction of dislocation (M--N).
See Figure 1 and 2 .
Important! When removing the rocker arm casing situated next to
the charge--air cooler (24), screw hexagon head bolts (28) out and
separate the axial compensator (27) from the charge--air pipe section
(26a). See Figure 1 .
2. Remove the lube oil supply pipe (14) and secure it against penetration
of dirt.

6621 111.01--04 E 05.98 L 40/54 102/ 07

 3. Fix the control levers (1 and 4) by means of the connecting links
(111.111). See Figure 4 .
4. Loosen six hexagon socket screws (9) and screw them out.
5. Close the cylinder head cover (6). Fasten the suspension device
(111.110) to the rocker arm casing (26) by means of four hexagon head
bolts (16 and 23) and suspend in lifting tackle using the rope (33). See
Figure 4 .
6. Screw pilot rod (034.006) into suspension device.
7. Carefully lift and remove the rocker arm casing, guiding it by means of
the pilot rod.
8. Close the air inlet in the cylinder head (7) by means of the sealing co-
ver (055.148) so that no foreign particle can fall into the inlet duct.
9. Put complete rocker arm casing down onto wooden support.

Operating sequence 3 -- Attaching the rocker arm casing

Starting condition Control lever fixed by means of connecting links, cylinder head cover
closed, suspension device fastened to rocker arm casing, pilot rod
screwed into suspension device.

Steps 1. Clean the sealing lips on the pipe couplings (12) and check them for
damage, renew pipe couplings if necessary.
2. Clean the contact faces on the cylinder head (7).
3. Suspend the attached suspension device (111.110) in the lifting tackle
by means of the rope (33).
4. Lift the rocker arm casing (26).
5. Clean the supporting face on the rocker arm casing.
Important! When attaching the rocker arm casing which is situated
next to the charge--air cooler (24), also clean the contact face between
charge--air pipe section (26a) and exhaust gas compensator (27).
6. Insert new O--ring seals (30 and 32), which have been lubricated with
acid--free grease, in the groove, taking note that they are not distorted.
7. Run the rocker arm casing over the cylinder, remove the sealing cover
(055.148) and lower the rocker arm casing carefully onto the cylinder
head, paying attention to the two cylindrical pins (31) in the cylinder
head. See Figure 3 .
Important! When lowering the rocker arm casing, guide it by
means of the pilot rod.
8. Remove the suspension device.
9. Open the cylinder head cover (6).
10.Verify that the thrust pieces of the control levers (1 and 8) are seated
on the thrust cups of the push rods.
11. Remove the connecting links (111.111).
12.Apply MoS2 lubricant to the threads and contact faces of the hexagon
socket screws (9).
13.Screw six hexagon socket screws in, hand--tight, and tighten at the
000.30).
specified torque (see work card 000.30
14.Attach the lube oil supply pipe (14) to the rocker arm casing.
15.Slip the pipe coupling over the parting line, align pipe coupling, apply
MoS2 lubricant to the threads and contact faces of the hexagon socket
000.30). See
screws and tighten at the specified torque (see work card 000.30
Figure 1 , 2 und 5 .
Important! When attaching the rocker arm casing positioned next
to the charge--air cooler, fasten axial compensator to charge--air pipe sec-
tion. For this purpose, insert hexagon head bolts (28) from the compensa-
tor side, screw them in and tighten them. See Figure 1 .
16.Check the valve clearance (A) on the inlet and exhaust valves, and re-
adjust it, if necessary -- see operating sequence 4.

6621 111.01--04 E 05.98 L 40/54 103/ 07

Operating sequence 4 -- Adjusting of the valve clearance

Starting condition Engine is cold (all engine parts have the same temperature).

▲ Attention! In case engine has operating temperature, six hours

after shut- down at the earliest.

Running gear of the respective cylinder turned to ignition TDC position (all
valves closed), cylinder head cover opened.

Steps 1. Loosen hexagon nut (2) and screw back valve adjusting screw (4).
2. Push setting gauge (113.130, exhaust valve) or a thickness gauge from
the set of feeler gauges (000.455, inlet valve) between valve shaft and
ball cup.

Valve clearance: Exhaust valve .... 0.8 mm

Inlet valve ........... 0.2 mm

3. Tighten valve adjusting screw until setting gauge or thickness gauge

fits snugly.
4. With the setting gauge or thickness gauge inserted, hold the valve ad-
justing screw and tighten the hexagon nut.

6621 111.01--04 E 05.98 L 40/54 104/ 07

 12 Pipe coupling 27 Axial compensator
24 Charge--air cooler 28 Hexagon head bolt
26 Rocker arm casing with integrated charge--air
pipe section M-N Displacement of the pipe coupling

Figure 1. Charge--air cooler and charge--air pipe

6621 111.01--04 E 05.98 L 40/54 105/ 07

 12 Pipe coupling
26 Rocker arm casing
with integrated
charge--air pipe section

M-N Displacement of the

pipe coupling

Figure 2. Pipe coupling between the charge--air pipe sections (sectional drawing)

1 Control lever
2 Hexagon nut
3 Valve adjusting screw
4 Control lever
6 Cylinder head cover
7 Cylinder head
8 Control lever
9 Hexagon socket screw
10 Spacer ring
11 Bearing bush
12 Pipe coupling
13 Axle
14 Lube oil supply pipe
15 Axle
26 Rocker arm casing
with integrated
charge--air pipe section
30 O--ring seal
31 Cylindrical pin
32 O--ring seal

A Valve clearance

Figure 3. Attached rocker arm casing with integrated charge--air pipe section and control levers

6621 111.01--04 E 05.98 L 40/54 106/ 07

 1 Control lever
4 Control lever
16 Hexagon head bolt
M16x160
17 Hexagon nut M24
23 Hexagon head bolt
M16x40
26 Rocker arm casing
with integrated
charge--air pipe section
33 Rope

Figure 4. Rocker arm casing with attached suspension device

12 Pipe coupling
26 Rocker arm casing
with integrated
charge--air pipe section

Figure 5. Position of screwed connection for pipe coupling

6621 111.01--04 E 05.98 L 40/54 107/ 07

Rocker arm
Removing and installing 111.02

Purpose of jobs to be done

Ensure that the work is carried out correctly,

check components for state/wear.

Brief description

Clearance and components of rocker arms are to be checked at regular

intervals.
The work/steps include:
removal of components,
checking of components,
installation of components.

Tools/appliances required

Qty Designation No. Availability

1 Assembly sleeve 111.122 Standard
1 Connecting link 111.111 Standard
1 Eye bolt 001.409 Standard
1 Thickness gauges 0.05--1 000.451 Optional
1 Hammer (wood/plastic) -- Inventory
1 Lifting tackle -- Inventory
1 Open--jaw and ring wrenches (set) -- Inventory
1 Measuring tool -- Inventory
1 Iron rod ø 11--11.5 -- Inventory
1 Round wood ø 70 -- Inventory
1 Screw drivers (set) -- Inventory
1 Hexagon screw drivers (set) -- Inventory
1 Rope -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

111.01

6701 111.02--01 E 09.06 L 40/54 101/ 07

Technical details

Term Information
Rocker arm 18.5 -- 33 kg
Axle 19.5 kg

Operating sequence 1 -- Removing the rocker arm

Starting condition Rocker arm casing and rocker arms removed, cylinder head cover open.

Steps 1. Unscrew hexagon nuts (2) and remove connecting link (111.111).
2. Undo screw plugs (15) and remove sealing rings (14).
3. Pull out parallel pins (9) using eye bolt (001.409).
4. Suspend rocker arms (1 and 5) with rope in lifting tackle.
5. Move axle (3) towards the housing end (H) only as far as is necess-
ary to allow the O-ring seal (10) to be removed.
6. Move axle (3) towards the housing end (K) and, at the same time,
slide the lubricated assembly sleeve (111.122) in from the housing
end (H).
7. Remove the axle (3) completely.
8. Remove O-ring seal (12).
9. Lift rocker arms (1 and 5) out of rocker arm casing (4) and put them
down.
▲ Attention! When removing the rocker arms, be careful to avoid
that they slip off the assembly sleeve! Risk of accident!
10. Undo hexagon bolts (13) and remove washers (7) as well as hexagon
bolts.
11. Suspend rocker arm (6) with rope in lifting tackle.
12. Move axle (8) towards the housing end (H) only as far as is necess-
ary to allow the O-ring seal (10) to be removed.
13. Slide the axle (8) towards the housing end (K) and remove it com-
pletely.
Important! Insert an iron rod in the front end oil bore to prevent the
axle from tilting.
14. Remove O-ring seal (12).
15. Lift rocker arm (6) out of rocker arm casing (4) and put it down.
16. Clean all parts.
17. Check wear parts and replace if necessary.
18. Blow out oil bores with compressed air.
19. Measure bore of bearing bushes and axles (3 and 8) using suitable
tools and set clearances.
Important! Replace if the clearances exceed the permissible values
(see Volume B1/Operating Instructions).
We recommend having new bearing bushes installed by a Customer Ser-
vice Centre.

▲ Attention! The bearing bush has a number of marks on its front

end! It must be installed in such a way that the same markings are
visible on the front end of the rocker arm and bearing bush and that
they are aligned with each other! Example: see Figure 4 .

6701 111.02--01 E 09.06 L 40/54 102/ 07

Operating sequence 2 -- Fitting the rocker arm

Starting condition Axles and running surfaces of bearing bushes completely clean, oil bores
free of dirt.

Steps 1. Suspend rocker arm (6) with rope in lifting tackle.

2. Raise the rocker arm (6) and insert it into the rocker arm casing (4).
3. Slightly oil the running surface of axle (8).
4. Fit the axle (8) completely.
Introduce the axle into the rocker arm casing bore from the housing
end (H), slide it the through the rocker arm (6) and insert it in the
rocker arm casing bore at the housing end (K).
▲ Attention! Before fitting the axle, verify that the bore for the paral-
lel pin (9) is in the correct position!

Important! Insert an iron rod in the front end oil bore to prevent the
axle from tilting.
5. Push the axle (8) towards the housing end (K) until the groove for the
O-ring seal (12) is accessible.
6. Insert a new O-ring seal (12) that has been oiled with clean lubricat-
ing oil in the ring groove, making sure that it is uniformly tensioned
over the entire circumference and is not twisted.
7. Push the axle (8) back towards the housing end (H) until the groove
for the O-ring seal (10) is accessible.
8. Insert a new O-ring seal (10) that has been oiled with clean lubricat-
ing oil in the ring groove, making sure that it is uniformly tensioned
over the entire circumference and is not twisted.
9. Push the axle (8) back in.
10. Fit parallel pin (9) using eye bolt (001.409) in order to fix axle (8) in
place. See Figure 2 .
11. Screw in screw plug (15) and sealing ring (14).
12. Insert the hexagon bolts (13) into the washer (7), place the washer on
axle (8), screw the hexagon bolts in and tighten them.
13. Insert spacer ring (11) between rocker arms (1 and 5), slide in oiled
assembly sleeve (111.122). See Figure 3 .
14. Suspend rocker arms (1 and 5) with rope in lifting tackle.
15. Raise the rocker arms (1 and 5) and insert them into the rocker arm
casing (4).
▲ Attention! When installing the rocker arms, be careful to avoid
that they slip off the assembly sleeve! Risk of accident!
16. Slightly oil the running surface of axle (3).
17. Fit the axle (3) completely.
For this purpose, introduce the axle into the rocker arm casing bore
from the housing end (H), slide it through the rocker arms (1 and 5)
and insert it in the rocker arm casing bore at the housing end (K). At
the same time, push the assembly sleeve out on the housing end (K),
through the rocker arm casing bore.
▲ Attention! Before fitting the axle, verify that the bore for the paral-
lel pin (9) is in the correct position!
18. Push the axle (3) towards the housing end (K) until the groove for the
O-ring seal (12) is accessible.
19. Insert a new O-ring seal (12) that has been oiled with clean lubricat-
ing oil in the ring groove, making sure that it is uniformly tensioned
over the entire circumference and is not twisted.
20. Push the axle (3) back towards the housing end (H) until the groove
for the O-ring seal (10) is accessible.

6701 111.02--01 E 09.06 L 40/54 103/ 07

 21. Insert a new O-ring seal (10) that has been oiled with clean lubricat-
ing oil in the ring groove, making sure that it is uniformly tensioned
over the entire circumference and is not twisted.
22. Push axle (3) back in.
23. Fit parallel pin (9) using the eye bolt in order to fix axle (3) in place.
See Figure 2 .
24. Screw in screw plug (15) and sealing ring (14).
25. Check that the rocker arms (1, 5 and 6) move easily.
26. Measure and note down the axial clearance and compare it with the
permissible value (see Volume B1/Operating Instructions).
27. Fix rocker arms (5 and 6) by means of the connecting links (111.111).
See Figure 1 .

6701 111.02--01 E 09.06 L 40/54 104/ 07

 1 Rocker arm 6 Rocker arm 11 Spacer ring
2 Hexagon nut M24 7 Washer 12 O-ring seal
3 Axle 8 Axle 13 Hexagon bolt
4 Rocker arm casing 9 Parallel pin
5 Rocker arm 10 O-ring seal H/K Housing end

Figure 1. Rocker arm casing with rocker arms

6701 111.02--01 E 09.06 L 40/54 105/ 07

 3 Axle
4 Rocker arm casing
8 Axle
9 Parallel pin
10 O-ring seal
14 Sealing ring
15 Screw plug

Figure 2. Rocker arm casing with rocker arms - section Z-Z (see Figure 1)

1 Rocker arm
5 Rocker arm
11 Spacer ring

Figure 3. Assembly sleeve with rocker arms fitted

6701 111.02--01 E 09.06 L 40/54 106/ 07

 Figure 4. Marks on rocker arm and bearing bush
(top: single-point marking / bottom: two-point marking)

6701 111.02--01 E 09.06 L 40/54 107/ 07

Cam follower/Push-- rod

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

6682 112--06 E 07.99 101/ 01

Push-- rod
Removing and installing 112.01

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Push--rods are to be disassembled and assessed within the scope of

maintenance and repair work.
The work/steps include:
removal of components,
checking of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

111.01
111.01

Technical details

Term Information
Push--rod 14 kg

6701 112.01--01 E 08.06 L 40/54 101/ 02

Operating sequence 1 -- Removal of the push-rod

Starting condition Rocker arm casing has been removed.

Steps 1. Cautiously pull out the push-rod (2) towards the top.
2. Remove the second push-rod (2) in the same manner.
3. Clean the push-rods (2) and check the ball sockets.

Operating sequence 2 -- Installation of the push-rod

Starting condition Push-rods have been cleaned.

Steps 1. Oil the ball sockets of the push-rod (2).

2. Cautiously insert the push-rod (2) into the push-rod covering (3) and
place it onto the thrust pad of the cam follower (4).
3. Install the second push-rod (2) in the same manner.
111.01). In the process,
4. Attach the rocker arm casing (see work card 111.01
place the thrust pads of the rocker arms (1) onto the ball sockets of
the push-rods (2).

1 Rocker arm
2 Push-rod
3 Push-rod covering
4 Cam follower

Figure 1. Push-rod with covering

6701 112.01--01 E 08.06 L 40/54 102/ 02

Cam follower
Removing and installing/checking 112.02

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Clearance and components of cam followers are to be checked at regular

intervals.
The work/steps include:
removal of components,
checking of components,
installation of components.

Safety requirements

- Engine shut--down
- Engine secured against starting
- Operating media system closed/depressurised

Tools/appliances required

Quant Denomination No. Availability

1 Thickness gauges 0.05--1 000.451 Standard
1 Eye bolt M6 000.023 Standard
1 Open--jaw and ring spanner (set) -- Standard
1 Screw driver (set) -- Standard

Related work cards

Work card Work card Work card

112.01

Operating sequence 1 -- Checking

Starting condition Covers of camshaft lagging are removed.

Steps 1. Check as to whether hexagon socket bolts (6) are tightened.

2. Check running surface of all rollers (2) for damage.
3. Check radial and axial clearances of rollers and cam followers (3
and 15). For clearances refer to Section 1.

6621 112.02--04 E 04.98 L 40/54 101/ 03

 4. With lube oil pump switched on, check as to whether all lubricating
points are adequately supplied with lube oil.

Operating sequence 2 -- Removing

Starting condition Push rods removed, cover of the camshaft lagging is removed.

Steps 1. Slacken hexagon nut (16) and screw off.

2. Screw out hexagon socket bolts (5) and remove discs (5 and 13).
Important! Remove disc (13) on the inlet cam follower (15) toge-
ther with lube oil pipe (14).
3. Remove outer butting rings (7).
4. Check clearance between bearing bush (8) of cam followers (3
and 15) and axle (11). For clearances refer to Section 1.
5. Pull inlet and exhaust cam followers off axle.
6. Remove inner butting rings (9).
7. After removal of the axle retention assembly consisting of plate (20)
and cylindrical pin (21), the axle can be shifted.
8. Clean and check bearing points, contact faces of thrust piece (4) and
running surface of rollers (2).
9. Clean all oil passages in axle and cam followers.

Operating sequence 3 -- Installation

Starting condition Axle and bores of bearing bushes are absolutely clean, oil passages free
from dirt.

Steps 1. If necessary, push axle (11) back, paying attention to the bores of the
axle retention.
Insert cylindrical pin (21) and mount plate (20) by means of hexagon
screws (12) and lock washers (19).
2. Slip inner butting rings (9) onto axle.
3. Slightly oil the the running surface of the bearing bushes and slip the
cam followers (3 and 15) onto axle.
4. Slip the outer butting rings (7) onto axle.
5. Slip the discs (5 and 13) on, screw in the hexagon socket bolts (6)
and tighten them.
▲ Attention! In the case of disc (13) on inlet cam follower (15), put
it on together with lube oil pipe (14), screw in hexagon socket bolts
(6) loosely, screw on hexagon nut (16) and tighten. Tighten hexagon
socket bolt.
6. After completion of installation, verify easy movement of cam
followers and check axial clearance (refer to Section 1). Check as to
whether all lubrication points are adequately supplied with oil.

6621 112.02--04 E 04.98 L 40/54 102/ 03

 1 Outlet cam 8 Bearing bush 15 Inlet cam follower
2 Roller 9 Butting ring 16 Hexagon nut
3 Exhaust cam follower 10 Bearing bracket 17 Lube oil pipe
4 Thrust piece 11 Axle 18 Inlet cam
5 Disc 12 Hexagon screw 19 Lock washer
6 Hexagon socket bolt 13 Disc 20 Plate
7 Butting ring 14 Lube oil pipe 21 Cylindrical pin

Bild 1. Exhaust and inlet cam follower

6621 112.02--04 E 04.98 L 40/54 103/ 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
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings/Top land ring
050 Cylinder liner
055 Cylinder head
073 Crankcase cover
100 Camshaft drive
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/Rocker arm
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140 Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Drive of fuel injection pump
203 Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pump
322 Charge air cooler
434 Fuel injection pipe

6682 113...--05 E 07.99 101/ 01

Inlet valve
Removing and installing 113.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

ensure correct execution of work,
check state/wear condition of components.

Brief description

Inlet valves are to be removed at regular intervals and overhauled if

necessary.
Valve guides must be checked and replaced if necessary within the scope
of maintenance and repair work.
The work/steps include:
checking of components,
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 113.140 Standard
1 Guide piece 113.140--3 Standard
1 Clamping piece 113.140--7 Standard
1 Plate 113.140--8 Standard
1 Washer 113.140--11 Standard
1 Valve spring tensioner 113.123 Standard
1 Feed spindle 113.123--1 Standard
1 Bridge 113.123--5 Standard
1 Deep groove thrust ball bearing 113.123--9 Standard
1 Conical socket 113.123--13 Standard
1 Spherical disk 113.123--14 Standard
1 High--pressure pump 009.341/(009.338) Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning device (hollow piston) 009.022 Standard
1 Tommy bar, 12 mm 000.264 Standard

6701 113.01--01 E 07.06 L 40/54 101/ 09

 Qty Designation No. Availability
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

009.03 009.05 055.05
113.02 113.03 113.04
113.05

Technical details

Term Information
Valve cone 5.5 kg

Operating sequence 1 -- Checking the valve rotator

The operation of the valve rotator (2) can be checked with the cylinder
head cover open and with the engine running (under at least 10% load) -
113.02. If an inlet valve has not been turned for a long
see Work Card 113.02
time, check the condition of valve cone (8) and valve seat.

Operating sequence 2 -- Removal of the inlet valve

Starting condition The cylinder head has been removed and clamped into the turnover stand
055.05).
(see Work Card 055.05

Important! If only the valve rotator or compression springs are to be

removed, the cylinder head remains in place and the piston is turned to
ignition TDC position.

Steps 1. Screw the feed spindle (113.123-1) all the way onto the valve cone
(8). Refer to Figure 2 /I.
2. Slip the bridge (113.123-5) onto the feed spindle, and place it on the
valve rotator (2).
3. Mount the conical socket (113.123-13), spherical disk (113.123-14),
and deep-groove thrust ball bearing (113.123-9). Refer to Fig-
ure 2 /I.
▲ Attention! Make sure that the conical socket, spherical disk, and
deep-groove thrust ball bearing are fitted correctly!
4. Coat the thread of the feed spindle with special lubricant.
5. Screw the hexagon nut (10) onto the feed spindle.
6. Pretension/press down the compression springs (3 and 4) by means
of the valve spring tensioner (113.123) until the two-part tapered
piece (1) can be removed. Hold the bridge steady using the tommy
bar (000.264). Refer to Figure 2 /II.
7. Remove the two-part tapered piece (1).

6701 113.01--01 E 07.06 L 40/54 102/ 09

 8. Back off the hexagon nut (10), relieving the tension of the compres-
sion springs (3 and 4). Refer to Figure 2 /III.
9. Remove the valve spring tensioner (113.123), while holding the valve
cone (8) by hand.
▲ Attention! If the valve cone is not held, it will fall out of the valve
guide when the hexagon nut is removed!
10. Push the valve cone (8) out of the valve guide (6), and put it down.
Important! Note which valve cone was inserted in each valve guide.
In case the valve cone is not replaced, it has to be reinserted into the
same valve guide.
11. Take the valve rotator (2) and the compression springs (3 and 4) off.
12. Remove the O-ring seal (5).
13. Clean all the individual parts and check them for wear (for maximum
clearances, refer to the Operating Instructions, Volume B1), replace
them if necessary.
14. Regrind the valve cone and/or the valve seat if necessary (see Work
Cards 113.04 and 113.05).
113.05
15. Check the condition of the valve guide, remove it if necessary. See
Operating Sequence 3 and 4.

Operating sequence 3 -- Checking the valve guide

▲ Attention! The valve guide is to be replaced whenever the wear

limit has been reached! The wear limit has been reached
- when the valve cone (20) butts against the cylindrical recess (C)
of the valve guide (21) on the combustion-chamber side! Refer to
Figure 3 .
- when the circumferential wear edge (A) on the valve guide (21) is
no longer visible or tangible, which may also only be the case on
part of the circumference!

Operating sequence 4 -- Removal of the valve guide

Starting condition The valve cone has been removed.

Steps 1. Insert the guide piece (113.140-3) into the valve guide (6), slip the
washer (113.140-11) on, and screw the hexagon nut (12) on hand-
tight.
2. Slip the clamping piece (113.140-7) and the plate (113.140-8) over
the guide piece, making sure that the clamping piece and plate are
centred properly. Refer to Figure 4 .
3. Slip the hydraulic tensioning device (009.022) over the guide piece,
and screw the hexagon nut (11) on hand-tight. Refer to Figure 4 .
4. Connect the high-pressure hose (009.306) to the hydraulic tensioning
device and the high-pressure pump (009.338 or 009.341). Connect
the oil pressure gauge (0-400 bar) to the high-pressure pump.
009.03), and
5. Switch the high-pressure pump on (see Work Card 009.03
slowly pump up the hydraulic tensioning device.
▲ Attention! Watch the pressure gauge while pumping up!
6. Pull the valve guide (6) out in several stages, releasing the pressure,
pressing the piston of the hydraulic tensioning device in, and turning
the hexagon nut (12) at each stage.
7. Release the pressure.
8. Press the piston of the hydraulic tensioning device in, disconnect the
high-pressure hose from the hydraulic tensioning device and high-
pressure pump.

6701 113.01--01 E 07.06 L 40/54 103/ 09

 9. Remove the tool.
10. Clean the valve guide, and check it for wear/damage; replace it if ne-
cessary.

Operating sequence 5 -- Installation of the valve guide

Starting condition The valve guide has been cleaned, checked and replaced if necessary.
The bore hole in the cylinder head has been cleaned.

Steps 1. Slip the valve guide (6) and the washer (113.140-11) onto the guide
piece (113.140-3), and screw the hexagon nut (12) on, hand-tight.
2. Pass the guide piece through the cylinder head (7).
3. Slip the plate (113.140-8) over the guide piece and place it on the
valve seat ring (9), making sure that plate and valve seat ring are
centred properly. Refer to Figure 4 .
4. Slip the hydraulic tensioning device (009.022) over the guide piece,
and screw the hexagon nut (11) on, hand-tight.
5. Connect the high-pressure hose (009.306) to the hydraulic tensioning
device and the high-pressure pump (009.338 or 009.341). Connect
the oil pressure gauge (0-400 bar) to the high-pressure pump.
009.03), and
6. Switch the high-pressure pump on (see Work Card 009.03
slowly pump up the hydraulic tensioning device.
▲ Attention! Make sure that the valve guide is drawn into the bore
hole correctly!
Watch the pressure gauge while pumping up!
7. Draw in the valve guide (6) in several stages, releasing the pressure,
pressing the piston of the hydraulic tensioning device in, and turning
the hexagon nut (11) at each stage.
8. Release the pressure.
9. Press the piston of the hydraulic tensioning device in. Disconnect the
high-pressure hose from the hydraulic tensioning device and the
high-pressure pump.
10. Remove the tool.

Operating sequence 6 -- Installation of the inlet valve

Starting condition All individual parts cleaned, checked, and replaced if necessary. Bore hole
of the valve guide and valve seat ring cleaned. Ink contact (“touching”)
113.03).
test was carried out (see Work Card 113.03

Steps 1. Insert a new O-ring seal (5) into the groove, making sure that it is not
twisted.
2. Install the compression springs (3 and 4) into the cylinder head (7),
and place the valve rotator (2) onto the compression springs. Refer
to Figure 1 .
3. Treat the shaft of the valve cone (8) with special lubricant.
4. Introduce the valve cone (8) into the valve guide (6).
5. Screw the feed spindle (113.123-1) all the way onto the valve cone
(8).
6. Slip the bridge (113.123-5) onto the feed spindle, and place it on the
valve rotator (2).
7. Mount the conical socket (113.123-13), spherical disk (113.123-14)
and deep groove thrust ball bearing (113.123-9). Refer to Figure 2 .
▲ Attention! Make sure that the conical socket, spherical disk and
deep groove thrust ball bearing are fitted correctly!
8. Coat the thread of the feed spindle with special lubricant.
9. Screw the hexagon nut (10) onto the feed spindle.

6701 113.01--01 E 07.06 L 40/54 104/ 09

 10. Pretension/press down the compression springs by means of the
valve spring tensioner (113.123) until the two-part tapered piece (1)
can be installed. Hold the bridge steady using the tommy bar
(000.264). Refer to Figure 2 .
11. Install the two-part tapered piece (1).
▲ Attention! Do not insert the tapered pieces into the thread under-
cut!
12. Check to see if both parts of the tapered piece (1) have been inserted
correctly and the gap between the two parts is evenly is uniform.
13. Back off the hexagon nut (10), thus relieving the compression springs
(3 and 4). Refer to Figure 2 .
14. Remove the valve spring tensioner (113.123).

1 Tapered piece, two-

part
2 Valve rotator
3 Compression spring
4 Compression spring
5 O-ring seal
6 Valve guide
7 Cylinder head
8 Valve cone
9 Valve seat ring

Figure 1. Inlet valve

6701 113.01--01 E 07.06 L 40/54 105/ 09

 1 Tapered piece, two-part 5 O-ring seal I-III Steps
2 Valve rotator 6 Valve guide
3 Compression spring 8 Valve cone
4 Compression spring 10 Hexagon nut M20

Figure 2. Removal of the two-part tapered piece

6701 113.01--01 E 07.06 L 40/54 106/ 09

 20 Valve cone
21 Valve guide

A Wear edge in new con-

dition
B Wear edge in worn
condition
C Cylindrical recess

Figure 3. Wear edge on the valve guide - illustration shows exhaust valve cone

6701 113.01--01 E 07.06 L 40/54 107/ 09

 6 Valve guide
7 Cylinder head
9 Valve seat ring
11 Hexagon nut M30
12 Hexagon nut M27x2

Figure 4. Removal and installation of the valve guide (illustration on the left: removal / illustration on the right: installation)

Figure 5. Tapered piece inserted correctly, thread undercut is visible.

6701 113.01--01 E 07.06 L 40/54 108/ 09

 Figure 6. Tapered piece inserted incorrectly

6701 113.01--01 E 07.06 L 40/54 109/ 09

Valve rotator
Checking 113.02

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

Valve rotators are to be assessed at regular intervals.

The work/steps include:
checking components,
removing components,
disassembling and assembling,
installing components.

Tools/appliances required

Qty Designation No. Availability

1 Screw drivers (set) -- Standard
1 Felt--tip pen/Marking pen -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

113.01

Design of the valve rotator

The basic body (1) has a number of pockets, arranged in circumferential

direction, with balls (2) that are forced against the upper end of an inclined
raceway by compression springs (6) acting in tangential direction. Refer
to Figure 3 . The disk spring (3) is located between the basic body and
the cover (4), onto which the valve spring forces are acting. Refer to Fig-
ure 1 . In disassembled condition, the various parts of the rotator are
held together by the snap ring (5).

Operating principle

As the valve starts to open, the increasing valve spring force causes the
disk spring (3) in the valve rotator to flatten and, at the same time, to exert
load on the balls (2) in the pockets of the basic body (1), which forces the
balls to roll down their inclined raceways. The disk spring itself rolls on the

6682 113.02--02 E 10.05 L 40/54, 48/60, L 58/64 CD 101/ 04

 balls. As the disk spring is supported by the balls, the pressure of the disk
spring acting onto the inner edge of the basic body (1) is reduced, which
results in a sliding motion. Disk spring, cover (4) and valve springs, how-
ever, are firmly connected with each other due to friction contact, and thus
prevented from turning. The relative rotation between disk spring / cover
and basic body is transmitted onto the valve via the basic body. As the
valve closes, the force acting on the disk spring and thus on the balls is
reduced, with the result that the balls are pushed back to their original
positions by the compression springs (6), without being rolled.

1 Basic body 4 Cover

2 Ball 5 Snap ring
3 Disk spring

Figure 1. Valve rotator of the inlet valve

Operating sequence 1 -- Checking the valve rotator

Under normal operating conditions, Rotocap valve rotators do not require

any maintenance. Abnormal operating conditions cause the malfunctions
described under operating sequence 2. The rotation of the valves ist to be
checked at the intervals specified in the maintenance schedule.

Starting condition Engine stopped, cylinder head cover opened, valve rotator installed.

Steps 1. Mark the valve rotator with a line by means of the felt-tip pen.
2. Start the engine and operate it at low load.
3. Watch the valve rotator of the inlet valves to see if the basic body
including valve cone rotate evenly:

Reference value = 1 valve rotation per minute

4. Stop the engine.

5. In case malfunctions occur, refer to operating sequence 2.

Operating sequence 2 -- Possible malfunctions and remedial measures

1. Contamination, especially of the ball pockets, which is due to resi-

dues in the oil (abrasives, combustion products). The deposits cause
the individual components to become stuck and hinder the movement
of the balls.

The valve rotator has to be removed, thoroughly washed, and oiled

before refitting. Please refer to operating sequence 3.

6682 113.02--02 E 10.05 L 40/54, 48/60, L 58/64 CD 102/ 04

 2. High base torque due to severe friction between rocker arm and end
of valve stem or due to shaft seals. In case the valve spring position
is excessively inclined, the cover (4) itself may cause a considerable
friction torque on the basic body (1) resulting in the standstill of the
rotator.

The parts that cause the friction and/or the valve spring have to be
replaced.
Important! In case the balls have produced indentations in the race-
ways of the basic body as a result of concentrated load because the valve
stopped rotating, the complete valve rotator has to be replaced.

▲ Attention! If the inlet valve has not rotated for an extended period
of time, check the condition of valve cone and valve seat (see work
card 113.03).
113.03

Operating sequence 3 -- Disassembly and assembly of the valve rotator

Starting condition Valve rotator removed (see work card 113.01

113.01) and placed on a support
(snap ring located on top).

Steps 1. Remove the snap ring (5).

2. Take off cover (4) and disk spring (3).
3. Remove all balls (2) and compression springs (6) from the basic body
(1). Refer to Figure 3 .
4. Wash all individual components in suitable cleaning agent and dry
them afterwards.
5. Check all individual components for wear and ball indentations; re-
place them if necessary (regarding set of wear parts, please refer to
the spare parts catalogue for the engine).

1 Basic body 6 Compression spring

2 Ball A max. admissible
3 Disk spring wear = 0.1 mm

Figure 2. Wear limit on the ball-pocket raceways

Important! When parts of the valve rotator are replaced, the basic
body of the rotator has to be marked with the item number of the set of
wear parts used.
6. Insert balls (2) and compression springs (6) into the ball-pocket race-
ways.
▲ Attention! Make sure that the balls are at the highest point of the
slanting ball-pocket raceways, and thus all located in the same
direction. Refer to Figure 3 .
7. Insert the disk spring (3), put on the cover (4) and install the snap
ring (5).

6682 113.02--02 E 10.05 L 40/54, 48/60, L 58/64 CD 103/ 04

 Important! The inner edge of the disk spring has to rest on the basic
body. Refer to Figure 1 .
8. Immerse the valve rotator in clean lubricating oil and take it back out
shortly before installation.
▲ Attention! Never pack the valve rotator with grease!

Operating sequence 4 -- Installation of the valve rotator

Starting condition Valve rotator cleaned and oiled.

Regarding the installation of the valve rotator, please refer to work card
113.01.
113.01

Important! Only use original valve springs, as only original valve

springs ensure faultless operation of the valve rotator.

Storage Parts that became soiled due to an extended storing period or during
transportation have to be washed in a suitable cleaning agent, dried and
afterwards immersed into clean lubricating oil for a few minutes.

Important! Parts kept in stock have to be stored in well-packed

condition and protected against dust, water, humidity and aggressive
media. Dust causes the individual components to become stuck and hind-
ers or prevents the rotation when the parts are taken into operation.

1 Basic body 3 Disk spring

2 Ball 6 Compression spring

Figure 3. Ball raceways in the basic body of the valve rotator

6682 113.02--02 E 10.05 L 40/54, 48/60, L 58/64 CD 104/ 04

Inlet and exhaust valve
Valve cone and seat surface
Checking and assessing 113.03

Purpose of jobs to be done

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

check components for condition/wear,
assess the contact pattern/wear.

Brief description

Inlet and exhaust valve cones and seat surfaces are to be checked at
regular intervals, and overhauled and/or replaced if necessary.
The work/steps include:
carrying out an ink contact (”touching”) test,
assessing contact pattern/wear condition.

Tools/appliances required

Qty Designation No. Availability

1 Touching up device 113.224 Standard
for engine 32/40
1 Touching bow 114.032 Standard
for engine 40/54
1 Touching bow 114.033 Standard
for engine 48/60 B
1 Touching bow 113.054 Standard
for engine 58/64
1 Touching--test ink -- Inventory
1 Grinding paste (silicon--free) -- Inventory
1 Hexagon screw drivers (set) -- Inventory
1 Open--jaw and ring wrenches (set) -- Inventory

Preliminary remarks

Exhaust and inlet valves with a poor contact pattern do not have a long life
expectancy. They have to be overhauled or replaced.
The intervals for overhaul as entered in the maintenance schedule (see
Volume B1 / Operating Instructions) are guide values and depend on the
operating mode and the engine condition, as well as the quality of the fuel
used. The most suitable intervals for overhaul have to be chosen, making
due allowance for the specified checks.
Due to the frequent temperature changes, the material of the valve cone is
subject to fatigue. The valve cones are to be replaced when the operating
times stated in the maintenance schedule (see Volume B1 / Operating In-
structions) have been reached, even if the admissible maximum remachin-
ing limits have not yet been reached.

6682 113.03--05 E 05.06 General 101/ 07

 ▲ Attention! Use beyond this limit involves an unpredictable risk
for the engine!

1 Cylinder head
2 Inlet valve cone
3 Valve seat ring
4 Exhaust valve cone
5 Valve seat ring

Figure 1. Inlet and exhaust valve

The valve seat angle (a) of the valve cone is 120ƒ , with a positive toler-
ance. The valve seat angle (b) in the valve seat ring has a negative toler-
ance, which results in a small differential angle (g). This ensures that in
operation the sealing zone for the hot gases is on the outer margin of the
valve seat area. Refer to Figure 2 .
The contact pattern is checked by means of a touching test.

2 Inlet valve cone a Angle on the valve cone g Differential angle

3 Valve seat ring b Angle on the valve seat
ring

Figure 2. Relation of the geometrical angles between valve seat ring and valve cone - Illustration shows inlet valve

▲ Attention! With valve seat grinders or valve seat lathes that have
long been in use, tolerances resulting from wear may change the
valve seat angle so that an incorrect contact pattern is produced! We
recommend checking by means of a touching test using a new, orig-
inal MAN B&W valve cone! If deviations are found, the valve seat
grinder or the valve seat lathe is to be checked!

6682 113.03--05 E 05.06 General 102/ 07

Operating sequence 1 -- Touching test

Starting condition The cylinder head has been mounted in the cylinder head turnover stand;
inlet/exhaust valves have been dismantled.

2 Inlet valve cone

Figure 3. Touching bow and/or touching up device - Illustration shows inlet valve

Steps 1. Carefully clean the valve seat surfaces.

▲ Attention! Do not damage the valve cone by using a wrong
cleaning tool (such as a slag hammer)!
2. Fasten the touching bow or the touching up device to the valve cone
(2 or 4). Refer to Figure 3 .
3. Apply a uniform film of touching-test ink, as thin as possible, to the
valve seat of the valve cone (2 or 4).
4. Slide the valve cone (2 or 4) into the appertaining valve guide in the
cylinder head (1) and turn it by one half revolution in vertical position
and under pressure, using the touching bow or the touching up de-
vice.
5. Take the valve cone (2 or 4) out.
6. Check the valve seat in the valve seat ring (3 or 5). If the differential
angle is correct and remachining has been carried out properly, there
must be a continuous bearing zone at the outer margin of the valve
seat.
7. Remove the touching bow or the touching up device.

Operating sequence 2 -- Assessing valve seat surfaces

Starting condition The cylinder head has been mounted in the cylinder head turnover stand,
inlet/exhaust valves have been dismantled.

6682 113.03--05 E 05.06 General 103/ 07

Diagnosis 1 The valve seat surfaces of the valve seat rings are clean, showing slight
varnishing or only minor pitting. Uniform contact pattern all around - refer
to Figure 4 .

Figure 4. Illustrating Diagnosis 1

Action Apply silicon-free grinding paste to the valve seat surface of the valve seat
rings (observe instructions of the supplier!) and clean by hand using the
touching bow or the touching up device until varnishing has been removed.
After cleaning, make a touching test (see operating sequence 1).

Important! Use as little grinding paste as possible for cleaning, and

carefully wash the valve cone and valve seat ring afterwards. Residues of
grinding paste promote wear.
Minor pitting left after removal of varnishing can be tolerated, it has but
little effect on the service life.

Diagnosis 2 The valve seat surface of the valve seat ring shows heavy deposits, rather
deep corrosion pitting and/or distinct pounding marks. There is wear on
the valve seat ring - refer to Figure 5 .

Figure 5. Illustrating Diagnosis 2

6682 113.03--05 E 05.06 General 104/ 07

Action Remachine the valve seat rings using the valve seat grinder and/or valve
seat lathe until the valve seat surfaces are clean or the appearance of the
contact faces is as new (see Work Cards 113.04 and 113.05).
113.05 After clean-
ing, make a touching test (refer to operating sequence 1).

Important! Keep grinding and/or turning treatment to a minimum

and subsequently wash the valve cone and valve seat ring carefully.
Grinding residues promote wear.
Minor pitting left after grinding/turning can be tolerated, it has but little ef-
fect on the service life.

Diagnosis 3 Valve seat surfaces of valve cones are clean, showing slight varnishing or
only minor pitting. Uniform contact pattern all around.

Action Apply silicon-free grinding paste to the valve seat surface of valve cone
and valve seat ring (observe instructions of the supplier!) and clean by
hand using the touching bow or the touching up device until varnishing has
been removed. After cleaning, make a touching test (see operating se-
quence 1).

Important! Use as little grinding paste as possible for cleaning, and

carefully wash the valve cone and valve seat ring afterwards. Residues of
grinding paste promote wear.
Minor pitting left after removal of varnishing can be tolerated, it has but
little effect on the service life.

Diagnosis 4 The valve seat surface of the valve cone shows heavy deposits, rather
deep corrosion pitting and/or distinct pounding marks. There is wear on
the valve cone - refer to Figure 6 .

Figure 6. Illustrating Diagnosis 4

Action Remachine the valve cone using the valve cone grinder until the valve
seat surfaces are clean or the appearance of the contact faces is as new
(see Work Cards 113.xx). After cleaning, make a touching test (refer to
operating sequence 1).

Important! Keep grinding treatment to a minimum and subse-

quently wash the valve cone carefully. Grinding residues promote wear.
Minor pitting left after grinding/turning can be tolerated, it has but little ef-
fect on the service life.

6682 113.03--05 E 05.06 General 105/ 07

Diagnosis 5 Valve cone showing incipient blow-by or cracks in the valve seat armour-
ing. Wear on the valve cone - refer to Figure 7 .

Figure 7. Illustrating Diagnosis 5

Action The valve cone is to be replaced.

Operating sequence 3 -- Assessing the valve cone

Starting condition The cylinder head has been mounted in the cylinder head turnover stand,
inlet/exhaust valves have been dismantled.

Diagnosis 6 Valve cone showing incipient shaft corrosion. Wear on the valve cone -
refer to Figure 8 .

A Shaft corrosion
Figure 8. Illustrating Diagnosis 6
Action The valve cone is to be replaced.

6682 113.03--05 E 05.06 General 106/ 07

Diagnosis 7 Valve cone showing burn-up on the valve plate. Wear on the valve cone -
refer to Figure 9 .

B Burn-up on the valve plate

Figure 9. Illustrating Diagnosis 7

Action If the limit values stated in Work Card 113.09 have been exceeded, the
valve cone is to be replaced.

Diagnosis 8 Valve cone showing stress cracking on the valve shaft. Wear on the valve
cone - refer to Figure 10 .

C Stress cracking on the

valve shaft
Figure 10. Illustrating Diagnosis 8

Action DThe valve cone is to be replaced if stress cracking is found on the valve
shaft. In this connection, crack testing according to Work Card 000.34 is
to be carried out.

6682 113.03--05 E 05.06 General 107/ 07

Valve seating surface
Grinding 113.04

Purpose of jobs to be done

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

ensuring correct execution of work,
restoring contact pattern.

Brief description

Valve seating faces are to be checked at regular intervals and remachined

if necessary. The valve seat grinder Hunger SB3M is to be used for this
purpose.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Quant Denomination No. Availability

1 Valve seat grinder for engine 58/64, 113.120--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 58/64 113.120--16 Optional
1 Centering device for engine 58/64 113.120--18 Optional
1 Valve seat grinder for engine 48/60, 113.132--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 48/60 113.132--16 Optional
1 Centering device for engine 48/60 113.132--18 Optional
1 Valve seat grinder for engine 40/54, 113.128--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 40/54 113.128--16 Optional
1 Centering device for engine 40/54 113.128--18 Optional
1 Valve seat grinder for engine 40/45, 113.134--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 40/45 113.134--16 Optional
1 Valve seat grinder for engine 52/55 B, 113.133--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 52/55 B 113.133--16 Optional
1 Centering device for engine 52/55 B 113.133--18 Optional
1 Hexagon screw driver (set) -- Optional
1 Open--jaw wrench (set) -- Optional
1 Hand dressing stone -- Optional

6619 113.04--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 101/ 05

Related work cards

Work card Work card Work card

113.03 113.08 113.10
113.14

Technical details

Term Information
Grinding area/valve seat diameter 60 -- 200 mm
Grinding angle in degrees 30/45
Speed of grinding spindle 7,000 rpm
Speed of grinder head (infinitely variable) 4 -- 20 rpm
Cross--feed per revolution of the grinding 0.3 mm
wheel
Power input approx. 600 W
Material of grinding wheel Special fused alumina
Outer diameter of grinding wheel 65 mm
Diameter of grinding wheel support 20 mm
Width of grinding wheel 8 mm
Degree of hardness of the grinding wheel F
Grain 80

Preliminary remarks

The tools/appliances mentioned above are contained in the portable box of

the valve seat grinder.

Operating sequence 1 -- Grinding the valve seat

Starting condition Valve guide in cylinder head or in valve cage and valve seat
surface, cleaned. In the case of cage valves, valve cage installed in
cylinder head or clamping device, lock nuts tightened at specified torques
000.30, 113.01 and 114.01
(refer to work card 000.30 114.01).

Important! Prior to putting the grinder into operation, study

113.10).
manufacturer’ s instructions carefully (refer to work card 113.10

▲ Attention! No grinding or dressing without wearing goggles!

Steps 1. Install pilot (4) in cleaned valve guide, measure valve seat, align
pilot, using eccentric taper adapters, if necessary. Install centering
device (7) with sufficient depth to ensure clearance in relation to
grinding wheel (if existing) (refer to work card 113.08).
113.08

6619 113.04--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 102/ 05

 1 Valve seat grinder type
SB3M
2 Basic machine with
gear, driving motor and
switch box
3 Grinding spindle with
grinding wheel and
dressing device
4 Pilot
5 Grinding wheel
6 Dressing diamond
7 Centering device
15 Valve seat surface on
valve cage or valve
seat ring
16 Cylinder head or
clamping device

Figure 1. Valve seat grinder type SB3M (illustration shows version for engine 58/64)
2. Position valve seat grinder. Prior to refacing of each individual
seating surface, dress grinding wheel with diamond (6). In case
of new grinding wheels, also the front faces must be dressed by
means of a hand-weel dresser to ensure that the wheel is in
balance (refer to work card 113.10).
113.10
3. To adjust grinding depth (0.1 mm), determine highest point of
seating surface.
4. The seating surface is to be ground from inside towards the outside
over the seating surface.
Important! Remove as little stock as possible, just as much
as necessary to obtain a smooth surface and to achieve a continuous and
unmarred grinding pattern on the outer half.
5. Subsequently, finish-grind seat with a feed of 0.025 maximum (half
graduation line), again from the inside towards the outside. To
improve the surface, clean oil should be applied to the seating face
during the finish-grinding process and subsequently the surface
should once be ground across the entire surface without any feed
pre-set.
6. Place the valve cone to be installed, or a new original
MAN B&W Diesel AG valve cone into the valve guide and make
touching test (refer to work card 113.03).
113.03
7. Following the refacing of a valve seat, the external valve seat
diameter increases. The front side of the valve seat rings or of the
valve cages must, therefore, be reground until the specified diameter
(E) is reached (refer to Table 1 and Figure 2 ).
By pulling off the grinding wheel accordingly, the contour of the
front face of the valve seat rings is to retain its shape or must not
be changed considerably (refer to work card 113.10).
113.10 For this

6619 113.04--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 103/ 05

 remachining process, the valve cages may be removed in order to
avoid grinding the cylinder head.
Important! On inlet valve cages of engine type 58/64, a newly
mounted valve seat ring must not be dismounted again.
8. Remove grinding device and clean entire cylinder head and valve
cage, particularly valve guide and seating surface.
Important! Original grinding wheels are to be used, as they are
matching the hardness of the valve seats.
Vibrations prevailing in the neighbouring area may cause chatter marks on
the seat surfaces. Refacing should, therefore, take place in an
environment free from vibrations or in resiliently mounted equipment.

Operating sequence 2 -- Maximum permissible remachining rates of valve seat surfaces on valve seat
cages and valve seat rings

Engine type 40/45 40/54 48/60 52/55 B 58/64

External valve seat diameter 132 132 160 160 185
Table 1. Desired value for external valve seat diameter

D Measuring edge for

maxium wear
E External valve seat
diameter
F Connecting contour on
front face of valve seat
in case of valve seat
rings
G Cylinder head
H Valve cage
J Valve seat ring
K Valve cage seating
face

Figure 2. Remachining limits on the valve seat

The max. admissible limit for remachining has been reached when the
valve seat has been refaced up to the edge D. Remachining beyond the
edge D is accompanied by a loss of hardness of the valve seat material

6619 113.04--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 104/ 05

 and thus the inner diamenter of the valve seat can no longer be
distinguished.
The external valve seat diameter E, increased by the refacing must be
worked to the specified dimension E by regrinding of the front face.
The contour on the front face of the valve seat rings is thereby to retain
its shape or must not be considerably changed. Valve cages may be
removed for this type of regrinding.

▲ Attention! In case the admissible wear limits have been

exceeded, regeneration of the inlet and exhaust valve cages is
possible in one of our Service Centres.
For removal and reinstallation of valve seat rings refer to work
card 113.13 or have them changed by a Service Centre. If on the
valve cage seating surface the external contour K and/or seating
surface on the cylinder head has been remachined, the distance
between lower side of the valve plate and the piston must be
113.14).
checked (refer to work card 113.14

6619 113.04--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 105/ 05

Valve cone
Grinding 113.05

Purpose of jobs to be done

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

ensuring correct execution of work,
restoring contact pattern.

Brief description

Valve seating faces are to be checked at regular intervals and remachined

if necessary. The valve cone grinder type Hunger VKM 3.1 is to be used
for this purpose.
The work concerns:
establishment of a correct contact pattern.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Valve cone grinder VKM 3.1 113.242 Optional
1 Collet chuck for engine 20/27 113.244 Optional
1 Collet chuck for engine 40/45, 40/54 113.248 Optional
1 Collet chuck for engine 48/60 113.249 Optional
1 Collet chuck for engine 52/55B 113.250 Optional
1 Grinding wheel 113.258--1 Optional
1 Dressing diamond 113.258--3 Optional
1 Coolant 113.258--5 Optional
1 Dial gauge -- Inventory
1 Magnetic post -- Inventory
1 Sliding caliper -- Inventory
1 Hammer (wood/plastic) -- Inventory

Related work cards

Work card Work card Work card

113.03 113.09

6682 113.05--02 E 12.02 General 101/ 08

Operating sequence 1 -- Checking the concentricity of the used valve cone

1 Valve cone 2 Collet chuck 3 Steady rest

Figure 1. Checking the concentricity of the valve cone (the inlet valve being shown in the illustration)

Steps 1. Clean the valve cone.

2. Clamp the valve cone into the valve cone grinder at the rear shaft
diameter. Refer to Figure 1 .
3. Measure the concentricity at the front shaft diameter and at the seat-
ing face of the valve cone.
4. Decide whether the valve cone can be remachined or whether it has
to be replaced.
Important! The maximum admissible eccentricity on the shaft and
seating face of the used valve cone is 0.05 mm. In case this value is ex-
ceeded, the valve cone has to be replaced!
For supplementary remarks concerning the assessment of the valve seat-
113.03.
ing face, see work card 113.03

Operating sequence 2 -- Grinding the valve cone seating face

▲ Attention! Prior to taking the device into operation, attentively

read the manufacturer’s directions for use. Use the protection
equipment provided.

Starting condition The valve cone has been cleaned.

For setting and grinding the valve cones, see the directions for use. In this
connection, pay attention to the following items:

Steps 1. Before starting to work, check the grinding wheel for firm seat.
2. Dress the grinding wheel using the dressing diamond.
▲ Attention! Because of the cutting speed, the grinding wheel diam-
eter must not be less than 150 mm.

6682 113.05--02 E 12.02 General 102/ 08

 Figure 2. Chucked-in exhaust valve cone
3. Depending on the engine type, insert the correct collet chuck in the
headstock.
4. Insert the valve cone in the work-piece headstock. Clamp the valve
cone on the collar provided for this purpose, keeping the distance as
short as possible (valve plate close to the collet chuck). Refer to Fig-
ure 2 .
5. Tighten the collet chuck (hand-tight, using a hook spanner). In order
to centre the collet chuck, knock against the valve plate bottom by
means of a plastic hammer (two to three light taps), retighten the
collet chuck once again.
6. Check the concentricity.
▲ Attention! In case the eccentricity exceeds the admissible value,
the service department of MAN B&W Diesel AG is to be consulted.
7. The slide has by the manufacturer been fixed to the desired angle by
means of a pin.
8. Prior to the first grinding pass, adjust the grinding wheel and valve
cone so that centre of valve cone seating face = grinding-wheel
centre. Refer to Figure 3 .
9. Advance until grinding of the valve cone seating face is started.
10. Carry out the grinding, applying light coolant and moving the grinding
wheel to and fro by hand. Take care that the grinding wheel remains
on the valve seat all the time.
Choose the grinding feed as small as possible (0.025 mm = 1/2 large
scale mark), so as to avoid chatter marks.
▲ Attention! By all means, supply a sufficient amount of coolant to
the wedge between grinding wheel and valve cone seating face.
During the course of the grinding process, make sure that the grind-
ing wheel does not interfere with the valve cone radius (R). Refer to
Figures 4 to 8 .
An increasing grinding noise is an indication that the grinding wheel
does no longer remove material. The grinding wheel is then to be
dressed.
When grinding valve cones of NIMONIC 80 A, the grinding wheel is
to be dressed more often, as it becomes loaded more quickly and
exerts pressure (high grinding sound).
11. Prior to the last grinding pass, redress the grinding wheel.
12. For finish-grinding (last grinding pass), use a low amount of advance
( 0.02 mm) and finish-grind properly.

6682 113.05--02 E 12.02 General 103/ 08

 ▲ Attention! After finish-grinding, do not push the grinding wheel
off the valve cone seating face but rather lift the valve cone seating
face from the grinding wheel.
When the maximum value (H) has been reached, the valve cone must
no longer be used (refer to Tables 2 to 7).
13. Remove the burr on the outer diameter of the valve plate using ap-
propriate tools (file, grinding stones) and/or break the edge on the
inner seat diameter by means of a grinding stone.

1 Valve cone
4 Grinding wheel

Figure 3. Position of the grinding wheel/valve cone seating face prior to grinding

Operating sequence 3 -- Maximum remachining on the exhaust valve

Preliminary remark Exhaust valves are subject to continuous development. This has in-
fluences on the shape and/or material composition of the valve cone.

Important! For carrying out remachining work on the valve cone

seat, it is important to classify the exhaust valve cone correctly by its
shape and condition and to read the corresponding maximum remachining
size from the respective table (see Tables 2 to 4).
Criterions of the exhaust valve cones:
- Exhaust valve cones are generally designed as one-part propeller
valves (old/previous design with vane sleeve).
- The valve seat may be designed with a connection angle (refer to
Figures 4 or 5 ) or with a recess (refer to Figure 6 ).
- Exhaust valve cones may either be manufactured from steel alloy with
armouring or from NIMONIC 80 A. For the exhaust valve, the same
remachining limits (H) apply.
Generally, the following applies: The admissible remachining limit has been reached on the valve cone
seating face when the valve cone seat width (G, new condition) has in-
creased to size (H).

Important! For admissible remachining on the outer valve diameter

and for the permissible burn-up and depth of corrosion on the valve plate,
113.09.
refer to work card 113.09

6682 113.05--02 E 12.02 General 104/ 08

Exhaust valve cone with vane sleeve

5 Exhaust valve cone H Max. remachining

6 Vane sleeve R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 4. Remachining an exhaust valve cone with vane sleeve (old design with connection angle)

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B

G new 4.0 7.3 9.8 11.5 9.3
H Maximum 15.5 23.5 25.5 32.0 27.5
Table 1. Remachining limits [mm] concerning Figure 4

Exhaust valve cone design with connection angle

5 Exhaust valve cone H Max. remachining

7 Rotary vane R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 5. Remachining an exhaust valve cone (design with connection angle)

6682 113.05--02 E 12.02 General 105/ 08

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B
G new 16.5
H maximum 25.8
Table 2. Remachining limits [mm] concerning Figure 5

Exhaust valve cone design with recess

5 Exhaust valve cone H Max. remachining

7 Rotary vane R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 6. Remachining an exhaust valve cone with recess

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B

G new 4.6 11.5 11.5
H maximum 7.8 18.4 18.4
Table 3. Remachining limits [mm] concerning Figure 6

Operating sequence 4 -- Maximum remachining on the inlet valve

Preliminary remarks Inlet valves are subject to continuous development. This has influences
on the shape and/or material composition of the valve cone.

Important! For remachining the valve cone seat, it is important to

classify the valve cone correctly by its shape and condition and to read the
maximum remachining size from the respective table.
Criterions of the inlet valve cones:
- The valve seat may be designed with a connection angle (refer to
Figure 7 ) or with a recess (refer to Figure 8 ).
- Inlet valve cones may either be manufactured from a steel alloy with
armouring (valve plate magnetic) or from NIMONIC 80 A (valve plate
not magnetic).
▲ Attention! For inlet valve cones with recess and of armoured de-
sign, other remachining limits apply than for inlet valve cones with
recess made from NIMONIC 80 A!

6682 113.05--02 E 12.02 General 106/ 08

 Important! Carry out the check for magnetism on the valve plate
underside.

Generally, the following applies: The admissible remachining limit has been reached on the valve cone
seating face when the valve cone seat width (G, new condition) has in-
creased to dimension (H).

Important! For admissible remachining on the outer valve diameter

and for the permissible burn-up and depth of corrosion on the valve plate,
113.09.
refer to work card 113.09

Inlet valve cone design with connection angle

8 Inlet valve cone H Max. remachining

R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 7. Remachining an inlet valve cone (design with connection angle)

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B

G new 4.0 7.3 9.8 9.3
H maximum 15.5 23.5 25.5 27.5
Table 4. Remachining limits [mm] concerning Figure 7

6682 113.05--02 E 12.02 General 107/ 08

Inlet valve cone design with recess

8 Inlet valve cone H Max. remachining

R Valve cone radius
G Valve cone seat width (in new condition) X Tangential point

Figure 8. Remachining an inlet valve cone with recess

Inlet valve cone with armouring and recess

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B
G new 4.6 6.7 8.0 11.5 11.5
H maximum 7.8 11 14.0 16.0 16.0
Table 5. Remachining limits [mm] concerning Figure 8

Inlet valve cone from NIMONIC 80 A, with recess

Engine type 20/27 40/45 40/54 48/60 48/60B 52/55 A+B
G new 4.6 6.7 8.0 11.5 8.7
H maximum 8.0 11 12.1 18.4 15.5
Table 6. Remachining limits [mm] concerning Figure 8

6682 113.05--02 E 12.02 General 108/ 08

Inlet-- and exhaust valve
Valve seat surface
measuring 113.08

Purpose of jobs to be done

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

ensuring correct execution of work,
restoring contact pattern.

Brief description

Before regrinding the valve seat or when replacing a valve seat ring,
measuring of the valve seat surface is necessary.
The work includes:
measuring components.

Tools/appliances required

Quant Denomination No. Availability

1 Valve seat grinder for engine 58/64, 113.120--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 58/64 113.120--16 Optional
1 Centering device for engine 58/64 113.120--18 Optional
1 Measuring device for engine 58/64 113.120--21 Optional
1 Valve seat grinder for engine 48/60, 113.132--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 48/60 113.132--16 Optional
1 Centering device for engine 48/60 113.132--18 Optional
1 Measuring device for engine 48/60 113.132--21 Optional
1 Valve seat grinder for engine 40/54, 113.128--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 40/54 113.128--16 Optional
1 Centering device for engine 40/54 113.128--18 Optional
1 Measuring device for engine 40/54 113.128--21 Optional
1 Valve seat grinder for engine 40/45, 113.134--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 40/45 113.134--16 Optional
1 Measuring device for engine 40/45 113.134--21 Optional
1 Valve seat grinder for engine 52/55 B, 113.133--1/2/3 Optional
Type SB 3 M
1 Pilot for engine 52/55 B 113.133--16 Optional
1 Centering device for engine 52/55 B 113.133--18 Optional
1 Measuring device for engine 52/55 B 113.133--21 Optional
1 Hexagon screw driver (set) -- Optional
1 Open--jaw wrench (set) -- Optional

6619 113.08--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 101/ 04

 Quant Denomination No. Availability
1 Memo pad -- Inventory
1 Felt--tip pen/Marking pen -- Inventory

Related work cards

Work card Work card Work card

113.04

Preliminary remarks

The mentioned tools/appliances are contained in the portable box of the

valve seat grinder.

Operating sequence 1 -- Measuring of the valve seating surface

Starting condition In case of cylinder heads with cage valves, valve cages installed in
cylinder head or clamping device, bolts tightened at specified torques
(refer to work card 000.30).
000.30
Valve guide and valve seating surface for intake and exhaust cleaned
carefully.

Steps 1. Turn cylinder head or clamping device with clamped valve cage in
such a way that the combustion chamber side is pointing upwards
(refer to Figure 1 ).
2. Introduce pilot (3) from above into valve guide (6) until the centering
cone (B) contacts the valve guide.
3. Screw nut (4) with taper adapter from below onto the pilot, thus
clamping the pilot centrically in the valve guide. Ensure that cone
engages in the valve guide.
4. Slip measuring device (1) over the pilot and clamp tightly at about
measuring level, using lock bolt (7).
5. By means of shifting the guide rods (9), set dial gauge (10) so that
feeler of dial gauge is seated at the outer third of the slant of the
valve seat (2). If necessary, adjust level of measuring device.
Tighten lock bolts (8) of guide rods.
6. Carefully turn measuring device through a full turn and, in doing so,
observe dial gauge reading. Turn the dial gauge to the highest point
and note down gauge reading.
7. Turn measuring device to lowest point and note down the reading as
well. The difference between the two readings is the figure for the
out-of-true state of the valve seat.
8. Using felt pen, mark the lowest point (D) of the valve seat (refer to
Figure 2 ).
Important! If the difference of the measured values results in a
figure greater than 0.1 mm, an eccentric taper adapter is to be selected
instead of the centrical adapter. Eccentricity of the taper adapter should be
about equal to the out-of-true state of the valve seat (e.g. 0.4 mm). Each
of the eccentric taper adapters is marked at its thickest point (E). Before
clamping, turn the taper adapter in order that the marking (E) points in the
same direction as marking (D) on on the valve seat (lowest point) (refer to
Figure 2 and steps 9 to 12). The result is that the pilot is aligned in such
a way that during the subsequent grinding process a seating surface is

6619 113.08--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 102/ 04

 produced which takes the best-possible position when the engine has
reached operating temperature.
9. Unscrew nut (4) with centrical taper adapter.
10. According to the differential value ascertained, select suitable
eccentric taper adapter (5).
11. Fit eccentric taper adapter (5) to pilot, paying attention to the marking
and clamp it with nut (4) turned upside down.
12. Carry out another measurement. The differentialvalue must not
exceed 0.1 mm. If it is greater than that figure, use eccentric taper
adapter next to it in size.
13. Detach measuring device.
14. Install centering device (11) (if provided). Prior to positioning the
centering device, push the three spring pre-loaded thrust bolts
towards the inside and lock by tightening the set screws. Push
centering device on pilot sufficiently far to ensure adequate clearance
with relation to the grinding wheel and lock by tightening clamping
screw (12). Loosen all set screws, so that thrust bolts are seated
resiliently and self-centering contact the gas duct. Subsequently lock
thrust bolts by tightening set screws.

1 Measuring device
2 Valve seat
3 Pilot
4 Nut with taper adapter
6 Valve guide
7 Lock bolt
8 Lock bolt
9 Guide rod
10 Dial gauge
11 Centering device
12 Clamping screw
B Centering cone

Figure 1. Measuring the valve seating surface

6619 113.08--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 103/ 04

 4 Nut with taper adapter
5 Eccentric taper
adapter
D Lowest point of valve
seat
E Marking on eccentric
taper adapter

Figure 2. Mounting and alignment of taper adapter

15. Oil front face of pilot with a few drops of lubricating oil.
16. Slip on grinder and start valve seat machining process (refer to work
113.04).
card 113.04
Tip! Exact setting economises grinding time and material up to the
admissible limit for remachining.

6619 113.08--03 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 104/ 04

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

Valve seating surface
Grinding 113.10

Purpose of jobs to be done

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

ensuring correct execution of work,
restoring contact pattern.

Brief description

Valve seating faces are to be checked at regular intervals and remachined

if necessary. The valve seat grinder Hunger SB3M is to be used for this
purpose.
Information is imparted concerning:
proper application/use,
dressing the grinding wheel,
maintaining components.

Tools/appliances required

Quant Denomination No. Availability

1 Valve seat grinder for engine 58/64, 113.120--1/2/3 Optional
Type SB 3 M
1 Basic machine for engine 58/64 with gear, driving 113.120--7/9 Optional
motor and switch box
1 Grinding spindle for engine 58/64 113.120--10 Optional
with grinding wheel
1 Spare grinding wheel (1 set = 5 pieces) 113.120--12 Optional
1 Spare diamond 113.120--13 Optional
1 Pilot for engine 58/64 113.120--16 Optional
1 Series transformer (at 110--115 V) for engine 58/64 113.120--17 Optional
1 Centering device for engine 58/64 113.120--18 Optional
1 Valve seat grinder for engine 48/60, 113.132--1/2/3 Optional
Type SB 3 M
1 Basic machine for engine 48/60 with gear, driving 113.132--7/9 Optional
motor and switch box
1 Grinding spindle for engine 48/60 with grinding 113.132--10 Optional
wheel
1 Spare grinding wheel (1 set = 5 pieces) 113.132--12 Optional
1 Spare diamond 113.132--13 Optional
1 Pilot for engine 48/60 113.132--16 Optional
1 Series transformer (at 110--115 V) for engine 48/60 113.132--17 Optional
1 Centering device for engine 48/60 113.132--18 Optional
1 Valve seat grinder for engine 40/54, 113.128--1/2/3 Optional
Type SB 3 M

6619 113.10--01 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 101/ 08

 Quant Denomination No. Availability
1 Basic machine for engine 40/54 with gear, driving 113.128--7/9 Optional
motor and switch box
1 Grinding spindle for engine 40/54 with grinding 113.128--10 Optional
wheel
1 Spare grinding wheel (1 set = 5 pieces) 113.128--12 Optional
1 Spare diamond 113.128--13 Optional
1 Pilot for engine 40/54 113.128--16 Optional
1 Series transformer (at 110--115 V) for engine 40/54 113.128--17 Optional
1 Centering device for engine 40/54 113.128--18 Optional
1 Valve seat grinder for engine 40/45, 113.134--1/2/3 Optional
Type SB 3 M
1 Basic machine for engine 40/45 with gear, driving 113.134--7/9 Optional
motor and switch box
1 Grinding spindle for engine 40/45 with grinding 113.134--10 Optional
wheel
1 Spare grinding wheel (1 set = 5 pieces) 113.134--12 Optional
1 Spare diamond 113.134--13 Optional
1 Pilot for engine 40/45 113.134--16 Optional
1 Series transformer (at 110--115 V) for engine 40/45 113.134--17 Optional
1 Valve seat grinder for engine 52/55 B, 113.133--1/2/3 Optional
Type SB 3 M
1 Basic machine for engine 52/55 B with gear, 113.133--7/9 Optional
driving motor and switch box
1 Grinding spindle for engine 52/55 B with grinding 113.133--10 Optional
wheel
1 Spare grinding wheel (1 set = 5 pieces) 113.133--12 Optional
1 Spare diamond 113.133--13 Optional
1 Pilot for engine 52/55 B 113.133--16 Optional
1 Series transformer (at 110--115 V) for engine 113.133--17 Optional
52/55 B
1 Centering device for engine 52/55 B 113.133--18 Optional
1 Hexagon screw driver (set) -- Optional
1 Open--jaw wrench (set) -- Optional
1 Hand dressing stone -- Optional
1 Fine--wire fuse (set) -- Optional

Related work cards

Work card Work card Work card

113.04 113.08

Technical details

Term Information
Grinding area/valve seat diameter 60 -- 200 mm
Grinding angle in degrees 30/45

6619 113.10--01 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 102/ 08

 Term Information
Speed of grinding spindle 7,000 rpm
Speed of grinder head (infinitely variable) 4 -- 20 rpm
Cross--feed per revolution of the grinding 0.3 mm
wheel
Power input approx. 600 W
Material of grinding wheel Special fused alumina
Outer diameter of grinding wheel 65 mm
Diameter of grinding wheel support 20 mm
Width of grinding wheel 8 mm
Degree of hardness of the grinding wheel F
Grain 80

Preliminary remarks

The mentioned tools/appliances are contained in the portable box of the

valve seat grinder.

Operating principle of valve seat grinder type Hunger SB3M

A motor located in the drive head (5) revolves the grinder head (1) round
the pilot (24) clamped in the valve guide (refer to Figure 1 ). The grinding
wheel (21) of the grinding spindle (17) mounted on the grinder head (1) will
thus be led round the valve seat (22) at a speed that can be adjusted. At
the same time, the grinding spindle slide (4) with grinding spindle (17)
together with the grinding wheel (21) are continuously moved transversely
outward at a feed of 0.3 mm per revolution. The valve seat is thus ground
progressively from the inside to the outside, ensuring that its proper
geometry is restored.

Operating sequence 1 -- Using the valve seat grinder

Starting condition In case of cylinder heads with cage valves, valve cages installed in
cylinder head or clamping device, screws tightened at specified torques.
Pilot inserted in valve guide in such a way that the dial gauge readings for
113.08).
facial run of the valve seat are below 0.1 mm (refer to work card 113.08
Centering device (23) installed.

Important! Prior to taking the grinder into use, study

manufacturer’s operating instructions carefully.

▲ Attention! No grinding or dressing without wearing safety

goggles!

Steps 1. Insert stop pipe (8) all the way into the machine and secure it by
means of clamping screw (10) -- refer to Figure 1 .
2. Screw the graduated ring (11) into drive head (5) as far as possible
and secure it using the knurled screw (12).
3. Slightly oil upper end and shoulder of pilot.
4. Position grinder on the pilot. Ensure that the adjusting screw (9) is
screwed out of the stop pipe (8) to such an extent that the stop pipe
is seated on the pilot.

6619 113.10--01 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 103/ 08

 5. Loosen counter nut (15) and introduce grinding spindle slide (4) into
the accordingly inclined prismatic guide (2 or 3) to such an extent that
the the rack mounted to the grinding spindle slide engages in the feed
pinion provided in the prismatic guide.
6. Move grinding spindle slide (4) by turning the setting screw (14) until
the circumferential surface of the grinding wheel (21) is situated
above the valve seat (22).
Tip! For changing the working area, the special clamp holder (16) of
the grinding spindle (17) can be fixed in different positions at the grinding
spindle slide (4).
7. Insert plug of the connecting cable of grinding spindle motor (17) into
the socket provided in grinder head (1) and secure it with safety clip.
8. Adjust grinder coarsely as follows: hold grinder head (1) from below
with one hand and lower the grinder cautiously after having loosened
clamping screw (10). Lower the grinder until the grinding wheel (21) is
situated about 2 mm above the valve seat. Arrest grinder in this
position by tightening the clamping screw (10).
Important! Prior to connecting the grinder to the mains, make sure
that the mains voltage is identical with the operating voltage indicated on
the type plate and that the control knob (6) is set to zero position.
9. Pull out cable pipe (13) from drive head (5) as far as possible and
insert plug into socket.
10. Secure drive head (5) against clockwise rotation. To achieve this,
attach a suitable stop for the cable pipe (13) to the cylinder head
resp. to the clamping device.
11. Check whether the grinder is ready for operation. Set toggle switch
on grinding spindle motor (17) to position I for a short period. Also
switch the grinder head drive on briefly by means of the control knob
(6).
12. Lower the grinder to valve seat level at fine feed. For doing so and
with the knurled screw (12) released, turn the graduated ring (11)
counter-clockwise until grinding wheel (21) slightly touches the valve
113.08).
seat at the highest point marked (refer to work card 113.08
13. Lift grinding wheel (21) off the valve seat (22) by screwing the
adjusting screw (9) into the stop pipe (8) and move it inwards by
turning the setting screw (14) until the rear edge of the grinding wheel
is positioned just in front of the inner edge of the valve seat. Now turn
adjusting screw (9) out of the stop pipe again until the stop pipe is
seated on the pilot.
14. Engage the feed gear. For doing so, tighten counter nut (15),
applying moderate force.
15. Adjust grinding depth. For this purpose, offset graduated ring (11) by
one to two graduation lines and arrest it by tightening the knurled
screw (12). Turning the graduated ring by one graduation line is
equivalent to a feed of 0.05 mm.
16. Switch on grinding spindle motor by means of the toggle switch.
▲ Attention! Attention should be paid that the cable pipe (13) abuts
against a stop so that the drive head (5) is prevented from rotating
(refer to step 10).
17. Switch on grinder head drive by means of control knob (6) and adjust
desired speed.
Tip! The speed of the grinder head is infinitely variable according to the
scale value. Valve seats of small diameters can be ground at a higher
grinder head speed than those of large diameters. Grind hard valve seats
at a lower grinder head speed than softer ones.
18. The valve seat is now automatically ground continuously, advancing
from the inside to the outside.

6619 113.10--01 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 104/ 08

 19. Switch off grinder head drive and grinding spindle motor as soon as
the grinding wheel has been fed beyond the outer edge of the valve
seat.
20. Repeat grinding operation (steps 13 -- 19) until the valve seat is
113.04).
properly machined all around (refer to work card 113.04

1 Grinder head 10 Clamping screw for stop 17 Grinding spindle

2 Prismatic guide 45ƒ pipe 18 Dressing tool
3 Prismatic guide 30ƒ 11 Graduated ring for 19 Handwheel for dressing
4 Grinding spindle slide grinding depth feed stroke
5 Drive head 12 Knurled screw for 20 Knurled screw for
6 Control knob for grinder graduated ring dressing feed
head speed 13 Cable pipe 21 Grinding wheel
7 Electric fuse 14 Setting screw for grinding 22 Valve seat
8 Stop pipe for vertical spindle slide 23 Centering device
adjustment 15 Counter nut 24 Pilot
9 Adjusting screw 16 Special clamp holder

Figure 1. Valve seat grinder type SB3M (illustration shows version for engine 58/64)

Preliminary remarks for dressing the grinding wheel

The tapered shape of the grinding wheels for use in valve seat grinders for
the machining of valve seats at 15ƒ angle and for front face grinding of
valve cages or the valve seat rings at 45ƒ angle, is to be prepared by
appropriate dressing.

Important! The minimum diameter of the grinding wheel is

determined by the size of the matching paper disks.

6619 113.10--01 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 105/ 08

Operating sequence 2 - Changing and preliminary shaping the grinding wheel

Steps 1. Hold grinding spindle shaft (26) by means of open-jaw wrench

(12 A/F) and screw off tensioning nut (25) in counter-clockwise sense
of rotation, using open-jaw wrench (24 A/F) - refer to Figure 2 ).
2. Change grinding wheel (21).
Important! Make sure that when using newly placed grinding
wheels, a paper disk (28) is positioned on each side.
3. Screw tension nut onto spindle shaft and tighten with moderate force.
▲ Attention! No grinding or dressing without wearing safety
goggles! In case of newly flanged grinding wheels, carry out a
five-minute test run (danger of injury!).
4. Start grinding spindle.
5. To minimise wobbling resp. imbalance, dress the front face of the
grinding wheel by using a hand dressing stone.
6. For machining the valve seat, preliminarily shape the grinding wheel
using a hand dressing stone (refer to Figure 2 ). The width of pass
on the grinding wheel circumference should be approx. 4 mm.

21 Grinding wheel
25 Tension nut
26 Grinding spindle shaft
28 Paper disk

Figure 2. Contour of grinding wheel for machining the valve seat

Operating sequence 3 - Dressing the grinding wheel for machining the valve seat

▲ Attention! Always wear safety goggles when dressing grinding

wheels.

Starting condition The dressing tool (18) can be attached to the special clamp holder (16) (as
in case of engine type 58/64 - refer to Figure 3 ) or supplied as a
separate dressing tool into which the grinding spindle (17) on its retainer
together with the prismatic guide (engines 40/45 to 52/55 B) are clamped.
The dressing tool is equipped with a dressing diamond (27), whose
dressing feed is adjusted by means of the knurled screw (20) and which
can be traversed using the hand wheel for dressing stroke (19). The
dressing tool is set at an angle of 15ƒ refer to Figure 3 )

Steps 1. Swich on grinding spindle motor.

2. By turning the hand wheel (19), position the dressing diamond (27)
approxiamately in front of the rotating grinding wheel (21), lower it
carefully until the diamond cutting point attacks the grinding wheel.

6619 113.10--01 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 106/ 08

 3. Position the dressing diamond (27) in front of the front edge or the
rear edge of the grinding wheel by turning the hand wheel.
4. Ajust the dressing amount at the knurled screw (20).
The maximum feed amount per dressing stroke should not exceed
0.1 mm. This is equivalent to turning the knurled screw by approx.
30ƒ . One turn is equivalent to a feed of 1 mm.
5. Slowly move the tip of the diamond over the grinding wheel by turning
the hand wheel (19) uniformly.
6. Carry out further dressing strokes, if necessary with reduced feed,
untill the grinding wheel is properly dressed.
7. Slightly round off the front and rear edges of the grinding wheel (21),
using hand the dressing stone.

16 Special clamp holder

17 Grinding spindle
18 Dressing tool
19 Hand wheel for
dressing stroke
20 Knurled screw for
dressing feed
21 Grinding wheel
25 Tension nut (24 A/F)
26 Grinding spindle shaft
(12 A/F)
27 Dressing diamond

Figure 3. Dressing tool for grinding wheel for machining of valve seat (illustration shows version for engine 58/64)

Operating sequence 4 - Dressing the grinding wheel for front face machining of valve cages or valve
seat rings

Steps 1. The angle of 45ƒ required for this purpose must be produced by
means of a hand dressing stone.
2. The front and the rear edges of the grinding wheel are to be rounded
off with a radius of approx. 1 mm.
3. When starting the grinding operation, the shape of the grinding wheel
is to be checked or adapted to the contour prevailing on the work
113.04).
piece (refer to work card 113.04

Operating sequence 5 - Maintenance

Steps 1. Clean the prismatic guides (2 or 3) as well as the grinding spindle

slide (4) at regular intervals using a dry cloth. Never oil or grease
these parts (refer to Figure 1 ).
2. Approx. every 10 operating hours, press lubricating grease into
lubricating nipple on grinder head (1).
3. Inspect carbon brushes of the grinding spindle driving motor after
approx. 250 operating hours and carbon brushes of the grinder head
driving motor after approximately 500 operating hours. Carbon
brushes must be replaced at the latest, when they are worn down to
a length of 6 mm.
▲ Attention! Be sure to pull mains plug out of socket before
checking carbon brushes.
4. If, after a long period of operation, the clearance between the
prismatic guide (2 or 3) and the grinding spindle slide (4) has become
excessive, the guide ledge must be readjusted. To do so, with the
grinding spindle slide inserted, first loosen the securing screws, then

6619 113.10--01 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 107/ 08

 slightly adjust the setting screws and thereafter firmly retighten the
securing screws.

6619 113.10--01 E 06.98 40/45, 40/54, 48/60, 58/64, 52/55 108/ 08

Valve plate - piston
Measuring the distance 113.14

Purpose of jobs to be done

Imparting the necessary knowledge,

keeping the state within the permissible range.

Brief description

The distance between valve plate and piston is to be specified after

specific maintenance work.
The work/steps include:
removing components,
installing components,
recording the measuring values.

Tools/appliances required

Quant Denomination No. Availability

1 Sliding caliper -- Inventory
1 Marking pencil -- Inventory
1 Sheet lead strip 1.5x5x70 -- Inventory
1 Adhesive tape -- Inventory

Related work cards

Work card Work card Work card

055.02 050.03 111.01
111.01
113.01 114.01

Preliminary remarks

All kinds of changes on the valve drive, the crankcase drive (length of
the connecting rod, piston height), especially reconditioning the valve
cage, the valve cage seat or the cylinder head etc. can influence the
distance (S) between the opened valve cone and the piston upper edge
in TDC. After each reconditioning or replacing on the points (1-2-3-4-5-10)
the dimension (S) has to be checked. This measuring process should be
part of the respective maintenance work, if possible. In case of engines
with valve cages on the four valves the cylinder head must not be
removed.

6619 113.14--02 E 04.98 40/54, 48/60, 58/64 101/ 04

Operating sequence 1 -- Removing the valve cages or the cylinder head

Starting condition Cam follower casing with bearing removed, piston is turned in ignition TDC
position (valves closed).

1 Sealing surface valve

cage/cylinder head
2 Sealing surface valve
cone/valve seat
3 Sealing ring
4 Sealing surface top
land ring/cylinder liner
collar
5 Sealing surface
cylinder liner collar/
backing ring
6 Sheet lead strip
10 Contact surface
backing ring/cylinder
crankcase
S Distance between the
valve plate bottom
edge and the piston
bowl approx. 5ƒ
BTDC/ATDC

Figure 1. Piston in TDC -- valves closed

Steps 1. In case of engines with valve cages on the inlet and outlet side,
all valve fixing nuts are to be loosened, screwed off and the thrust
flanges have to be removed (in case of outlet valves move the water
duct cock plug into “Zu” position).
2. In case of engines with valve cages only on the outlet side or without
valve cages the cylinder head must be removed as described in work
card 055.02.
055.02
3. Apply markings (M) on all valves, using the marking pen.The marking
has to be applied on the extension of the line center cylinder -- center
valve at the outer edge of the valve cage or valve seat (refer to
Figure 2 ).
4. For removing the valve cages of engines with valve cages on the
outlet and inlet side proceed as described in work cards 113.01 and
114.01.

6619 113.14--02 E 04.98 40/54, 48/60, 58/64 102/ 04

 M Marking

Figure 2. Marking the position of the mounted valves

Operating sequence 2 -- Measuring

Steps 1. Coil sheet lead strips (6) round a marking needle or something
similar (refer to Figure 3 ). Height on the winding approx. 8-9 mm.
2. Clean and degrease all valve plates, adhere prepared sheet lead strip
with adhesive tape approx. 20-25 mm from the valve plate’ s edge in
perpendicular position above the marking (M).

6Sheet lead strip

7Adhesive tape
8Valve plate
9Valve cage or cylinder
head
M Marking

Figure 3. Adhering a sheet lead strip to valve plate

6619 113.14--02 E 04.98 40/54, 48/60, 58/64 103/ 04

 3. Mount on valve cages or the cylinder head and rocker arm casing
and fasten with specified torque.
4. Turn engine once over TDC.
5. Remove rocker arm casing and valve cages or cylinder head again.
6. Measure thickness of deformed sheet lead strips with slide gaugh
and note down.
Important! The thickness (S) may not be less than 3.6 mm on
no valve (cold engine). Dimension (S) in new estade approx. 5.2 mm.
For corrective measures oversize sealing rings (3) are available (refer to
work card 050.03).
050.03

6619 113.14--02 E 04.98 40/54, 48/60, 58/64 104/ 04

Exhaust valve
Removing and installing 114.01

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

Exhaust valves are to be removed at regular intervals and overhauled if

necessary.
Valve guides must be checked and replaced if necessary within the scope
of maintenance and repair work.
The work/steps include:
checking of components,
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Driving shaft secured against turning

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 113.140 Standard
1 Guide piece 113.140--3 Standard
1 Clamping piece 113.140--7 Standard
1 Plate 113.140--8 Standard
1 Washer 113.140--11 Standard
1 Valve spring tensioner 113.123 Standard
1 Feed spindle 113.123--1 Standard
1 Bridge 113.123--5 Standard
1 Deep groove thrust ball bearing 113.123--9 Standard
1 Conical socket 113.123--13 Standard
1 Spherical disk 113.123--14 Standard
1 High--pressure pump 009.341/(009.338) Standard
1 High--pressure hose 009.306 Standard
1 Hydraulic tensioning device (hollow piston) 009.022 Standard
1 Tommy bar, 12 mm 000.264 Standard

6701 114.01--01 E 07.06 L 40/54 101/ 08

 Qty Designation No. Availability
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

000.34 009.03 009.05
055.05 113.03 113.04
113.05

Technical details

Term Information
Valve cone 5.5 kg

Operating sequence 1 -- Checking the valve rotator

The functioning of the valve rotator (rotating vane on the valve stem
and thrust bearing) can be checked with the cylinder-head cover
open and the engine running (under at least 10% load). There must
be a uniform, visible rotation of the valve. If not, the exhaust valve
must be removed, the individual components cleaned, and the thrust
bearing (2) checked and replaced if necessary.
If a valve has not turned for a long time, check the condition of the
valve cone (8) and valve seat.

Operating sequence 2 -- Removing the exhaust valve

Starting condition The cylinder head has been removed and clamped into the turnover stand
(see Work Card 055.05).
055.05

Important! If only the thrust bearing or compression springs are to

be removed, the cylinder head remains in place, and the piston is turned to
ignition TDC position.

Steps 1. Screw the feed spindle (113.123-1) all the way onto the valve cone
(8). Refer to Figure 2 /I.
2. Slip the bridge (113.123-5) onto the feed spindle, and place it on the
thrust bearing (2).
3. Mount the conical socket (113.123-13), spherical disk (113.123-14)
and deep-groove thrust ball bearing (113.123-9). Refer to Fig-
ure 2 /I.
▲ Attention! Make sure that the conical socket, spherical disk, and
deep-groove thrust ball bearing are fitted correctly!
4. Coat the thread of the feed spindle with special lubricant.
5. Screw the hexagon nut (10) onto the feed spindle.
6. Pretension/press down the compression springs (3 and 4) by means
of the valve spring tensioner (113.123) until the two-part tapered

6701 114.01--01 E 07.06 L 40/54 102/ 08

 piece (1) can be removed. Hold the bridge steady using the tommy
bar (000.264). Refer to Figure 2 /II.
7. Remove the two-part tapered piece (1).
8. Back off the hexagon nut (10), relieving the tension on the compres-
sion springs (3 and 4). Refer to Figure 2 /III.
9. Remove the valve spring tensioner (113.123), while holding the valve
cone (8) by hand.
▲ Attention! If the valve cone is not held, it will fall out of the valve
guide when the hexagon nut is removed!
10. Push the valve cone (8) out of the valve guide (6) and put it down.
Important! Note which valve cone was in each valve guide. If the
valve cone is not replaced, it has to be re-inserted into the same valve
guide as before.
11. Take off the thrust bearing (2) and compression springs (3 and 4).
12. Remove the O-ring seal (5).
13. Clean all the individual parts, and check them for wear (see Operat-
ing Instructions, Volume B1, for max. clearances), replace them if
necessary.
14. Clean the fillet and the transitions above the vane area until the metal
has a bright appearance (e.g., by wet blast cleaning). Carry out a
000.34).
Magnaflux inspection (see Work Card 000.34
In case of crack indications, contact an authorised Service Center to
clarify whether or not the parts can be further used.
15. If required, regrind the valve cone and/or the valve seat (see Work
Cards 113.04 and 113.05).
113.05
16. Check the condition of the valve guide; replace it if necessary. See
Operating Sequence 3 and 4.

Operating sequence 3 -- Checking the valve guide

▲ Attention! The valve guide is to be replaced whenever the wear

limit has been reached! The wear limit has been reached
- when the valve cone (20) butts against the cylindrical recess (C)
of the valve guide (21) on the combustion-chamber side! Refer to
Figure 3 .
- when the circumferential wear edge (A) on the valve guide (21) is
no longer visible or tangible, which may also only be the case on
part of the circumference!

Operating sequence 4 -- Removing the valve guide

Starting condition The valve cone has been removed.

Steps 1. Insert the guide piece (113.140-3) into the valve guide (6), slip on the
washer (113.140-11), and screw the hexagon nut (12) on, hand-tight.
2. Slip the clamping piece (113.140-7) and plate (113.140-8) over the
guide piece, making sure that the clamping piece and plate are cen-
tred properly. Refer to Figure 4 .
3. Slip the hydraulic tensioning device (009.022) over the guide piece,
and screw the hexagon nut (11) on, hand-tight. Refer to Figure 4 .
4. Connect the high-pressure hose (009.306) to the hydraulic tensioning
device and high-pressure pump (009.338 or 009.341). Connect the
oil pressure gauge (0-400 bar) to the high-pressure pump.
009.03), and
5. Switch the high-pressure pump on (see Work Card 009.03
slowly pump up the hydraulic tensioning device.
▲ Attention! Watch the pressure gauge while pumping up!

6701 114.01--01 E 07.06 L 40/54 103/ 08

 6. Pull the valve guide (6) out in several stages, releasing the pressure,
pressing the piston of the hydraulic tensioning device in, and turning
the hexagon nut (12) at each stage.
7. Release the pressure.
8. Press the piston of the hydraulic tensioning device in; disconnect the
high-pressure hose from the hydraulic tensioning device and high-
pressure pump.
9. Remove the tool.
10. Clean the valve guide, and check it for wear/damage; replace it if ne-
cessary.

Operating sequence 5 -- Installing the valve guide

Starting condition The valve guide has been cleaned, checked and replaced if necessary.
The bore hole in the cylinder head has been cleaned.

Steps 1. Slip the valve guide (6) and washer (113.140-11) onto the guide piece
(113.140-3), and screw the hexagon nut (12) on, hand-tight.
2. Pass the guide piece through the cylinder head (7).
3. Slip the plate (113.140-8) over the guide piece, and place it on the
valve seat ring (9), making sure that the plate and valve seat ring are
centred properly. Refer to Figure 4 .
4. Slip the hydraulic tensioning device (009.022) over the guide piece,
and screw the hexagon nut (11) on, hand-tight.
5. Connect the high-pressure hose (009.306) to the hydraulic tensioning
device and high-pressure pump (009.338 or 009.341). Connect the
oil pressure gauge (0-400 bar) to the high-pressure pump.
009.03), and
6. Switch the high-pressure pump on (see Work Card 009.03
slowly pump up the hydraulic tensioning device.
▲ Attention! Make sure that the valve guide is drawn into the bore
hole correctly!
Watch the pressure gauge while pumping up!
7. Draw in the valve guide (6) in several stages, releasing pressure,
pressing the piston of the hydraulic tensioning device in, and turning
the hexagon nut (11) at each stage.
8. Release the pressure.
9. Press the piston of the hydraulic tensioning device in; disconnect the
high-pressure hose from the hydraulic tensioning device and high-
pressure pump.
10. Remove the tool.

Operating sequence 6 -- Installing the exhaust valve

Starting condition All individual parts cleaned, checked and replaced if necessary. Bore hole
of the valve guide and valve seat ring cleaned. An ink contact (”touching”)
113.03).
test was carried out (see Work Card 113.03

Steps 1. Insert a new O-ring seal (5) into the groove, making sure that it is not
twisted.
2. Install the compression springs (3 and 4) into the cylinder head (7),
and place the thrust bearing (2) onto the compression springs. Refer
to Figure 1 .
3. Treat the stem of the valve cone (8) with special lubricant.
4. Insert the valve cone (8) into the valve guide (6).
5. Screw the feed spindle (113.123-1) all the way onto the valve cone
(8).
6. Slip the bridge (113.123-5) onto the feed spindle, and place it on the
thrust bearing (2).

6701 114.01--01 E 07.06 L 40/54 104/ 08

 7. Mount the conical socket (113.123-13), spherical disk (113.123-14),
and deep-groove thrust ball bearing (113.123-9). Refer to Figure 2 .
▲ Attention! Make sure that the conical socket, spherical disk and
deep-groove thrust ball bearing are fitted correctly!
8. Coat the thread of the feed spindle with special lubricant.
9. Screw the hexagon nut (10) onto the feed spindle.
10. Pretension/press down the compression springs by means of the
valve spring tensioner (113.123) until the two-part tapered piece (1)
can be installed. Hold the bridge steady using the tommy bar
(000.264). Refer to Figure 2 .
11. Install the two-part tapered piece (1).
▲ Attention! Do not insert the tapered pieces into the thread under-
cut!
12. Verify that the two parts of the tapered piece (1) have been inserted
correctly and that the gap between the two parts is uniform.
13. Back off the hexagon nut (10), relieving the tension on the compres-
sion springs (3 and 4). Refer to Figure 2 .
14. Remove the valve spring tensioner(113.123).

1 Tapered piece, two-

part
2 Thrust bearing
3 Compression spring
4 Compression spring
5 O-ring seal
6 Valve guide
7 Cylinder head
8 Valve cone
9 Valve seat ring

Figure 1. Exhaust valve

6701 114.01--01 E 07.06 L 40/54 105/ 08

 1 Tapered piece, two-part 5 O-ring seal I-III Steps
2 Thrust bearing 6 Valve guide
3 Compression spring 8 Valve cone
4 Compression spring 10 Hexagon nut M20

Figure 2. Removal of the two-part tapered piece

6701 114.01--01 E 07.06 L 40/54 106/ 08

 20 Valve cone
21 Valve guide

A Wear edge in new con-

dition
B Wear edge in worn
condition
C Cylindrical recess

Figure 3. Wear edge on the valve guide

6701 114.01--01 E 07.06 L 40/54 107/ 08

 6 Valve guide
7 Cylinder head
9 Valve seat ring
11 Hexagon nut M30
12 Hexagon nut M27x2

Figure 4. Removal and installation of the valve guide (illustration on the left: removal / illustration on the right: installation)

6701 114.01--01 E 07.06 L 40/54 108/ 08

Operating device

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

6682 125--06 E 07.99 101/ 01

Three-- way valve
Checking, overhauling 125.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Three--way valve 125.98.306
125.98
1 Set of wear parts 125.99.306
125.99

Three-way valve M306

Operating sequence 1 -- Disassembly of the three-way valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.02--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw off the roller lever (11), screw out the valve guide (12) together
with valve tappet (13) and spring.
4. Disassemble the valve further, and thoroughly clean all individual
parts.
5. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the three-way valve M306, a set of wear parts can
be obtained from MAN B&W Diesel AG.
6. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the three-way valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points.

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particules may cause disturbances in
the valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Roller lever
12 Valve guide
13 Valve tappet
14 Valve seat

V Wear parts

Figure 1. Sectional view of the three-way valve M306

Operating principle

Connection 1 2 4
Position I closed connected
Position II connected closed

6682 125.02--01 E 04.98 General 102/ 02

Three-- way valve
Checking, overhauling 125.04

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Hook spanner -- Inventory
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Three--way valve 125.98.317
125.98
1 Set of wear parts 125.99.317
125.99

Three-way valve M317

Operating sequence 1 -- Disassembly of the three-way valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.04--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the hexagon socket bolts (11) and take off the upper part
of the casing (12).
4. Using the hook spanner, turn out the valve guide (15) together with
piston (13) and valve tappet (14).
5. Take out the valve seat (16) and remove the valve (17).
6. Disassemble the valve further, thoroughly clean all individual parts
and discharge the compressed air.
7. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the three-way valve M317, a set of wear parts can
be obtained from MAN B&W Diesel AG.
8. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the three-way valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Hexagon socket bolt

12 Casing -- upper part
13 Piston
14 Valve tappet
15 Valve guide
16 Valve seat
17 Valve
18 Casing -- lower part

V Wear parts

Figure 1. Sectional view of the three-way valve M317

Operating principle

Connection 1 2 4
5 pressurised connected closed
5 pressureless closed connected

6682 125.04--01 E 04.98 General 102/ 02

3/2-- way solenoid valve
Checking, overhauling 125.05

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Screw drivers (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Qty Designation No.

1 3/2--way valve 125.98.329
125.98
1 Set of wear parts 125.99.329
125.99

3/2-way solenoid valve M329

Operating sequence 1 -- Disassembly of the 3/2-way solenoid valve

Starting condition Compressed air and control air system resp. in unpressurised condition.
Valve cleaned on the outside.

6682 125.05--01 E 03.05 General 101/ 03

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out hexagon bolts (11) and hexagon socket bolts (12).
4. Remove connecting piece (13) with emergency switch (14) and un-
screw hexagon socket bolt (12).
5. Disassemble the valve further, and thoroughly clean all individual
components.
6. Check the wear parts (V) for signs of wear and/or hardening (in the
case of sealing rings), replace parts as necessary.
Tip! For overhauling the 3/2-way solenoid valve M329, a set of wear
parts can be obtained from MAN B&W Diesel AG.
7. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 3/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and in the compressed air/control air system resp.
1. When installing new sealing rings, make sure that they are not
twisted.
2. Prior to assembly, slightly oil all parts.
▲ Attention! Make sure that the pins in the valve casing are arran-
ged correctly, depending on the desired application of the 3/2- way
solenoid valve M329. Incorrect arangement of the pins may result in
severe personal injury and engine damage.

11 Hexagon bolt
12 Hexagon socket bolt
13 Connecting piece
14 Emergency switch
15 Valve casing

V Wear parts

Figure 1. Sectional view of the 3/2-way solenoid valve M329

6682 125.05--01 E 03.05 General 102/ 03

Mode of operation

Depending on the arrangement of the pins in the valve casing, the

functions illustrated in the Figures 1 and 2 can be achieved.

Figure 2. Valve functions depending on the arrangement of the pins

6682 125.05--01 E 03.05 General 103/ 03

5/2-- way solenoid valve
Checking, overhauling 125.08

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Qty Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Qty Denomination No.

1 5/2--way solenoid valve 125.98.367
125.98

5/2-way solenoid valve M367

Operating sequence 1 -- Disassembly of the 5/2-way solenoid valve

Starting condition Compressed air and/or control air system without pressure. Governor
cleaned on the outside.

6682 125.08--02 E 03.99 General 101/ 02

Steps 1. Loosen pipe connections (mark them, if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Disassemble the valve and thoroughly clean all individual parts.
4. Check the wear parts for signs of wear and/or hardening (in case of
sealing rings), replace parts as necessary.
5. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the 5/2-way solenoid valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and in the compressed air/control air system resp.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

Figure 1. 5/2-way solenoid valve

Mode of operation

Connection 5 4 1 2 3
Solenoid de-energised connected connected closed
Solenoid energised closed connected connected

6682 125.08--02 E 03.99 General 102/ 02

Pressure reducing valve
Checking, overhauling 125.09

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Pressure reducing valve with manometer 125.98.409
125.98
1 Set of wear parts 125.99.409
125.99

Pressure reducing valve M409

Operating sequence 1 -- Disassembly of the pressure reducing valve

Starting condition Compressed air and/or control air system without pressure. Valve cleaned
on the outside.

6682 125.09--01 E 04.98 General 101/ 02

Steps 1. Loosen pipe connections (mark them if necessary), remove fixing
bolts and valve.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. Screw out the cylindrical screws (11) and knurled screw (14).
4. Separate the upper part of the casing (12) from the lower part (13)
and remove the wear parts (V).
5. Disassemble the valve further and thoroughly clean all individual
parts.
6. Check the wear parts (V) for signs of wear and/or hardening (in case
of sealing rings), replace parts as necessary.
Tip! For overhauling the pressure reducing valve M409, a set of wear
parts can be obtained from MAN B&W Diesel AG.
7. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the pressure reducing valve

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.
1. When installing new sealing rings, pay attention that they are not
twisted.
2. Prior to assembly, slightly oil all parts.

11 Cylindrical screw
12 Casing -- upper part
13 Casing -- lower part
14 Knurled screw

V Wear parts

Figure 1. Sectional view of the pressure reducing valve M409

6682 125.09--01 E 04.98 General 102/ 02

Compressed air filter
Checking, overhauling 125.10

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Control elements in the compressed air and control air system resp. are to
be checked and, if necessary, overhauled at regular intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Screw driver (set) -- Standard
1 Grease (acid--free) -- Inventory

Spare parts required

Quant Denomination No.

1 Compressed air filter 125.98.462
125.98
1 Filter insert 125.99.462
125.99

Compressed air filter M462

Operating sequence 1 -- Disassembly of the compressed air filter

Starting condition Compressed air and/or control air system without pressure. Filter cleaned
on the outside.

6682 125.10--01 E 04.98 General 101/ 02

Steps 1. Loosen the pipe connections (mark them, if necessary), remove fixing
bolts and filter.
2. Close open pipe ends by appropriate means to prevent penetration of
dirt.
3. First of all, drain the compressed air filter via the hexagon bolt (13).
4. Screw off the hexagon nut (11) and take off the clamp.
5. Disassemble the filter and thoroughly clean all individual parts.
6. Clean the filter insert (12) according to manufacturer’s specification
or, if necessary, replace it by a new one.
Tip! The filter insert for the compressed air filter M462 can be obtained
from MAN B&W Diesel AG.

Operating sequence 2 -- Assembly of the compressed air filter

For assembly, proceed in the reverse order followed for removal, paying
attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work, as even minute dirt particles may cause disturbances in the
valve and/or in the compressed air/control air system.

11 Hexagon nut
12 Filter insert
13 Hexagon bolt

Figure 1. Sectional view of the compressed air filter M462

6682 125.10--01 E 04.98 General 102/ 02

Limit switch
Checking, overhauling 125.12

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Electric/electronic control and/or switch elements are to be checked and, if

necessary, overhauled at regular intervals.
The work/steps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

Numb Qualification Time requ

1 Technical assistant 0.5

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Screw driver (set) -- Standard

Spare parts required

Quant Denomination No.

1 Limit switch 125.98.745
125.98
1 Set of wear parts 125.99.745
125.99

Limit switch M745

Operating sequence 1 -- Disassembly of the limit switch

Starting condition No voltage is applied to the limit switch.

Steps 1. Loosen the connecting cables (mark them, if necessary), remove

fixing bolts and switch.

6682 125.12--01 E 04.98 General 101/ 02

 2. Remove the roller lever(1), screw out the cylindrical screws (2) and
take off the push-button.
3. Screw out the cylindrical screws (3) and take off the cover (4).
4. Disassemble the limit switch further and thoroughly clean all
individual parts.
5. Before assembly, check all moving parts for smooth movement.

Operating sequence 2 -- Assembly of the limit switch

For assembly, proceed in the reverse order followed for disassembly,

paying attention to the following points:

Important! During assembly, ensure scrupulous cleanliness at the

place of work.

1 Roller lever
2 Cylindrical screw
3 Cylindrical screw
4 Cover

Figure 1. Illustration of the limit switch M745

6682 125.12--01 E 04.98 General 102/ 02

Pressure reducing station
Checking, overhauling 125.21

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 req.

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Screw drivers (set) -- Standard
1 Grease (acid--free) -- Inventory

Pressure reducing station M615

Preliminary remarks

Marine engine installations use the pressure reducing station M615 to

reduce the pressure of the air coming from the starting air vessel from 30
bar to 8 bar. The pressure reducing station is installed in the control
console, behing the lining. It has two filters and two reducing valves, and a
lever to change over from one brancch to the other (see the schematic).
As soon as such change-over has become necessary, the pressure
reducing station should be checked or overhauled at the next opportunity.
With due regard to the significance of control air supply, work on the
pressure reducing station should be carried out with utmost care; wear
parts have to be kept in stock and substituted in time.

6629 125.21--01 E 09.98 General 101/ 03

 1 Hexagon head bolt
2 Casing
3 Hexagon head bolt
4 Casing
5 Cylindrical bolt
6 Screw plug
7 Setting screw
8 Hexagon head bolt
9 Switching lever unit
10 Drain valve

Figure 1. M615 pressure reducing station -- sectional view/schematic

Operating sequence 1 -- Replace filter elements

Steps 1. Remove obstructing parts of the covering.

2. Depressurise the system, open the draining cocks in the system and
on the pressure reducing station 615 (item 10).
3. Remove the hexagon head bolt (3) on both sides, and replace the
wear parts (V), i.e. the filter element and sealing ring.

Operating sequence 2 -- Check/overhaul

Starting condition Before doing this job check thoroughly whether it is necessary.

Steps 1. Remove obstructing parts of the covering.

2. Depressurise the system, open the relieve and draining cocks.
3. Undo pipe connections (mark if advisable), take off the fixing bolts
and dismount the pressure reducing station.
4. Protect open pipe ends to prevent dirt from entering.
5. Remove the hexagon head bolt (3) on both sides, and replace the
wear parts (V), i.e. the filter element and sealing ring.
6. Loosen the hexagon head bolt (1), separate casings (2) and (4) and
disassemble the wear parts (V).
7. Unscrew 5 cylindrical bolts (5) and disassemble the wear parts (V).
8. Unscrew 2 screw plugs (6) and remove the wear parts (V).
9. Loosen 2 setting screws (7) and disassemble the wear parts (V).
10. Loosen 4 hexagon head bolts (8) and pull the switching lever unit (9)
out.
11. Screw out the drain valve (10).
12. Clean all the parts and blast them with compressed air.
13. Check the wear parts and replace them if necessary. Sealing rings
have to be replaced in each case.
14. Check al the moving parts for ease of movement prior to and after
assembly.

6629 125.21--01 E 09.98 General 102/ 03

 Re-assemble the unit in reverse order. After remounting the pressure
reducing station to the controls and connecting the pipes, check the
pressure reducing station for leaks and proper functioning. The pressure
gauge shows the pressure in both control-air paths.

Important! When doing work on components/fittings to which

compressed air is admitted, ensure meticulous cleanliness because even
microscopically small dirt particles may lead to serious malfunctions.

6629 125.21--01 E 09.98 General 103/ 03

Speed control

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

6682 140--02 E 07.99 101/ 01

Booster servomotor (2-- stage)
Maintaining and checking 140.02

Purpose of jobs to be done

Carrying out work in time according to the maintenance schedule,

avoiding operation problems/damage.

Brief description

The booster servomotor is to be maintained within specified intervals.

The work/steps include:
removal of components,
disassembly and assembly,
mounting of components.

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard

Related work cards

Work card Work card Work card

140.01

Preliminary remarks

Always drain oil from booster servomotor when changing the oil charge of
the Woodward governor.

Operating sequence 1 -- Removing and disassembling

Important! Before removing or reassembling, refer to Woodward

Booster Servomotor Manual.

Steps 1. Disconnect delivery and return pipes as well as compressed air pipe
(match-mark pipes and associated connecting fittings, if necessary)
and remove servo-motor.
2. Unscrew four nuts, take off cover and pour out the oil.
3. Take out compression spring and piston.
4. Clean all the component parts in fuel, check seal rings, replace if
necessary and check suction and delivery valves in cover for
tightness and free movement.

6619 140.02--01 E 04.98 General 101/ 02

 1 Oil inlet from governor
2 Oil outlet to speed
control system of
governor
3 Oil outlet to working
section of governor
4 Oil outlet to control
section of governor
5 Throttle valve for 4
6 Lift limiting screw for
auxilary piston
7 Lift limiting screw for
master piston
8 Air inlet
9 Cover

Figure 1. Booster servomotor

Operating sequence 2 -- Reassembling and mounting

Steps 1. To assemble the servo-motor, reverse the sequence of operations

outlined above and check to see that the piston and the valve balls
move freely. Check setting of lift limiting screw.
2. Mount servo-motor on engine and reconnect the two oil pipes to the
governor.
3. Reconnect pressure air pipe.
Important! Make sure that all pipes are reconnected in the same
position as when removed.
4. Fill governor with oil (if it has not already been done).
5. Start engine several times to cause air pocket to flow from the oil
space to the governor, and have servo-motor filled with oil.
6. Fill in oil until level lies at the lower mark on the sight glass an check
all connections for tightness.

6619 140.02--01 E 04.98 General 102/ 02

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
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings/Top land ring
050 Cylinder liner
055 Cylinder head
073 Crankcase cover
100 Camshaft drive
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/Rocker arm
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140 Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Drive of fuel injection pump
203 Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pump
322 Charge air cooler
434 Fuel injection pipe

6682 160...--06 E 07.99 101/ 01

Starting air pilot valve
Disassembling and assembling 160.01

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Starting air pilot valves are to be disassembled and overhauled at regular

intervals.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Tools/appliances required

Quant Denomination No. Availability

1 Open--jaw and ring spanner (set) -- Standard
1 Securing compound -- Inventory
(Loctite 243)

Operating sequence 1 -- Removing and disassembling

Important! A check is to be carried out for faultless operation

at the intervals specified in the maintenance schedule. When opening
the starting-air system, particular care must be given to the fact that no
dirt enters the valves and the pipes. Open pipe and tube ends are to be
closed off with plastic caps or adhesive tape. The pilot valve must only
be disassembled in a workplace which is absolutely clean. For cleaning
purposes, grease solvents and compressed air are to be used.
When reassembling, painstaking care must be exercised that the place of
work is absolutely clean. Dirt can cause trouble in the starting system.

Steps 1. Remove the compressed-air inlet pipe and the control pipe from the
valve casing.
2. Remove the complete pilot valve and disassemble it. Clean all parts
and blow through the control-air bores, check the sliding surfaces and
the seal ring seal (4) for wear. Replace if necessary.

6619 160.01--01 E 04.98 40/54, 58/64 101/ 03

 1 Valve casing
2 Spacer disk
3 Control piston
4 Seal ring set,
comprising: O-ring seal
and PTFE ring
5 Hexagon bolt
6 Pitot tube
7 Starting cam
A Gap dimension
B Dimension when new
2 á 0.6 mm

Figure 1. Assembling of starting air pilot valve

Operating sequence 2 -- Fitting the seal ring set (4) on control piston (3)

Steps 1. Lay the O-ring seal in the groove.

2. Lay the PTFE ring in water or oil and warm it up to 80-100ƒ C
3. Slide the PTFE ring over the edge of the groove and into the groove.
4. The PTFE ring has been enlarged in the process, now slide it
carefully over the oiled guide bevel of the casing and into the oiled
casing bore.

3 Control piston
4 Seal ring set,
comprising: O-ring seal
and PTFE ring

Figure 2. Control piston

6619 160.01--01 E 04.98 40/54, 58/64 102/ 03

Operating sequence 3 -- Assembling and installing

Check all the parts for cleanliness and reassamble and install them in the
reverse order to that given above. When doing so, particular attention is
to be paid to the following.

Steps 1. Check the ease of movement of the control piston (3).

2. Fit the hexagon bolt (5), using Loctite 243.
3. Check gap dimension (A) and, if necessary, correct it by changing
dimension (B) at spacer (2) (for Dimension A refer to Operating
Manual/Technical Data).
4. After having connected the pipes, check for leaks and for correct
functioning.

6619 160.01--01 E 04.98 40/54, 58/64 103/ 03

Starting valve
Checking, removing and installing 161.01

Purpose of jobs to be done

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

ensure/restore operational reliability.

Brief description

Starting valves are to be checked at regular intervals and overhauled if

necessary.
The work/steps include:
checking for leaks,
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 161.015 Standard
1 Tube nut 221.136--1 Standard
1 Support 221.136--6 Standard
1 Threaded spindle 221.136--15 Standard
1 Threaded piece 161.015--1 Standard
1 Cleaning device 055.121 Standard
1 Torque wrench 008.017 Standard
1 Shackle A1.6 002.454 Standard
1 Adapter 12.5x20 001.927 Standard
1 Extension piece 12.5x250 001.912 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 30x12.5 001.759 Standard
1 Tommy bar, 12 mm 000.264 Standard
1 Ring nut M24 000.192 Standard
1 Lifting eye bolt M12 000.142 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Lifting tackle with rope -- Inventory

6701 161.01--01 E 03.02 L 40/54 101/ 06

 Qty Designation No. Availability
1 Depth gauge -- Inventory
1 Grease (acid--free) -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Securing compound -- Inventory
(Loctite 243)

Related work cards

Work card Work card Work card

000.30 055.03

Technical details

Term Information
Bolt projection (A) 145 mm
Thrust flange 7.5 kg
Starting valve 5.5 kg

Preliminary remarks

▲ Attention! If the starting-air pipe gets hot during operation, the

engine should be shut down immediately, if possible, and the defec-
tive starting valve be replaced! Before working on the starting valve,
depressurize all air pipes. Close the shut-off valve on the com-
pressed-air tank.

Operating Sequence 1 -- Checking for leaks

Steps 1. Seal off the control-air pipe with a cap nut and a pipe plug ahead of
the distributor pipe to the starting-air pilot valves (after removing a
section of pipe).
Important! This prevents control air being admitted to any starting
valve.
2. Open the indicator valve on the cylinder head.
3. Turn the running gear until the piston is at ignition TDC (intake and
exhaust valves closed).
4. Inject air into the starting-air pipe. Leaky starting valves can be
detected by air emerging from the indicator valve.
Important! Repair leaky starting valves immediately, if possible,
since otherwise the valve seat will be damaged even more.

6701 161.01--01 E 03.02 L 40/54 102/ 06

 2 Valve head
3 Casing
4 O-ring seal
5 Piston
6 Hexagon nut (self-lock-
ing)
7 Hexagon nut
8 Stud bolt
9 Thrust flange
10 O-ring seal
11 Ring seal
12 Ring seal
13 Compression spring
14 Cylinder head

A Bolt projection

Figure 1. Starting valve in cylinder head

Operating Sequence 2 -- Removing the starting valve

Starting condition Cylinder head cover is open.

Steps 1. Loosen and unscrew two hexagon nuts (7).

2. Screw the ring screw (000.142) into the thrust flange (9), and remove
the latter.
3. Screw the threaded rod (161.015-1) all the way onto the valve head
(2).
4. Screw the threaded spindle (221.136-15) all the way onto the
threaded rod.
5. Mount the support (221.136-6) over the stub bolts (8), and screw the
tube nut (221.136-1) on – see Figure 2 .
6. Loosen the starting valve (1) by turning the tube nut, and lift it out
carefully.
7. Screw the “ring nut” [eye nut] (000.192) onto the threaded spindle,
fasten the rope to the tube nut with the shackle (002.454), and sling
it from the lifting tackle.
8. Remove the starting valve, and set it down on a work bench.
9. Dismantle the equipment.
10. Clean the starting-valve hole in the cylinder head with the cleaning
device (055.121).
Important! Watch that no objects fall into the combustion chamber.
11. Check the valve seat surface in the cylinder head, and reseat it if
necessary (see Work Card 055.03).
055.03
12. Cover the opening in the cylinder head.

6701 161.01--01 E 03.02 L 40/54 103/ 06

 1 Starting valve
8 Stud bolt
14 Cylinder head

Figure 2. Removing the starting valve

1 Starting valve
8 Stud bolt
14 Cylinder head

Figure 3. Removing the starting valve

6701 161.01--01 E 03.02 L 40/54 104/ 06

Operating Sequence 3 -- Installing the starting valve

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

Assembly and installation is done by analogy with removal, in the reverse
order. Note the following points in particular:
1. Insert new O-ring seals (4 and 10) greased with acid-free grease into
the ring grooves; make sure that they are tensioned uniformly over
the entire circumference, and are not twisted.
2. Install the starting valve (1) by means of the threaded rod (161.015-1)
and eye screw (000.142).
3. Coat the threads and bearing surfaces of the hexagon nuts (7) with
MoS2 lubricant, screw them on, and tighten them alternately with the
000.30).
specified torque (see Work Card 000.30
▲ Attention! If the starting valve is installed in a cylinder head that
is still warm from running, tighten the two hexagon nuts (7) only
hand-tight at first; only tighten with the specified torque after the
temperature has reached equilibrium!
If blind inserts are installed instead of the starting valves, tighten
them with the specified torque, too!
4. After installing the starting valve, check for leaks (see Operating
Sequence 19.
5. Close the cylinder head cover.

1 Starting valve
8 Stud bolt
14 Cylinder head

Figure 4. Installing the starting valve

Operating Sequence 4 -- Installing the stud bolts (8)

Starting condition Starting valve removed and cleaned, stud bolts unscrewed, and tapped
holes cleaned.

Steps 1. Prepare the starting valve (1) for installation.

2. Coat the engaging thread of the stud bolts (8) with Loctite 243, and
screw them in up to the specified projection (A).
3. Install the starting valve and thrust flange (9) (see Operating
Sequence 3).
4. Coat the threads and bearing surfaces of the hexagon nuts (7) with
MoS2 lubricant, screw them on, and tighten them alternately with the
000.30).
specified torque (see Work Card 000.30

6701 161.01--01 E 03.02 L 40/54 105/ 06

 ▲ Attention! Carry out Items 3 and 4 promptly. The hexagon nuts (7)
should be tightened with the specified torque before the Loctite 243
on the screwed-in stud bolts (8) has set (about 15 minutes)!

6701 161.01--01 E 03.02 L 40/54 106/ 06

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

Qty Designation No. Availability

1 Torque wrench 008.016 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 24x12,5L 001.768 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Side nippers -- Inventory
1 Grinding paste (silicone--free) -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory
1 Touching--test ink -- Inventory

Related work cards

Work card Work card Work card

000.30 161.01

Operating sequence 1 -- Disassembling the starting valve

Starting condition The starting valve has been removed.

Steps 1. Clamp the starting valve into the vice, at two faces of valve cone (10).
2. Unscrew hexagon nut (1), relieving the tension on the compression
spring (2).
3. Remove piston (14) from valve cone (10).
4. Take off casing (3) with compression spring (2).

6644 161.02--01 E 11.03 L 40/54, 48/60, 48/60 B 101/ 03

 5. Remove sealing rings (4 and 7) from piston (14).
6. Clean all individual parts and check them for wear and damage.
7. Check valve seat by means of an ink-contact “touching” test.
Grinding the valve seat If grinding is necessary, clamp the casing (3) carefully into the vice, taking
care not to damage any sealing faces. Coat the valve seat with grinding
paste. Install the valve cone (10) with piston (14) but without compression
spring and sealing rings (4 and 7) in the casing. Turn the valve cone to
and fro. Lift the valve cone occasionally so as to permit redistribution of
the grinding paste. After grinding, clean the valve cone, casing and piston
carefully.

▲ Attention! Remove as little material as possible and do not grind

longer than necessary to obtain a uniform, pale-grey ring face (check
by means of an ink-contact “touching” test)!

Operating sequence 2 -- Assembly of the starting valve

Starting condition All individual parts have been cleaned, checked and replaced if necessary.

Steps For assembly of the starting valve, proceed in the reverse order followed
for disassembly, paying attention to the following:

: Install new sealing rings (4 and 7) into the piston (14) - see operating
sequence 3.
: Coat the thread and the contact face of the hexagon nut (1) with MoS2
lubricant, screw the nut on and tighten it to the specified torque (see
000.30).
Work Card 000.30

Operating sequence 3 -- Fit the sealing rings (4 and 7)

Steps 1. Insert the O-ring seal (5 or 8) into the groove, taking care that it is
evenly tensioned over the entire circumference and not twisted.
2. Heat the PTFE ring (6 or 9) in oil to 80• - 100•C.
▲▲ Caution! Do not place the PTFE ring into the oil bath and/or
take it back out with your bare hand!
3. Pull the PTFE ring over the piston (14) and into the groove.
4. Restore the original shape of the expanded PTFE ring (6 or 9) by in-
serting the piston (14) into the oiled casing (3).

6644 161.02--01 E 11.03 L 40/54, 48/60, 48/60 B 102/ 03

 1 Hexagon nut
(self-locking)
2 Compression spring
3 Casing
4 Sealing ring
7 Sealing ring
10 Valve cone
14 Piston

Figure 1. Starting valve

4 Sealing ring
5 O-ring seal
6 PTFE ring
7 Sealing ring
8 O-ring seal
9 PTFE ring
14 Piston

Figure 2. Piston with sealing rings

6644 161.02--01 E 11.03 L 40/54, 48/60, 48/60 B 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/
Drive of fuel injection pump

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

6682 200...--06 E 07.99 101/ 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

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard

Related work cards

Work card Work card Work card

200.05 201.01 209.01

Preliminary remark

Wear in pump elements is primarily caused by abrasive or corrosive com-

ponents in the fuel. Even in unfavourable circumstances, proper pre--hea-
ting, separating and filtering, combined with regular maintenance and the
prompt replacement of wear parts (baffle screws), will help prolong service
life.

Sequence of operations -- checking

Starting condition Covers of the camshaft casing have been removed.

Steps 1. Check status (lubrication) of injection cam, drive roller and

cam--follower guide (see work cards 201.01 and 209.01).
209.01
2. Remove the collar studs (40) between the control rod (13) and
articulated head (38) and check that the control rod and control
sleeve (16) move slightly.

6701 200.01--01 E 05.02 L 40/54 101/ 04

 Tip! Control sleeves that have become stuck or glued up can be loose-
ned by applying some diesel fuel.
3. Replace the collar studs (40) and secure using a lock nut (39).
4. Shut off fuel inlet and outlet pipes (see Operating Instructions,
Volume B1).
5. Undo hexagon bolts (27) and remove plates (28).
6. Undo both baffle screws (25) and check for wear (see work
card 200.05),
200.05 replace if necessary.
7. Screw baffle screws (25) and new seals (26) finger tight into the fuel
injection pump.
8. Fasten plates (28) to fuel injection pump using hexagonal
screws (27), tighten screws. See Figure 2 .
9. Open fuel inlet and outlet pipes.
10. Check remaining fuel injection pumps in the same way (see items 1
to 9).
11. Check leakage fuel outlet of all fuel injection pumps at longer
intervals.
Important! If there is excessive leakage, remove the relevant
pump (9). If the seals (12) and the O--ring seal (23) are OK, the pump
must be replaced.

▲ Attention! A pump consists of pump pistons (11) and a mono-

block cylinder (10)! The pump pistons and monoblock cylinder have
to be replaced as a unit as they are manufactured as a unit! It is also
recommended to replace the seals (12) and O- ring seal (23) when a
new pump is fitted!

6701 200.01--01 E 05.02 L 40/54 102/ 04

 1 Hexagon bolt
2 Valve support
3 Spring pin
4 Hexagon bolt
5 Spacer
6 Compression spring
7 Valve cone
8 Housing
9 Pump
*10 Monoblock cylinder
11 Pump pistons
12 Sealing ring
13 Control rod
14 Cylinder bolt
15 O--ring seal
16 Control sleeve
17 Compression spring
18 Support plate
19 Spring plate
20 Snap ring
21 Stud bolt
22 Spring plate
23 O--ring seal
24 Hexagon nut
*25 Baffle screw
26 Sealing ring
27 Hexagon bolt
28 Plate
29 Cylinder pin
30 Sleeve
31 Spacer
32 Snap ring
33 Spring
34 Spring plate
35 Ball
36 O--ring seal
37 Rotary shaft seal
38 Articulated head
39 Lock nut
40 Collar studs
41 Countersunk screw
42 Shim
43 Pointer
44 Spring pin
45 Flange
46 Hexagon bolt

Figure 1. Fuel injection pump

* The shape of the baffle screws and the exhaust openings in the monoblock cylinder may differ from that shown in the figures.

6701 200.01--01 E 05.02 L 40/54 103/ 04

 8 Housing
*25 Baffle screw
27 Hexagon bolt
28 Plate

Figure 2. Fuel injection pump - View X (see Figure 1)

* The shape of the baffle screws and the exhaust openings in the monoblock cylinder may differ from that shown in the figures.

6701 200.01--01 E 05.02 L 40/54 104/ 04

Fuel injection pump
Shutting off 200.02

Purpose of jobs to be done

Ensure correct execution of work, enabling emergency operation,

reworking crankpin after slight damage.

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

Qty Designation No. Availability

1 Clamp 200.055 Standard
1 Hexagon screw drivers (set) -- Standard

Preliminary remark

In the event of problems with the injection system, the cylinder head, the
valve control or a disassembled running gear, the associated fuel injection
pump must be shut off to permit emergency operation (see Operating
Instructions, Volume B1).
When disconnected, the control rod of the relevant fuel injection pump will
be locked in the ”Zero Filling” position.

▲▲ Caution! The fuel supply to the fuel injection pump must not be
shut off (lubrication of pump piston)!

Filling for the remaining fuel injection pumps is enabled by bending the
buckling lever located on the fuel injection pump.

Sequence of operations -- shutting off a fuel injection pump

Starting condition Actions necessary to permit emergency operation performed (see

Operating Instructions, Volume B1).

Steps 1. With the engine stopped, check that the control rod (3) is in the ”Zero
Filling” position.
With the engine running, pull the control rod into the ”Zero Filling”
position against the force of the buckling lever spring and hold firmly.
2. Place two--part clamp (200.055) onto control rod (3) and loosely
screw in hexagon socket screws (2).

6701 200.02--01 E 05.02 L 40/54 101/ 02

 3. Push clamp as far as feed and tighten hexagon socket screws (2)
finger tight. See Figure 1 .

1 Fuel injection pump

2 Hexagon socket screw
M8x60
3 Control rod
4 Buckling lever

Figure 1. Fuel injection pump with blocked control rod

6701 200.02--01 E 05.02 L 40/54 102/ 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 consist of:
removal of components,
installation of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised
- Operating media systems drained

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 200.085 Standard
1 Support 200.085--1 Standard
1 Support 200.060 Standard
1 Torque wrench 008.017 Standard
2 Shackle A0.6 002.452 Standard
1 Extension piece 20x400 001.914 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 36x20 001.771 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Lifting tackle with rope -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory

6701 200.03--01 E 06.02 L 40/54 101/ 07

Related work cards

Work card Work card Work card

000.30 000.31 200.07
434.01

Technical details

Term Information
Fuel injection pump 90 kg

Operating sequence 1 -- Removal of the fuel injection pump

Steps 1. Turn the engine so that the roller of the fuel cam follower is positioned
on the base circle of the injection cam. Refer to Figure 2 .
2. Close all required shut-off valves (fuel pipe, air pipe, etc.).
3. Drain the operating media (oil, fuel, etc.) from the pipes.
4. Remove all attached pipes (air, leakage fuel etc.) from the fuel injec-
tion pump (2).
434.01.
5. Dismantle the fuel injection pipe (1) - see Work Card 434.01
6. Unscrew hexagon bolts (9 and 15), and dismantle the fuel supply
pipe (10) and return pipe (7).
7. Remove the collar pin (16), and separate the connection rod (6) from
the fuel injection pump (2).
▲ Attention! The connection rod is adjusted to the correct length
and locked by MAN B&W Diesel AG! It is recommended not to dis-
assemble the rod and/or to change the adjusted length!
8. In order to protect the control rod (5), push it all the way in (full-load
position).
9. Loosen and unscrew three hexagon nuts (3).
10. Fasten the support (200.060) to the fuel injection pump (2). Refer to
Figure 2 .
11. Attach the rope (19) to the support (200.085-1) by means of the
shackle (002.452), and suspend the rope from the lifting tackle.
12. Lift the support (200.085-1) and move it over the fuel injection pump
(2).
13. Fasten the support (200.085-1) to the support (200.060)/fuel injection
pump (2) by means of the shackle (002.452).
14. Remove the respective floor plate from the gallery.
15. Carefully pull the fuel injection pump (2) out/remove it. Refer to Fig-
ure 3 .
▲ Attention! When pulling out/removing the fuel injection pump,
make sure that the studs (4) are not damaged!
16. Take the fuel injection pump (2) away from the working place, and put
it down onto a clean wooden support. Refer to Figure 4 .
▲ Attention! Do not set the fuel injection pump down onto the con-
trol rod (5)!
17. Remove the tool from the fuel injection pump (2).
18. Cover the resultant opening on the fuel injection pump drive.
19. Remove the O-ring seal (14).
20. Clean the fuel injection pump (2) on the outside.

6701 200.03--01 E 06.02 L 40/54 102/ 07

Operating sequence 2 -- Installation of the fuel injection pump

Starting condition Fuel injection pump cleaned and checked, control rod all the way pushed
in as a precautionary measure of protection (full-load position). The roller
of the fuel cam follower is positioned on the base circle of the injection
cam. Floor plate removed from the gallery.

Steps 1. Clean the contact face on the fuel injection pump (2) and fuel injec-
tion pump drive.
2. Clean the contact faces on the fuel injection pump (2), fuel supply
pipe (10) and return pipe (7), as well as the flanges on the fuel pipes.
3. Fasten the support (200.060) to the fuel injection pump (2).
4. Attach the rope (19) to the support (200.085-1) by means of the
shackle (002.452), and suspend the rope from the lifting tackle.
5. Fasten the support (200.085-1) to the support (200.060)/fuel injection
pump (2) by means of shackle (002.452).
6. Carefully lift the fuel injection pump (2). Refer to Figure 4 .
7. Insert a new O-ring seal (14) that has been coated with clean lubri-
cating oil into the ring groove, taking care that it is evenly tensioned
over the entire circumference and not twisted.
8. Move the fuel injection pump (2) over the fuel injection pump drive.
Refer to Figure 3 .
9. Remove the cover from the fuel injection pump drive.
10. Slowly and carefully lower the fuel injection pump (2) into the bore.
Refer to Figure 2 .
▲ Attention! When installing/lowering the fuel injection pump, make
sure that the studs (4) are not damaged!
11. After the fuel injection pump (2) has been completely lowered into the
bore, remove the tool.
12. Fasten the floor plate to the gallery.
13. Insert new O-ring seals (8) that have been coated with clean lubricat-
ing oil into their grooves, making sure that the O-ring seals are not
twisted.
14. Put the fuel supply pipe (10) and return pipe (7) in place; screw the
hexagon bolts (9 and 15) in, hand-tight.
15. Coat the threads and seating surfaces of the hexagon nuts (3) with
MoS2 lubricant, and screw them on until they are seated.
16. Align the fuel injection pump (2), fuel supply pipe (10) and return pipe
(7).
17. Alternately tighten the hexagon nuts (3) in several stages, applying
000.30).
the specified torque (see Work Card 000.30
18. Tighten the hexagon bolts (9 and 15).
434.01.
19. Fit the fuel injection pipe (1) - see Work Card 434.01
20. Attach all pipes (air, leakage fuel, etc.), which have previously been
removed, to the fuel injection pump (2).
21. Open all stop cocks, which have previously been closed.
22. Connect the control rod (5) with the connection rod (6). Refer to Fig-
ure 1 .
▲ Attention! The connection rod is adjusted to the correct length
and locked by MAN B&W Diesel AG! It is recommended not to
change the adjusted length (unless a new fuel injection pump is
fitted)!

When attaching a new fuel injection pump to the control linkage, the fol-
lowing is to be observed:
23. Check the start and duration of delivery prior to taking the engine into
operation (see Work Card 200.07).
200.07 The values determined are to be
compared with those of the other fuel injection pumps fitted.

6701 200.03--01 E 06.02 L 40/54 103/ 07

 24. After taking the engine into operation, determine the firing pressure
by taking indicator diagrams and compare it with the firing pressure of
the neighbouring cylinders.

1 Fuel injection pipe

2 Fuel injection pump
3 Hexagon nut
4 Stud
5 Control rod
6 Connection rod
7 Fuel return pipe
8 O-ring seal
9 Hexagon bolt
10 Fuel supply pipe
11 Spring plate
12 Tappet (fuel injection
pump drive)
13 Cylinder crankcase
14 O-ring seal
15 Hexagon bolt
16 Collar pin
17 Lock nut
18 Flange (fuel injection
pump drive)

Figure 1. Fuel injection pump

6701 200.03--01 E 06.02 L 40/54 104/ 07

 2 Fuel injection pump
4 Stud
5 Control rod
6 Connection rod
13 Cylinder crankcase
19 Rope
20 Hexagon socket bolt
M10x25

Figure 2. Removal/installation of the fuel injection pump

6701 200.03--01 E 06.02 L 40/54 105/ 07

 Figure 3. Removal/installation of the fuel injection pump

6701 200.03--01 E 06.02 L 40/54 106/ 07

 Figure 4. Removal/installation of the fuel injection pump

6701 200.03--01 E 06.02 L 40/54 107/ 07

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,
assembly of components.

Tools/appliances required

Qty Designation No. Availability

1 Fitting/unfitting tool 200.054 Standard
1 Threaded spindle 200.054--1 Standard
1 Claw 200.054--2 Standard
1 Torque wrench 008.016 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 24x12.5 001.757 Standard
1 Eye bolt 001.404 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Screw drivers (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory
1 Special lubricant -- Inventory
(Molykote G Rapid, Molykote G--n)

Related work cards

Work card Work card Work card

000.30 000.32 200.03

6701 200.04--01 E 06.02 L 40/54 101/ 07

Operating sequence 1 -- Disassembly of the fuel injection pump

Starting condition Fuel injection pump removed and cleaned on the outside.

Steps 1. Unscrew hexagon bolt (1), take off the valve support (2) and put it
down onto a clean support.
2. Dismantle the distance sleeve (5), compression spring (6) and valve
cone (7) from the monoblock cylinder (10).
3. Remove the sleeve (30).
4. Insert the threaded spindle (200.054-1) into the bore hole on the cas-
ing (8), and fasten it in place by means of hexagon nut (51). Refer to
Figure 2 /A.
5. Slip the claw (200.054-2) over the threaded spindle, and place it on
the spring plate (19). Screw the hexagon nut (50) onto the threaded
spindle.
6. Screw the eye bolt (001.404) into the support cup (18).
7. By tightening the hexagon nut (50), compress the compression spring
(17) to such a degree that the pressure on the support cup (18) is
relieved. Refer to Figure 2 /B.
8. Remove the support cup (18) laterally. Refer to Figure 2 /C.
9. Slacken the hexagon nut (50), thus relieving the compression spring
(17). Refer to Figure 2 /D.
10. Remove the fitting/unfitting tool (200.054).
11. Take off the spring plate (19) and the compression spring (17).
12. Remove the snap ring (20), pull the spring plate (22) out.
13. Extract the regulating sleeve (16).
14. Pull the pump plunger (11) out, and put it down onto a clean support.
▲ Attention! Do not touch the pump plunger with bare hands!
Protect the control edges on the pump plunger from damage!
15. Unscrew the hexagon bolts (27), and remove the plates (28). Refer
to Figure 4 .
16. Unscrew both baffle screws (25).
17. Screw the hexagon bolts (4) out, and remove the monoblock cylinder
(10).
Tip! Use two hexagon bolts as forcing-off bolts.
18. Unscrew the hexagon bolts (46), and take the flange (45) off.
19. Dismantle the control rod (13).
20. Remove the O-ring seal (36)
21. Unscrew the countersunk bolt (41), and remove the pointer (43) in-
cluding the adjusting washer (42).
22. Remove the shaft seal (37).
23. Check the valve (31 to 35) in the valve support (2) for tightness and
movability, disassemble the valve if necessary.
24. Clean all the individual parts with clean Diesel oil and check them for
wear and damage.
Important! A pump element (9) consists of the monoblock cylinder
(10) and the pump plunger (11). Monoblock cylinder and pump plunger
may only be replaced as a unit, as they have been fitted together.

6701 200.04--01 E 06.02 L 40/54 102/ 07

 1 Hexagon bolt
2 Valve support
3 Spring pin
4 Hexagon bolt
5 Distance sleeve
6 Compression spring
7 Valve cone
8 Casing
9 Pump element
*10 Monoblock cylinder
11 Pump plunger
12 Sealing ring
13 Control rod
14 Cylindrical screw
16 Regulating sleeve
17 Compression spring
18 Support cup
19 Spring plate
20 Snap ring
22 Spring plate
23 O-ring seal
*25 Baffle screw
26 Sealing ring
27 Hexagon bolt
28 Plate
29 Parallel pin
30 Sleeve
31 Distance sleeve
32 Snap ring
33 Compression spring
34 Spring plate
35 Ball
36 O-ring seal
37 Shaft seal
41 Countersunk bolt
42 Adjusting washer
43 Pointer
44 Spring pin
45 Flange
46 Hexagon bolt

Figure 1. Fuel injection pump

* The shape of the baffle screws and the suction holes in the monoblock cylinder may differ from that shown in the diagrams.

6701 200.04--01 E 06.02 L 40/54 103/ 07

 11 Pump plunger 19 Spring plate A-D Steps
17 Combustion spring 50 Hexagon nut M20
18 Support cup 51 Hexagon nut M24

Figure 2. Untensioning/tensioning the compression spring in the fuel injection pump (removal/installation of the support cup)

6701 200.04--01 E 06.02 L 40/54 104/ 07

 2 Valve support
3 Spring pin
5 Distance sleeve
6 Compression spring
7 Valve cone
*10 Monoblock cylinder
31 Distance sleeve
32 Snap ring
33 Compression spring
34 Spring plate
35 Ball

Figure 3. Fuel injection pump - View W (refer to Figure 1)

* The shape of the baffle screws and the suction holes in the monoblock cylinder may differ
from that shown in the diagrams.

8 Casing
*25 Baffle screw
27 Hexagon bolt
28 Plate

Figure 4. Fuel injection pump - View X (refer to Figure 1)

* The shape of the baffle screws and the suction holes in the monoblock cylinder may differ
from that shown in the diagrams.

Operating sequence 2 -- Assembly of the fuel injection pump

Starting condition All individual parts cleaned and checked for damage, replaced if
necessary. Valve (31 to 35) in the valve support (2) has been assembled.
Refer to Figure 3 .

▲ Attention! Fuel injection pumps must be assembled with the

greatest of care, as they will only work properly and seal effectively
if their components are clean and not damaged! This particularly
applies to the monoblock cylinder and pump plunger!

Important! Prior to assembly, slightly oil all individual parts with light
lubricating oil.
Exception: : Metallic sealing and contact faces have to be absolutely dry
when assembled.
: In case a different lubricant is specified in the steps.

Steps 1. Insert a new O-ring seal (36) into the ring groove, making sure that it
is evenly tensioned over the entire circumference and not twisted.
2. Grease the control rod (13) with special lubricant.
3. Install the control rod (13) into the casing (8).
4. Put the flange (45) in place on the casing (8), making sure that the
spring pin (44) engages in the centring bore of the flange. Screw the
hexagon bolt (46) in and tighten it.
5. Slip the shaft seal (37) onto the control rod (13) and insert them into
the bore hole.

6701 200.04--01 E 06.02 L 40/54 105/ 07

 6. Using the countersunk bolt (41), fasten the pointer (43) including ad-
justing washers (42) to the casing (8).
7. Insert new sealing rings (12) that have been coated with clean lubri-
cating oil into the ring groove, making sure that they are evenly ten-
sioned over the entire circumference and not twisted.
8. Insert a new O-ring seal (23) that has been coated with clean lubri-
cating oil into the ring groove, making sure that it is evenly tensioned
over the entire circumference and not twisted.
9. Install the monoblock cylinder (10) into the casing (8), paying atten-
tion to the parallel pin (29).
▲ Attention! When installing the monoblock cylinder into the cas-
ing, make sure that it is not being tilted!
10. Coat the threads and seating faces of the hexagon bolts (4) with
MoS2 lubricant, screw the bolts in and tighten them crosswise to the
specified torque (see Work Card 000.30).
000.30
11. Screw the baffle screws (25) including sealing rings (26) into the cas-
ing (8), and tighten them.
12. Fasten the plates (28) to the casing (8) by means of hexagon bolts
(27); secure the hexagon bolts. Refer to Figure 4 .
13. Carefully push the pump plunger (11) into the monoblock cylinder
(10).
▲ Attention! Do not touch the pump plunger with the bare hand!
Take care that the control edges on the pump plunger are not dam-
aged during the installation process!
14. Install the regulating sleeve (16) so that the markings (M) on the con-
trol rod (13) and regulating sleeve coincide. Refer to Figure 5 .
15. Fit the spring plate (22) over the regulating sleeve (16) into the casing
(8).
Important! Prior to the installation of the spring plate, verify once
again that the markings of regulating sleeve and control rod coincide.
16. Slightly oil the snap ring (20), and install it.
17. Insert the threaded spindle (200.054-1) into the bore hole on the cas-
ing (8), and fasten it in place by means of the hexagon nut (51).
Refer to Figure 2 .
18. Put the compression spring (17) onto the spring plate (22).
19. Put the spring plate (19) onto the compression spring (17).
20. Slip the claw (200.054-2) over the threaded spindle and put it onto
the spring plate (19). Screw the hexagon nut (50) onto the threaded
spindle. Refer to Figure 2 /D.
21. By tightening the hexagon nut (50), compress the compression
spring/spring plate (17/19) far enough to permit installation of the
support cup (18). Refer to Figure 2 /C.
22. Screw the eye bolt (001.404) into the support cup (18).
23. Slip the support cup (18) laterally onto the pump plunger foot. Refer
to Figure 2 /B.
24. Slacken the hexagon nut (50).
▲ Attention! When slackening the hexagon nut, verify that the sup-
port cup is centred by the spring plate and is seated correctly! Refer
to Figure 2 /A.
25. Remove the fitting/unfitting tool (200.054); unscrew the eye bolt.
26. Slip the sleeve (30) onto the monoblock cylinder (11).
27. Slightly grease the distance sleeve (5) and valve cone (7) using clean
lubricating oil.
28. Install the valve cone (7), compression spring (6) and distance sleeve
(5) into the monoblock cylinder (10). Refer to Figure 3 .
29. Place the valve support (2) on the monoblock cylinder (10), making
sure that the spring pin (3) engages in the centring bore of the mono-
block cylinder. Refer to Figures 1 and 3 .

6701 200.04--01 E 06.02 L 40/54 106/ 07

 30. Coat the threads and seating faces of the hexagon bolts (1) with
MoS2 lubricant, screw the bolts in and tighten them crosswise in three
stages to the specified torque (see Work Card 000.30).
000.30

*10 Monoblock cylinder

13 Control rod
16 Regulating sleeve

M Marking
control rod-regulating
sleeve

Figure 5. Fuel injection pump -- View Z (refer to Figure 1)

* The shape of the baffle screws and the suction holes in the monoblock cylinder may devi-
ate from that shown in the diagrams.

6701 200.04--01 E 06.02 L 40/54 107/ 07

Fuel injection pump
Baffle screws
Checking and replacing 200.05

Purpose of jobs to be done

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

checking state/wear condition of components,
preventing operating problems/damage.

Brief description

Baffle screws latest have to be checked/replaced in time according to the

maintenance schedule.
The work/steps include:
removal of components,
checking of components,
installation of components.

Tools/appliances required

Qty Denomination No. Availability

1 Open--jaw and ring wrench (set) -- Standard
1 Hexagon screw driver (set) -- Standard
1 Pliers for locking wire -- Inventory

Preliminary remarks

Baffle screws are submitted to heavy stresses due to pressure changes of

the streaming fuel. They have to be considered as wear parts, which help
to avoid problems on higher-value parts. Smaller wear particles are
removed by the fuel stream. Greater particles can cause damages to the
pump element or the seating face of the injection valve.

Operating sequence 1 -- Removing buffle screws

Steps 1. Close fuel admission and return pipe (if possible).

2. Remove wire retentions (3) on baffle screws (refer to Figure 4 ).
3. Screw out front baffle screw (2). In doing so, collect draining off fuel
with suitable receptacle.
4. Screw out rear baffle screw (2).

6619 200.05--01 E 11.98 40/54, 48/60, 58/64 101/ 04

Operating sequence 2 -- Checking buffle screws for wear

Steps 1. Baffle screws have to be replaced if they are damaged on the funnel
external edges (refer to Figure 1 ).

Figure 1. Damaged nose-type baffle screw

2. Baffle screws have to be replaced if the funnel inner contour is
affected to a level that the damage reaches up to the funnel edge
(refer to Figure 2 ).

Figure 2. Damaged nose-type baffle screw

3. Baffle screws which have suffered only a slight material abrasion in
the funnel inner contour can be still used. They have to be rechecked
or replaced, however, at the latest after 500 operating hours or in
case that the operating values have changed (refer to Figure 3 ).
4. Check baffle screws with friction welded MV6 trunk-type construction
for fissures on the friction welded part and renew, if necessary.

6619 200.05--01 E 11.98 40/54, 48/60, 58/64 102/ 04

 Figure 3. Damaged nose-type baffle screw

Important! Engines type L58/64 should be checked after 1500

operating hours, but at the latest after 2000 operating hours.

1 Injection pump 3 Wire retention

2 Baffle screw (with hexagon socket or 4 Wear region
hexagon insert bit)

Figure 1. Details of the injection pump of engine type L58/64 with trunk baffle screws

6619 200.05--01 E 11.98 40/54, 48/60, 58/64 103/ 04

Operating sequence 3 -- Installing buffle screws

Steps 1. Clean sealing faces on injection pump (1).

2. Provide baffle screws with new copper sealing rings and screw in.
Important! When installing baffle screws with trunk-type
construction watch that they are not submitted to impacts or lateral
pressure (e.g. by depositing roughly).
3. Install new wire retention.
4. Open fuel admission and return pipe.

6619 200.05--01 E 11.98 40/54, 48/60, 58/64 104/ 04

Fuel injection pump
Measuring the plunger lift 200.06

Purpose of jobs to be done

Enable/support economic operation.

Brief description

Check the injection time within the scope of the IMO certification.
The work includes:
determining the plunger lift.

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 Measuring device 200.091 Standard
1 Support 200.091--1 Standard
1 Clamping piece 200.091--2 Standard
1 Clamping piece 200.091--3 Standard
1 Dial gauge 200.091--4 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Memo pad -- Inventory

Operating sequence - Measuring the plunger lift

Starting condition Cover of the camshaft casing removed.

Steps 1. Check whether the position of the eccentric shaft coincides with the
value stated in the acceptance test record, if necessary, adjust the
eccentric shaft to the corresponding value.
2. Check that clamping piece (200.091-3) is freely movable.
3. Put clamping piece (200.091-2) onto the injection cam follower (9) of
one cylinder and firmly clamp it to the injection cam follower by
tightening the hexagon bolts (7). Refer to Figure 1 .
▲ Attention! Make sure that the clamping piece rests on and against
the injection cam follower.
4. Attach support (200.091-1) to the camshaft covering (3). Refer to
Figure 1 .
5. Insert dial gauge (200.091-4) in the support and secure it by means
of the knurled screw (6).

6621 200.06--01 E 11.05 L 40/54 101/ 03

 6. Turn the running gear in the sense of rotation of the engine until the
cam base circle is reached. Set the dial gauge to “Zero”.
▲ Attention! Turn in the sense of rotation of the engine only in or-
der to compensate the clearances existing in the camshaft drive.
7. Using the turning device (electric motor), turn the running gear until
the piston is positioned shortly before ignition TDC.
8. Actuate the turning gear by means of the hand crank until the piston
is in ignition TDC position (marking on the flywheel).
▲ Attention! In case the ignition TDC is exceeded, repeat the tur-
ning process. Turn in the sense of rotation of the engine only!
9. Take a reading on the dial gauge and note down the value.
10. Remove the complete measuring device (200.091).
11. Determine the values for the remaining cylinders the same way and
noting them down.
12. Calculate the average value and compare with the average value of
the parent--engine given in the Technical File, Section 3 of the
IMO--certification.

1 Fuel injection pump

2 Fuel injection pump
drive
3 Camshaft covering
4 Stud
5 Hexagon nut
6 Knurled screw
7 Hexagon bolt M10x40
8 Washer
9 Injection cam follower
10 Camshaft

Figure 1. Injection cam follower with attached measuring device (illustration shows:attachment of the measuring device)

6621 200.06--01 E 11.05 L 40/54 102/ 03

 Figure 2. Injection cam follower with attached measuring device (illustration
shows::measuring device at greatest cam elevation)

6621 200.06--01 E 11.05 L 40/54 103/ 03

Control linkage

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

6682 203--02 E 07.99 101/ 01

Control linkage
Maintaining and checking 203.01

Purpose of jobs to be done

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

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

The control linkage must be checked and lubricated at regular intervals.

The work includes:
checking components.

Safety requirements

- Engine shut down

Tools/appliances required

Qty Designation No. Availability

1 Grease gun 003.005 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Lubricating grease, acid--free -- Inventory

Preliminary remark

The control rod was set up exactly when the engine was put into
operation and may only need to be adjusted when individual parts
are replaced and when a new fuel injection pump is fitted!

When the control rod is in the ”Zero Position”, the control rods of all
fuel injection pumps must be in the ”Zero Filling” position,
otherwise it may not be possible to turn off the engine as some fuel
injection pumps will still be pumping fuel!

Sequence of operations -- maintenance and checking

Steps 1. Check the complete control rod for wear.

2. Check that the control rod is set correctly.
3. Check that the control rod joints are light.
4. Check that the hexagon bolts and nuts are secure.
5. Check that the buckling lever (4) moves easily.
6. Apply lubricating grease to all articulated heads on the control rod
and connection rods.

6644 203.01--02 E 01.02 L 48/60 101/ 02

 1 Fuel injection pump
2 Control rod
3 Connection rod
4 Buckling lever
5 Control shaft
6 Bearing block

Figure 1. Control linkage

6644 203.01--02 E 01.02 L 48/60 102/ 02

Camshaft

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

6682 209--03 E 07.99 101/ 01

Camshaft
Checking 209.01

Purpose of jobs to be done

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

check state/wear condition of the components.

Brief description

The running surfaces and bearing points of cams are to be checked at

regular intervals.
The work includes:
checking components.

Safety requirements

- Engine shut down

- Engine secured against starting

Tools/appliances required

Qty Designation No. Availability

1 Oil stone -- Inventory

Related work cards

Work card Work card Work card

102.01

Preliminary remarks

▲ Attention! The settings of the inlet and exhaust cams were ad-
justed at MAN B&W Diesel AG and must not be altered (distance
between the inlet/outlet valves and the pistons)!
The setting of the injection cams was also determined at MAN B&W
Diesel AG. Alteration of the injection-cam setting should only be
done in exceptional cases, and by trained personnel!

Important! The replacement of cams or the camshaft is to be car-

ried out by a Service Center with the special tools available there.

6701 209.01--01 E 03.02 L 40/54 101/ 02

Sequence of operations -- Check

Steps 1. Take the cover off the camshaft casing.

2. Check the running surfaces of the exhaust cam (5), injection cam (4)
and inlet cam (2) for damage.
Important! Rotate the running gear by means of the turning gear,
and check the entire circumference of the individual cams.
Smooth minor roughness with an oil stone.
3. Check the camshaft bearing bolts (3) and the hexagon bolts (1) for
correct tightening and firm seat (see Work Card 102.01).
102.01
4. Check whether all the bearings are receiving a sufficient quantity of
oil.
5. Attach the cover of the camshaft casing.
6. Check the remaining cams in the same way (Items 1 to 5).

1 Hexagon bolt
2 Inlet cam
3 Camshaft bearing bolt
4 Injection cam
5 Exhaust cam

Figure 1. Camshaft with cams (Illustration shows engine with eccentric shaft for fuel injection timing.)

6701 209.01--01 E 03.02 L 40/54 102/ 02

Fuel injection valve

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

6682 221--06 E 07.99 101/ 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

- Engine secured against starting
- Operating media systems closed/depressurised
- Operating media systems drained

Tools/appliances required

Qty Designation No. Availability

1 Pin spanner 434.026 Standard
1 Removing tool 221.136 Standard
1 Tube nut 221.136--1 Standard
1 Sleeve 221.136--6 Standard
1 Threaded spindle 221.136--15 Standard
1 Threaded piece 221.136--23 Standard
1 Cleaning device 055.121 Standard
1 Claw spanner 009.070 Standard
1 Torque wrench 008.017 Standard
1 Shackle A1.0 002.453 Standard
1 Adapter 12.5x20 001.927 Standard
2 Extension piece 20x200 001.913 Standard
1 Cross handle 001.891 Standard
1 Socket wrench insert 30x12.5 001.759 Standard
1 Ring nut M24 000.192 Standard
1 Open--jaw and ring wrenches (set) -- Standard

6701 221.01--01 E 08.02 L 40/54 101/ 08

 Qty Designation No. Availability
1 Wire brush -- Inventory
1 Lifting tackle with rope -- Inventory
1 Depth gauge -- Inventory
1 Wooden spatula -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Securing compound -- Inventory
(Loctite 243)
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

000.19 000.30 221.05
434.01

Technical details

Term Information
Fuel injection valve 12 kg
Bolt projection (B) 145 mm

Operating sequence 1 -- Removal of the fuel injection valve

Important! An engine, which usually runs on heavy fuel oil, is to be

operated on Diesel oil for a short period before the fuel injection valves are
removed.

Starting condition The cooling water for cooling the fuel injection valve has been completely
drained. The shut-off valves on the fuel pipes have been closed. Cylinder
head cover and indicator valve have been opened.

▲▲ Caution! Do not remove the fuel injection valves until the en-
gine has come to a complete stop and the indicator valve is open!
The combustion chamber can be under high pressure when the indi-
cator valve is closed!

Steps 1. Unscrew the pipes for cooling water supply from the cylinder head
(4); drain the cooling bores of the fuel injection valve (7) by purging
them with compressed air.
434.01).
2. Remove the fuel injection pipe (see Work Card 434.01
3. Loosen the threaded piece (5), screw it off and remove it from the
cylinder head (4). Refer to Figure 2 .
4. Loosen and unscrew the hexagon nuts (1).
5. Screw the extractor (221.128) into the thrust flange (3) and remove
the latter. Refer to Figure 3 .
6. Screw the threaded spindle (221.136-15) on until it rests on the fuel
injection valve (7). Refer to Figure 4 /I.
7. Put the sleeve (221.136-6) over the studs (2) and onto the bush (11).
Refer to Figure 4 /i.

6701 221.01--01 E 08.02 L 40/54 102/ 08

 8. Screw the tube nut (221.136-1) onto the threaded spindle until it con-
tacts the deep groove thrust ball bearing (14). Refer to Figure 4 /I.
9. Extract the fuel injection valve (7) by turning the tube nut. Refer to
Figure 4 /II.
Important! The fuel injection valve may only be removed using the
fitting/unfitting tool (221.136).
10. Screw the ring nut (000.192) onto the threaded spindle. Refer to Fig-
ure 4 /II.
11. Attach the rope to the ring nut by means of the shackle (002.453),
and suspend the rope from the lifting tackle.
12. Carefully pull the fuel injection valve (7) out of the cylinder head (4),
and put it down onto a clean support.
▲ Attention! During removal, make sure that the sealing ring (6) is
also removed!
13. Cover the opening on the cylinder head (4).
14. Dismantle the fitting/unfitting tool (221.136).
15. Remove off the sealing ring (6).
16. Clean the complete fuel injection valve on the outside.
Important! Clean the fuel injection valve away from the workbench.
17. Remove adherent coke deposits by means of the wire brush. Clean
the cylindrical shoulder of the nozzle body particularly carefully.
▲ Attention! Only use a wooden spatula to scrape the fuel injection
nozzle clean to avoid damaging the nozzle orifices!

Operating sequence 2 -- Installation of the fuel injection valve

Starting condition Fuel injection valve, particularly the cylindrical shoulder of the nozzle body,
has been carefully cleaned. Spray pressure, tightnes and nozzle orifices
have been checked.

Important! Clean any fuel injection valve from the spare parts stock
or from a replacement delivery on the outside, and check it.

Steps 1. Fit a new sealing ring (6) on the fuel injection valve (7).
Important! Make sure that the sealing ring fits tightly on the nozzle
body.
2. Insert new O-ring seals (8) that have been coated with clean lubricat-
ing oil into the ring grooves. See to it that that they are evenly ten-
sioned over the entire circumference and not twisted.
3. Place the thrust flange (3) on the fuel injection valve (7), making sure
that the spring pin (10) engages in the centring bore of the thrust
flange. Refer to Figures 1 and 5 .
4. Slip the threaded piece (221.136-23) through the thrust flange (3),
and screw it onto the fuel injection valve (7), thus joining thrust flange
and fuel injection valve together. Refer to Figure 5 .
5. Attach the rope to the lifting eye bolt (12) by means of the shackle
(002.453), and suspend the rope from the lifting tackle. Lift the fuel
injection valve (7).
6. With the fuel injection valve (7) hanging vertically, fill the inside
(spring chamber) by pouring some clean fuel oil through the bore hole
for the threaded piece (5).
Important! This is essential as a way of damping the compression
spring during commissioning.
7. Remove the cover from the opening in the cylinder head (4).

6701 221.01--01 E 08.02 L 40/54 103/ 08

 8. Thoroughly clean the insert (13) and the valve seat (A) in the cylinder
head using the cleaning device (055.121). Refer to Figures 1
and 6 .
▲ Attention! During cleaning, take care that no foreign matter falls
into the combustion chamber!
9. Carefully install the fuel injection valve (7) into the cylinder head (4).
▲ Attention! Make sure that the bore hole for the threaded piece is
aligned correctly during the installation process!
Press the fuel injection valve in until it is seated.
10. Remove the tool.
11. Coat the thread of the threaded piece (5) with MoS2 lubricant, screw
the threaded piece into the fuel injection valve (7), and tighten it to
the specified torque (see Work Card 000.30).
000.30
434.01).
12. Fit the fuel injection pipe (see Work Card 434.01
13. Coat the threads and seating faces of the hexagon nuts (1) with
MoS2 lubricant, screw the nuts onto the studs (2), and tighten them to
000.30).
the specified torque (see Work Card 000.30
▲ Attention! If the fuel injection valve is installed in a cylinder head
that is still hot (operating temperature), the hexagon nuts should
initially only be screwed down hand-tight and only tightened to the
specified torque when the cylinder head has cooled down!
14. Close the indicator valve.
15. Fill the fuel-injection-valve cooling system with cooling water.
16. Open the shut-off valves on the fuel pipes.
17. Close the cylinder head cover.

Operating sequence 3 -- Installation of the studs (2)

Starting condition Fuel injection valve dismantled and cleaned, studs removed, and tap holes
cleaned.

Steps 1. Prepare the fuel injection valve (7) for installation.

2. Coat the screw-in threads of the studs (2) with Loctite 243 securing
compound and screw them in until the bolt projection (B) is as seci-
fied. Refer to Figures 1 and 5 .
3. Install the fuel injection valve (see operating sequence 2).
4. Coat the threads and seating faces of the hexagon nuts (1) with
MoS2 lubricant, screw the nuts onto the studs (2) and tighten them to
000.30).
the specified torque (see Work Card 000.30
▲ Attention! Carry out the steps 3 and 4 promptly! The hexagon
nuts should be tightened to the specified torque before the Loc-
tite 243 sealing compound applied to the screwed in studs has fully
hardened (takes about 15 mins.)!

6701 221.01--01 E 08.02 L 40/54 104/ 08

 1 Hexagon nut 6 Sealing ring A Valve seat
2 Stud 7 Fuel injection valve B Bolt projection
3 Thrust flange 8 O-ring seal
4 Cylinder head 9 Spring pin
5 Threaded piece 10 O-ring seal

Figure 1. Fuel injection valve and threaded piece

6701 221.01--01 E 08.02 L 40/54 105/ 08

 4 Cylinder head 7 Fuel injection valve
5 Threaded piece

Figure 2. Removal/installation of the threaded piece

2 Stud
3 Thrust flange
10 O-ring seal

Figure 3. Removal of the threaded piece and fuel injection valve

6701 221.01--01 E 08.02 L 40/54 106/ 08

 2 Stud
4 Cylinder head
7 Fuel injection valve
11 Bush
14 Deep-groove thrust
ball bearing

I-II Steps

Figure 4. Removal of the fuel injection valve

6701 221.01--01 E 08.02 L 40/54 107/ 08

 2 Stud
3 Thrust flange
4 Cylinder head
7 Fuel injection valve
9 Spring pin
10 O-ring seal
12 Lifting eye bolt M16

B Bolt projection

Figure 5. Installation of the fuel injection valve

4 Fuel injection valve

13 Insert

Figure 6. Cleaning the insert and the valve seat in the cylinder head

6701 221.01--01 E 08.02 L 40/54 108/ 08

Fuel injection valve
Checking 221.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work includes:
checking components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 2

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Connecting piece 221.197--26 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Connecting piece 221.196--26 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Connecting piece 221.195--26 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Connecting piece 221.200--24 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Connecting piece 221.201--23 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Connecting piece 221.202--22 Standard
1 Compressed air max. 15 bar -- Inventory

6629 221.02--03 E 10.02 32/40 upw 101/ 06

 Qty Designation No. Availability
1 Anti--corrosion oil -- Inventory
1 Receptacle for anti--corrosion oil -- Inventory
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard

Related work cards

Work card Work card Work card

221.03 221.04

Remark: The tool numbers of the individual pressure tester components consist of
the tool number of the pressure tester and the item number of the individ-
ual component. Refer to Figures 1 and 2 .
Example: Tool number of the high-pressure hose for engine type
L 58/64: 221.202-6.

Preliminary remarks

The functioning and setting of the injection valve influence the combustion
process, the operating data and the loading of the injection system. In
case the operating data (firing pressure, exhaust gas temperature)
change, the opening pressure and tightness of the valves concerned are
to be checked. The pressure tester permits pressure testing by means of
a hydro-pneumatic high-pressure pump. The device ensures that the work
can be carried out comfortably and under reproducible conditions.

Note

When testing injection valves of modern four-stroke engines, atomisation

no longer is a test criterion, as the nozzle’s behaviour during engine oper-
ation cannot be duplicated by means of the pressure tester.
A poor injection pattern does not permit to draw conclusions on the
nozzle’s performance in the engine. It is fully operational, provided that
the criteria with regard to opening pressure, tightness and unclogged
nozzle bores are fulfilled.

6629 221.02--03 E 10.02 32/40 upw 102/ 06

Structure and diagram of the pressure tester

1 Pressure gauge 0-600 bar 6 High-pressure hose 14 Nozzle-jet collector

2 Air cock 10 Hydraulic pump 15 Collector cover
3 Filter pressure regulator 11 Pressure control valve 16 Fixing head
4 Pneumatic coupling 12 Oil tank
5 Pressure relief valve 13 Oil collecting pan

Figure 1. Pressure tester

Legend: as for Figure 1

9,22,23,24,26
Connecting piece

Figure 2. Pressure tester diagram

6629 221.02--03 E 10.02 32/40 upw 103/ 06

Operating sequence 1 -- Preparation of check

Important! Heavy fuel oil residues in injection valves may adversely

affect the test results and impede cleaning. We therefore recommend op-
erating the engine on Diesel oil for approx. one hour prior to dismantling
injection valves. If this is not possible and the engine has to be shut down
from operation on heavy fuel oil, the injection valve has to be disas-
sembled and cleaned before the checks described here can be carried
out.

Starting condition The injection valve has been removed and cleaned on the outside.

Important! Anti-corrosion oil is to be used for testing the injection

valves because this oil serves as a preservation agent at the same time.
Only absolutely clean anti-corrosion oil may be filled into the pressure
tester; otherwise, disturbances may occur in the pump or in the injection
valve to be tested. The content level in the oil tank (12) is to be checked.

Steps 1. Depending on the engine type, insert the correct reducing jaws into
the fixing head (16) - for the 58/64 engine type, reducing jaws are not
required. Insert the injection valve into the fixing head and clamp it
evenly using the retainer.
2. Depending on the engine type, screw the suitable connecting piece
(9, 22, 23, 24, 26) in at the delivery pipe connection of the injection
nozzle, and screw the high-pressure hose (6) onto the connecting
piece.
3. Place the nozzle-jet collector (13-15) under the injection nozzle and
push it upward so as to ensure that the jets to be expected hit the
outer walls of the nozzle-jet collector.
▲ Attention! Never let the injection nozzle spray into the open, but
always directly into the collector! Fuel jets must not be touched, as
they pierce the skin tissue and cause painful infections! Naked
flames are not allowed in the working area! No smoking at all! If
possible, remove the oil vapour by suction!
Checking and adjusting the injection valves includes the following steps:
- Check the opening pressure,
- check the nozzle bores,
- adjust the specified pressure,
- check for tightness.

Operating sequence 2 -- Check the opening pressure

Steps 1. Turn the knob on the filter pressure regulator (3) all the way to the left
(Minus -), and set the air cock (2) to “Ein” (On).
2. Close the pressure relief valve (5).
3. By turning the knob on the filter pressure regulator (3) to the right
(Plus +), start the hydraulic pump (10) and slowly increase the pres-
sure until the injection valve opens. Note down the opening pressure
and compare it with the specified value (for specified value, refer to
the Operating Instructions, sheet 2.5.2). Keep the pressure tester
running for at least 20 seconds, thus flushing the injection valve.
Important! The hydraulic pressure has to be increased slowly until
the opening pressure is reached, as otherwise faults will occur when read-
ing off the opening pressure. The test pressure must not exceed 400 bar!
When the injection test is carried out for the first time on new nozzle el-
ements, the nozzle needle may be stuck due to preservation and has to be

6629 221.02--03 E 10.02 32/40 upw 104/ 06

 loosened by flushing it thoroughly. In the case of injection nozzles that
have already been used, collect the anti-corrosion oil contaminated with
fuel, and do not fill it back into the pressure tester.

With new nozzles, a drop in opening pressure by 50-90 bar may already
occur after a few operating hours.
This pressure drop does not represent a malfunction and is typical of all
fuel injection valves.

Decision Decrease in opening pressure less than/more than 90 bar?

Decrease in opening pressure less Continue with the next step.

than 90 bar -
Decrease in opening pressure more Disassemble the injection valve
than 90 bar - 221.03).
(according to work card 221.03
Carry out a visual inspection
(spring broken)
If components are in good order,
continue with the next step.

Operating sequence 3 -- Check the nozzle bores

Steps 1. Turn the filter pressure regulator all the way to the left (Minus - ),
open the pressure relief valve (5), and continue as follows (for item-
221.03):
related details, refer to work card 221.03
2. Loosen the hexagon nut (44), and turn back the setting screw (45)
until the tension of the compression spring (49) has been released.
3. Close the pressure relief valve. Start the hydraulic pump by means of
the knob on the filter pressure regulator, and adjust the opening pres-
sure to 30 bar by turning the setting screw (45).
Decision Are all nozzle bores open? Refer to Figure 3 .

Yes - continue with the next step.

No - disassemble the injection valve (according to work card
221.03).
221.03

Figure 3. Judging the nozzle bores. On the left - open, on the right - partly
clogged

Operating sequence 4 -- Adjust the opening pressure to the specified value

Steps 1. Increase the hydraulic pressure by means of the knob on the filter
pressure regulator (3). At the same time, slightly tension the com-
pression spring (49) using the setting screw (45). Repeat the pro-
cess until the specified value (tolerance 20 bar) has been reached
(for specified value, refer to the Operating Instructions, sheet 2.5.2).
Important! Do not adjust a higher pressure than specified as, other-
wise, deformation of the compression spring will result. Only after installa-

6629 221.02--03 E 10.02 32/40 upw 105/ 06

 tion of a new compression spring, adjust the injection pressure to the
specified higher value at first in order to compensate an initial settling of
the compression spring.
2. If the specified value has been adjusted reproducibly, lock the setting
screw (45) by means of the hexagon nut (44), and check the opening
pressure once again.

Operating sequence 5 -- Check the tightness

Steps 1. For checking the tightness, adjust the pressure to 250 bar by means
of the knob on the filter pressure regulator (3), and keep it at this
value. The injection nozzle can be considered tight if no drop falls
within a period of 5 seconds.
Decision Tightness ok? Refer to Figure 4 .

Yes - the injection valve can be used!

No - the injection valve is to be sent to MAN B&W Diesel AG
Augsburg for regeneration.

Figure 4. Judging the tightness. On the left - tight, on the right - dripping

6629 221.02--03 E 10.02 32/40 upw 106/ 06

Fuel injection valve
Disassembling 221.03

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work/steps include:
disassembly of components,
checking of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Socket wrench 221.143 Standard
1 Torque wrench 008.017 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Socket wrench 221.194 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Socket wrench 221.040 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Socket wrench 221.127 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Socket wrench 221.119 Standard

6629 221.03--03 E 10.02 32/40 upw 101/ 06

 Qty Designation No. Availability
1 Torque wrench 008.005 Standard
1 Eye bolt 001.412 Standard
1 Chuck 002.701 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Wire brush -- Inventory
1 Wooden spatula -- Inventory
1 Cleaning wires (set) -- Inventory
1 Depth gauge -- Inventory
1 Tank with fuel -- Inventory
1 Cleaning material (wool) -- Inventory
1 Paper towels -- Inventory
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Securing compound -- Inventory
(Loctite 243)

Related work cards

Work card Work card Work card

000.30 221.02 221.04

Preliminary remarks

Important! Injection valves are to be disassembled if the checks

according to work card 221.02 revealed defects and in case the nozzle
element is to be replaced due to the operating time reached.
Disassembly is carried out in the pressure tester.

Operating sequence 1 -- Disassembly of a fuel injection valve

Steps 1. Rinse the injection valve in fuel, and remove coke deposits sticking to
it by means of a wire brush.
2. Swing the collecting tank (13-15) to the side, and insert suitable re-
ducing jaws into the fixing head (16) of the clamping device (for the
58/64 engine type, reducing jaws are not required).
3. Insert the injection valve into the fixing head, with the injection nozzle
facing downward, and clamp it in place evenly.
4. Loosen the hexagon nut (44), and back off the setting screw (45) until
the tension on the compression spring (49) has been released.
5. Unscrew the hexagon bolts (60) from the fixing head (16). Turn the
fixing head with the injection valve by 180•, and screw the hexagon
bolts back in.
6. Carefully loosen the nozzle tensioning nut (52).

6629 221.03--03 E 10.02 32/40 upw 102/ 06

 Important! If a strong resistance is felt while loosening the nut, it
has to be tried to restore easy movement of the thread by soaking in fuel
oil and by turning the nut back and forth until it can be moved easily. Do
not exert force when loosening the nozzle tensioning nut, as otherwise the
thread may seize and the parts become unusable.

6 High-pressure hose
13-15 Collecting tank
16 Fixing head
60 Hexagon bolt

Figure 1. Pressure tester

7. Unscrew the nozzle tensioning nut and take the nozzle body off.
Take care that the nozzle needle (43) does not fall out.
8. Pull the nozzle needle (43) out of the nozzle body, and immerse it in
fuel for cleaning.
Important! Do not interchange the nozzle needles of the individual
nozzle bodies. They are produced in paires.
9. Unscrew the hexagon bolts (60) from the fixing head (16). Turn the
fixing head with the injection valve back by 180•, and screw the hexa-
gon bolts back in.
10. Remove the injection valve from the fixing head of the pressure
tester, and put it down onto the work bench.
11. Unscrew the setting screw.
12. In case the inner parts are not loose, screw the eye bolt (001.412)
into the thrust pad (48), and pull the thrust pad out. Afterwards, re-
move the compression spring and spring plate (50).
Important! In the case of the 32/40 engine, the set screw (47) has
to be removed for this purpose. On the valves of the larger engines, this
is not required.
13. Immerse all parts in Diesel oil for cleaning, and wash them off, then
blow them by means of compressed air.

6629 221.03--03 E 10.02 32/40 upw 103/ 06

 42 Nozzle body
43 Nozzle needle
44 Hexagon nut
45 Setting screw
46 Holder
47 Set screw
48 Thrust pad
49 Compression spring
50 Spring plate
51 Parallel pin
52 Nozzle tensioning nut

Figure 2. Injection valve (figure shows injection valve of the 32/40 engine type)

Operating sequence 2 -- Check the components

The component check includes the following:

- the nozzle bores,
- the condition of the fitting area,
- the movability of the needle,
- traces of corrosion on the nozzle tensioning nut and on the nozzle
body,
- the nozzle specification.
Tip! Pay particular attention to such sources of error that caused un-
satisfactory results when the injection valve was checked.

6629 221.03--03 E 10.02 32/40 upw 104/ 06

Steps 1. Distinguishing characteristics of nitride-hardened nozzle elements
and seat-insert nozzle elements (refer to Figure 3 ).

Figure 3. Distinguishing characteristic:

On the left - nitride-hardened nozzle element, on the right - seat-insert nozzle el-
ement
2. For nozzle-bore cleaning, clamp a suitable cleaning wire into the
chuck (002.701) and run it through the nozzle bores (refer to Fig-
ure 4 ).

41 Cleaning wire
42 Nozzle body

Figure 4. Cleaning the nozzle bores

3. Inspect all components, especially the sealing faces, for damage/
traces of wear.
Important! The seats and fitting areas must neither be reworked by
hand nor remachined, as the required accuracy cannot be achieved.
4. Check to see if the nozzle needle can be easily moved in the nozzle
body, without noticeable resistance (refer to Figure 5 ).

42 Nozzle body
43 Nozzle needle

Figure 5. Checking the nozzle needle for movability

6629 221.03--03 E 10.02 32/40 upw 105/ 06

 5. Inspect the nozzle body for traces of corrosion. These may be max.
2.5 mm deep. Check the nozzle cooling water outlet temperature; if
necessary, increase it to max. 90ƒ C.
6. Read the nozzle specification off at the collar of the nozzle body, and
compare it with the required specification (refer to Figure 6 ).
For the original specification, please refer to the engine’s acceptance
records.

Figure 6. Nozzle element. On the left - nozzle specification, on the right - regener-
ation marking.
7. Replace damaged parts. Always replace nozzle needle and nozzle
body together. If necessary, have them regenerated by MAN B&W
Diesel AG, Augsburg or Hamburg. Other workshops are not autho-
rised to do this job.
Important! Regenerated nozzle elements are marked by RA or RH
and the date of regeneration. Repeated regeneration is only possible in
the case of seat-insert nozzle elements.

6629 221.03--03 E 10.02 32/40 upw 106/ 06

Fuel injection valve
Assembling 221.04

Purpose of jobs to be done

Impart required knowledge,

ensure correct execution of work.

Brief description

Fuel injection valves affect the loads on the injection system and the
operating values of the engine. They must be checked in case of
deviation from the operational values and overhauled or replaced, if
necessary.
The work includes:
reassembling components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.5

Tools/appliances required

Qty Designation No. Availability

1 Nozzle test bed L,V32/40 221.197 Standard
1 Reducing jaw for injection valve (set) 221.197--21 Standard
1 Socket wrench 221.143 Standard
1 Torque wrench 008.017 Standard
1 Nozzle test bed L,V32/40 DF 221.196 Standard
1 Reducing jaw for injection valve (set) 221.196--21 Standard
1 Nozzle test bed L,V32/40 CR 221.195 Standard
1 Reducing jaw for injection valve (set) 221.195--21 Standard
1 Socket wrench 221.194 Standard
1 Nozzle test bed L40/54 221.200 Standard
1 Reducing jaw for injection valve (set) 221.200--19 Standard
1 Socket wrench 221.040 Standard
1 Nozzle test bed L,V48/60 221.201 Standard
1 Reducing jaw for injection valve (set) 221.201--18 Standard
1 Socket wrench 221.127 Standard
1 Nozzle test bed L58/64 221.202 Standard
1 Socket wrench 221.119 Standard
1 Torque wrench 008.005 Standard

6629 221.04--02 E 01.05 32/40 upw 101/ 04

 Qty Designation No. Availability
1 Eye bolt 001.412 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Lubricant (Optimol ”Paste White T”) -- Inventory
1 Securing compound Loctite 243 -- Inventory

Related work cards

Work card Work card Work card

000.30 221.02 221.03

Operating sequence 1 -- Assembly of a fuel injection valve

Important! Prior to assembly, check whether the specification of the

injection nozzle coincides with the required specification. The original
specification can be gathered from the acceptance record (number,
number of nozzle bores, bore diameter, injection angle).

Starting condition The injection valve has been disassembled, all individual components
carefully cleaned and defective parts replaced.

Steps 1. This applies only to the 32/40 engine: Carefully clean the set screw
(47) and the bore hole according to Loctite specification.
2. Screw the eye bolt (001.412) into the thrust pad (48), hold the holder
(46) at an angle (with the sealing face pointing up), and insert the
thrust pad including compression spring (49) and spring plate (50),
paying attention to the position of the groove for the set screw (47) -
refer to Figure 1 .
Verify that the spring plate has been positioned correctly.
3. This applies only to the 32/40 engine: Coat the thread of the set
screw with Loctite 243 securing compound over a length of 5 mm,
and screw the set screw into the holder until it does no longer pro-
trude.
Verify that the thrust pad is still movable in axial direction.
4. Unscrew the eye bolt.
5. Screw the setting screw (45) in, do not yet tension the compression
spring.
6. Depending on the engine type, insert a suitable reducing jaw into the
fixing head (16) of the pressure tester (for the 58/64 engine type, re-
ducing jaws are not required). Refer to Figure 2 .
7. Insert the holder (46) into the fixing head (16) in such a way that the
sealing face for the nozzle body (42) points down, and clamp it
evenly. Turn the fixing head by 180ƒ and fix it in place.
8. Dip the nozzle needle (43) into clean fuel oil, and insert it into the
nozzle body. Verify that it moves easily.
9. Check the nozzle needle lift between the upper edge of the nozzle
body and the step on the nozzle needle.
For the specified value, refer to Volume B1, section “Technical Data”.
10. Wipe the sealing face dry using a paper towel. Slip the nozzle body
and the nozzle needle onto the holder, paying attention to the position
of the two parallel pins (51).
11. Coat the pressure shoulder (D) on the nozzle body (42) with lubricant
“Optimol Paste White T”. Refer to Figure 1 .

6629 221.04--02 E 01.05 32/40 upw 102/ 04

 12. Apply lubricant “Optimol Paste White T” to the thread of the holder
and the nozzle tensioning nut (52) as well as the pressure shoulder
(D) on the nozzle tensioning nut. Refer to Figure 1 .
13. Screw the nozzle tensioning nut onto the holder, hand-tight, and
000.30) in a second
tighten it to the specified torque (see work card 000.30
step. Turn the fixing head by 180ƒ and fix it in place.
14. Screw the hexagon nut (44) loosely onto the setting screw, and
tighten it only after adjusting the injection pressure (see work
card 221.02).
221.02

42 Nozzle body
43 Nozzle needle
44 Hexagon nut
45 Setting screw
46 Holder
47 Set screw
48 Thrust pad
49 Compression spring
50 Spring plate
51 Parallel pin
52 Nozzle tensioning nut

D Pressure shoulder

Figure 1. Injection valve (figure shows injection valve of the 32/40 engine type)

6629 221.04--02 E 01.05 32/40 upw 103/ 04

 6 High-pressure hose
13-15 Receptacle
16 Fixing head
60 Hexagon bolt

Figure 2. Pressure tester

6629 221.04--02 E 01.05 32/40 upw 104/ 04

Fuel injection valve
Sealing faces on the threaded piece
Grinding 221.05

Purpose of jobs to be done

Ensure correct execution of work,

assess wear pattern/condition,
restore contact pattern.

Brief description

The sealing faces on the threaded piece to the fuel injection valve are to
be checked for damage and, if necessary, remachined every time it is
removed.
The work concerns:
establishment of a correct contact pattern.

Tools/appliances required

Qty Designation No. Availability

1 Grinding device for delivery pipe 434.043 Optional
1 Locating plate 434.043--1 Optional
1 Threaded ring 434.043--2 Optional
1 Bearing ring 434.043--3 Optional
1 Bearing flange 434.043--4 Optional
1 Counter flange (threaded piece) 434.043--6 Optional
1 Spacer ring 434.043--8 Optional
1 Stop gauge (threaded piece) 434.043--9 Optional
2 Bearing block 434.043--10 Optional
1 Swivel arm 434.043--11 Optional
1 Bracket 434.043--12 Optional
1 Stop 434.043--13 Optional
1 Grinding wheel 434.043--16 Optional
1 Base plate 434.043--17 Optional
1 Sliding carriage 434.043--18 Optional
1 Shaft 434.043--19 Optional
1 Stop 434.043--20 Optional
1 Adapter flange (threaded piece) 434.043--22 Optional
2 Ball bearing 434.043--24 Optional
2 Ball bearing 434.043--25 Optional
1 Hook spanner 434.043--37 Optional
1 Face spanner 434.043--38 Optional
2 Clamping lever 434.043--41 Optional

6701 221.05--02 E 08.06 L 40/54 101/ 06

 Qty Designation No. Availability
1 Clamping piece 434.043--42 Optional
5 Emery paper 434.043--44 Optional
1 Hexagon screw driver 5 000.294 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Electric angle grinder -- Optional
1 Safety goggles -- Inventory
1 Cleaning agent -- Inventory

Related work cards

Work card Work card Work card

221.01

Operating sequence 1 -- Attaching the threaded piece to the grinding device for delivery pipe

Starting condition Threaded piece removed and cleaned (see work card 221.01).
221.01

Important! The grinding device for the delivery pipe must be

installed and operated on a solid support. Vibrations of the grinding device
have an influence on the surface quality of the sealing faces to be ground.
The threaded pieces to be ground must be absolutely free from lube oils
and greases. Any kind of contamination, especially lubricants, reduce the
service time of the emery paper considerably.

Steps 1. Loosen both clamping levers (434.043-41) and swivel out the electric
angle grinder (3) together with the bracket (434.043-12) up to the
stop.
2. Screw the adapter flange (434.043-22) onto the threaded ring
(434.043-2) by means of the hexagon socket bolts (2) and tighten
them. See Figure 1 .
3. Attach the stop gauge (434.043-9) to the adapter flange by means of
two hexagon socket bolts (6). See Figure 3 .
Important! 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 (434.043-6) onto the threaded piece (1).
▲ Attention! The threaded piece has a left-hand thread on the in-
jection valve side!
5. Screw the threaded piece (1) into the adapter flange by means of the
counter flange, until the cone of the threaded piece contacts the stop
gauge.
6. Screw the counter flange onto the adapter flange and tighten it using
the face spanner (434.043-38) and hook spanner (434.043-37).
7. Attach the clamping piece (434.043-42) to the end of the threaded
piece (1). See Figure 1 .
8. Remove the stop gauge (434.043-9).
9. Slip the tommy bar (000.262) radially into the threaded ring
(434.043-2), screwing the ring in until it contacts the locating plate
(434.043-1).

6701 221.05--02 E 08.06 L 40/54 102/ 06

 ▲▲ Caution! It is important that every time a threaded piece is to
be newly ground, the threaded ring is screwed in to such an extent
that it contacts the locating plate!
10. Press the yellow stop knob on the electric angle grinder (3), put grin-
ding wheel (434.043-16) together with emery paper (434.043-44)
onto the electric angle grinder and tighten by means of mounting nut.
11. Pull the sliding carriage (434.043-18) back by means of the support
adjusting crank (4).
12. Swivel the bracket (434.043-12) back in again until it contacts the
stop, blocking it on the sliding carriage by means of the two clamping
levers (434.043-41).

Operating sequence 2 -- Regrinding of the sealing faces on the threaded piece

Starting condition Threaded piece correctly attached to the grinding device for delivery pipe.
Grinding wheel with new emery paper mounted on the electric angle
grinder.

▲ Attention! The remachining of the sealing face is intricate and

requires particular care! It is recommended to have this work carried
out in a service centre or by personnel from MAN B&W Diesel!

Steps 1. Swing the swivel arm (434.043-11) with the electric angle grinder (3)
to the right-hand stop (5). See Figure 2 .
2. Move the grinding wheel (434.043-16) towards the sealing face of the
threaded piece (1) by means of the support adjusting crank (4) until
the grinding wheel touches the sealing face.
3. Move the swivel arm to the left-hand stop (434.043-13) so that the
front side of the grinding wheel faces the threaded piece (1). See
Figure 4 .
▲▲ Caution! Wear safety goggles when grinding threaded pieces!
4. Establish the voltage supply for the electric angle grinder (3) and
switch the grinder on.
5. Turn the threaded piece (1) evenly at the clamping piece
(434.043-42), and, at the same time, move the swivel arm with the
electric angle grinder (3) around the sealing face contour.
▲ Attention! The grinding wheel must not contact the adapter
flange!
6. The feed is effected at the threaded ring (434.043-2) 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 (4)! 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 (1). Turn off the electric
angle grinder (3).
8. Evaluate the result of the grinding process. Repeat the grinding
process until the sealing face has been ground evenly bright.
▲ Attention! In case the required contact pattern can no longer be
realised by means of the grinding device for delivery pipe, the grin-
ding device is to be sent to an MAN service centre for repair!

Important! Remove used up emery paper immediately and replace

by new emery paper.

6701 221.05--02 E 08.06 L 40/54 103/ 06

 9. Remove the threaded piece (1) from the grinding device for delivery
pipe and take off the counter flange.

1 Threaded piece 3 Electric angle grinder

2 Hexagon socket bolt M5x10 4 Support adjusting crank

Figure 1. Grinding device for delivery pipe with attached threaded piece

6701 221.05--02 E 08.06 L 40/54 104/ 06

 2 Hexagon socket bolt
M5x10
5 Stop

Figure 2. Grinding device for delivery pipe

1 Threaded piece
6 Hexagon socket bolt
M6x35

Figure 3. Attaching the threaded piece to the grinding device for delivery pipe

6701 221.05--02 E 08.06 L 40/54 105/ 06

 5 Stop

Figure 4. Right-hand and left-hand stop for the swivel arm

6701 221.05--02 E 08.06 L 40/54 106/ 06

Charge air and exhaust pipe

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

6682 280...--06 E 07.99 101/ 01

Charge air bypass device
Disassembly and assembly,
replacement of sealing elements 280.02

Purpose of jobs to be done

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

ensure correct execution of work,
ensure/restore operational reliability.

Brief description

Control elements in the charge air/exhaust gas system are to be checked

and, if necessary, replaced within the scope of maintenance and repair
work.
The work/steps include:
removal/disassembly of components,
replacement of sealing rings/sealing elements,
assembly/attachment of components.

Safety requirements

- Engine shut down

- Engine secured against starting

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 2

Tools/appliances required

Qty Designation No. Availability

1 Pliers for retaining rings A 10--25 002.121 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Hexagon screw drivers (set) -- Standard
1 Screw drivers (set) -- Standard
1 Grease (acid--free) -- Inventory

6682 280.02--01 E 02.03 General 101/ 04

Operating sequence 1 -- Removal of the bypass flap with drive element

20 Bypass flap
21 Drive element
22 Control pipes
23 Bolted flange joint
24 Seal
25 Adapter flange
Figure 1. Charge air bypass device

Starting condition Control pipes (22) and bypass pipes of the charge air bypass device de-
pressurised.

Steps 1. Separate the control pipes (22) from the drive element (21).
2. Unfasten the bolted flanged joints (23) (refer to Figure 1 ).
3. Dismantle any supports which may be fitted to the adapter flange
(25).
4. Pull the bypass flap (20) with the drive element out of the flange con-
nection, paying attention to the seals (24) in order to prevent that
they are damaged.

Operating sequence 2 -- Replacement of the seal and wear-part sets on the drive element

Steps 1. Remove the bypass flap (20) and the drive element (21) from the
adapter flange (25).
2. Unscrew the hexagon socket bolts (8) of the two covers (7).
3. Take the cover (7) with the cover seal (6) off, paying attention to re-
turn springs (16) which may be fitted. Remove the return springs
(16) - refer to Figure 2 .
4. Move both pistons (5) out of the casing (10) of the drive element by
turning the pinion shaft (11). When removing the two pistons, pay
attention to the guide segments (9).
▲ Attention! Never use compressed air to move the two pistons out
of the casing.
Generally, the following applies: Whenever work is to be done on
the drive element, the connection to the compressed air supply is to
be interrupted.
5. Remove guide rings (4) and O-ring seals (3).
6. Take the retaining ring (1) off by means of the pliers (002.121) pro-
vided for this purpose, and pay attention to the backing ring (2) in the
process.

6682 280.02--01 E 02.03 General 102/ 04

 7. Push the pinion shaft (11) out of the casing (10).

1 Retaining ring 8 Hexagon socket bolt 15 Lower slide ring

2 Backing ring 9 Guide segment 16 Return spring
3 O-ring seal 10 Casing 17 O-ring seal
4 Guide ring 11 Pinion shaft 18 Cap nut
5 Piston 12 O-ring seal 19 Set screw
6 Cover seal 13 O-ring seal
7 Cover 14 Upper slide ring

Figure 2. Drive element

8. Remove the upper and lower slide ring (14 and 15) with O-ring seals
(12 and 13).
9. Clean all components and check them for wear.

10. For assembly, proceed in the reverse order followed for disassembly,
using a new set of seals (consisting of items 3, 6, 12, 13, and 17) as
well as a new set of wear parts (consisting of items 4, 9, 14, and 15).
Important! Do not overstrain the retaining ring (1) when fitting it.
11. When inserting the pistons (5) into the casing (10), make sure that
the gear racks of the pistons engage correctly in the tooth system of
the pinion shaft (11), moving symmetrically.
12. Fit the covers (7) with the cover seals (6) on the casing (10) in correct
position, paying attention to the marking “UP” provided on the cover.

6682 280.02--01 E 02.03 General 103/ 04

Operating sequence 3 -- Fitting the bypass flap with the drive element

Starting condition Bypass flap and drive element checked for tightness. Bypass flap and
drive element fitted to the adapter flange.

Steps 1. Slip the bypass flap (20) with drive elements (21) between the flange
connection of the bypass pipes, making sure that they are positioned
correctly. Furthermore, pay attention to the seals (24) and take care
not to damage them.
2. Refasten the bolted flange joints (23) and tighten them, crosswise.
3. If applicable, remount the supports which were previously attached to
the adapter flange (25).
4. Fit the control pipes (22) to the drive element (21), and check the
system for tightness.
▲ Attention! In case the bypass flap (20) is found to be defective or
untight, it is to be replaced completely!

6682 280.02--01 E 02.03 General 104/ 04

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
027 Torsional vibration damper
030 Connecting rod/Big end bearing
034 Piston/Piston rings/Top land ring
050 Cylinder liner
055 Cylinder head
073 Crankcase cover
100 Camshaft drive
102 Camshaft bearing/Camshaft thrust bearing
111 Rocker arm casing/Rocker arm
112 Cam follower/Push- rod
113... Inlet and exhaust valve
125 Operating device
140 Speed control
160... Starting air pilot valve/Starting valve/
Main starting valve
200... Fuel injection pump/Drive of fuel injection pump
203 Control linkage
209 Camshaft
221 Fuel injection valve
280... Charge air and exhaust pipe
300... Lube oil and cooling water pump
322 Charge air cooler
434 Fuel injection pipe

6682 300...--06 E 07.99 101/ 01

Lube oil pump
Disassembling and assembling 300.01

Purpose of jobs to be done

Check state/wear condition of components,

prevent operating problems/damage.

Brief description

Lubricating--oil pumps require little or no maintenance. But if operating

problems occur, it is necessary to check the individual components for
damage, and replace them if necessary. If there is damage to the
bearings, replace the entire pump.
The work/steps include:
removal of components,
disassembly and assembly,
mounting of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 3
1 Assistant 3

Tools/appliances required

Qty Designation No. Availability

1 Forcing--off device 009.340 Optional
1 Counterbrace 009.340--11 Optional
1 Forcing--off device 009.331 Optional
1 Forcing--off device 009.331--3 Optional
1 Pipe 009.331--6 Optional
1 Forcing--off disk 009.331--8 Optional
1 Forcing--off bolt 009.331--9 Optional
1 Torque wrench 008.011 Standard
1 Torque wrench 008.017 Standard
1 Power amplifier 008.030 Standard
1 Adapter 12.5x20 001.927 Standard
1 Adapter 25x20 001.924 Optional
1 Adapter 20x12.5 001.923 Standard
1 Cross handle 001.892 Optional
1 Cross handle 001.891 Standard

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 101/ 04

 Qty Designation No. Availability
1 Socket wrench insert 55x25 001.804 Optional
1 Socket wrench insert 14x12.5 001.753 Standard
1 Socket wrench insert 30x12.5 001.759 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Depth gauge -- Inventory
2 Threaded rod -- Standard
1 Lifting tackle with rope -- Inventory
1 Collecting tank -- Inventory
1 Hammer (wood/plastic) -- Inventory
1 Sealing compound -- Inventory

Related work cards

Work card Work card Work card

000.30

3 Drive cover
4 Blank flange
5 Pump casing
6 Ring seal
7 Ring seal
8 Bearing unit (two-part)
9 Hexagon-head bolt
10 Valve casing
11 Valve head
12 Compression spring
13 Ring seal
14 Hexagon-head screw
15 Valve bonnet
16 Screw plug
17 Adapter disk
19 Drive shaft
20 Impeller axle
22 Sleeve
23 Hexagon-head bolt

Figure 1. Lubricating-oil pump (two-stage)

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 102/ 04

 1 Nut 24 Cap screw A Spacing
2 Drive gear-wheel

Figure 2. Forcing-off device for gear-wheel of lubricating-oil pump

Introductory remarks

The lube-oil pump consists of two separate pumps of identical construc-

tion, which are connected by means of the adapter disk (17).

Operating sequence 1 -- Removing and disassembling the lubricating-oil pump

Steps 1. Disconnect the pipes and blank flanges (4) from the lube-oil pump,
allowing the oil to drain into the tank. Be careful not to damage
gaskets and ring seals.
2. Sling the pump from the lifting tackle with a rope, and tauten the
rope.
3. Unscrew the fastening screws on the drive cover (3), remove the
pump carefully, and set it down on a wooden rest.
4. Remove the cap screw (24) that secures nut (1) with the screwdriver
(000.293).
5. Mount the forcing-off device (009.331-3) on the drive gear-wheel (2),
slide the pipe (009.331-6) on, and unscrew nut (1).
6. Force off the drive gear-wheel, using the forcing-off device and the
forcing-off disk (009.331-8).
7. Loosen and unscrew the hexagon-head bolts (23) between the pump
casing (5) and the adapter disk (17).
8. Separate Pump 2 from Pump 1, being careful not to damage the
cylindrical pins. Remove the adapter disk (17).
9. Loosen and unscrew the hexagon-head bolts (23) between the pump
casing (5) and the drive cover (3).
10. Mark the drive shafts (19), impeller axles (20), and bearing units (8)
on both pumps, so that they can be re-installed in the same position.
11. Remove the drive shafts, impeller axles, and bearing units.
12. Remove the taper pins on the drive cover (3) with suitable equipment,
and remove the drive cover with the bolted-on bearing unit.
13. Unscrew the hexagon-head bolts (9) and separate the pressure relief
valve from Pump 2, being careful not to damage the cylindrical pins).
Important! Only disassemble the pressure relief valve if it malfunc-
tions. In that case, proceed as follows:

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 103/ 04

 14. Unscrew two opposite hexagon-head screws (14) on the valve cover
(15), and replace them by two M8-size threaded spindles, about 100
mm long.
15. Screw two M8 hexagon nuts all the way onto the two spindles, until
they rest against the valve cover, and unscrew the other hexagon-
head screws.
16. Relieve the initial tension of the compression springs (12) by backing
off the two M8 hexagon nuts uniformly; steady with the two threaded
spindles.
17. Remove the valve cover (15) and the compression spring (12) with
valve disk (11).
Important! Do not unscrew the screw plug (16). Do not unscrew or
re-adjust the lock screw.
18. Clean all parts, and check them for damage; check the appearance
and wear of the bearing and sliding surfaces. Replace all ring seals,
gaskets, and spring washers.
▲ Attention! If there is damage to the bearings, replace the entire
lube-oil pump.

Operating sequence 2 -- Assembling and mounting the lubricating-oil pump

Starting condition All parts cleaned and checked. All ring seals, gaskets, and spring washers
replaced.
Assembly and mounting are done by analogy to disassembly and removal,
in reverse order. Mind the following points:
1. Lubricate all moving parts with oil.
2. Do not change the setting of the pressure-relief valve (opening pres-
sure set to 7.5 bars).
3. Do not insert paper gaskets between the drive cover, casing, and
pressure-relief valve.
4. Coat the threads of the hexagon-head bolts (9, 23) with oil, screw
them in – not forgetting the spring washers (circlips) – and tighten
000.30).
with the specified tightening torque (see Work Card 000.30
5. If Pump 2 is mounted onto Pump 1, make sure that the teeth of the
drive shafts (19) engage correctly.
6. Check the entire pump for ease of movement.
7. To remount the drive gear-wheel (2), place it on the lightly oiled tap-
ered section of the drive shaft (19), mount the forcing-off device
(009.331-3), and slide the pipe (009.331-6) on.
8. Oil nut (1), screw it onto the drive shaft (19), and tighten it with the
specified initial torque (see Work Card 000.30).
000.30
9. Measure and note down the distance (A) between the end face of the
drive shaft (19) and the nut (1) with a depth gauge.
10. Tighten the nut with the specified tightening torque (see Work Card
000.30).
000.30 Repeat the measurement according to Item 9, and compare
the two values.
The spacing (A) must have increased by 0.6 mm to 1.5 mm.
11. Secure the nut (1) by tightening the cap screw (24) firmly.
12. Before installing, clean the sealing surface between the pump and
engine and coat it with Hylomar SW32M sealant.
13. Fill the pump with oil.
14. Connect the pipes (unpressurized) to the pump, and screw on the
blank flanges (4).
15. When starting the engine, check the pump and piping for leaks and
noises. Loud noises indicate that the lube-oil pump is aspirating air,
so that the pump does not deliver at full capacity and cavitation may
occur.

6682 300.01--04 E 02.00 32/40, 40/54, 48/60, 58/64 104/ 04

Lube oil pump
Assessing the individual components 300.02

Purpose of jobs to be done

Check state/wear condition of components,

ensure/restore operational reliability.

Brief description

Lubricating--oil pumps require little or no maintenance. But if operating

problems occur, it is necessary to check the individual components for
damage, and replace them if necessary. If there is damage to the
bearings, replace the entire pump.
The work /steps include:
Measure components and
assess wear pattern/condition.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1

Tools/appliances required

Qty Designation No. Availability

1 Feeler gauge (set) 000.451 Standard
1 Micrometer (outside) -- Inventory
1 Micrometer (inside) -- Inventory
1 Abrasive (emery cloth K400) -- Inventory
1 Oil stone -- Inventory
1 Sealing compound -- Inventory

Related work cards

Work card Work card Work card

300.01

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 101/ 05

Preliminary remarks

These criteria are provided for the evaluation of wear parts on lube oil
pumps. The stated criteria are to render it possible to decide which
components of the gear pump can further be used and which not.
The criteria for the evaluation regarding re-usability are based on the
assumption that the operating conditions of the lube oil pump do not
change during the course of the operating time. This especially applies to
quality and cleanliness of the lubricant used, its treatment and the
occurring maximum temperatures and loading of the pumps.
Components, the re-usability of which is uncertain, are to be replaced in
principle or the time interval to the next pump inspection is to be shortened
in order to rule out the risk of an unexpected pump failure.
Already for the removal of components, proper tools are to be used, in
order to avoid that parts are damaged during dismantling.
The parts to be inspected are to be cleaned thoroughly after removal.
During the assembly of the pump, it is important, beside scrupulous
cleanliness, to make sure that all the re-used components are remounted
as originally positioned within the pump.

Criteria for the evaluation of wear parts on lube oil pumps

1. Seals
On principle, seals are to replaced by new ones every time the lube oil
pump is dismantled.
Grooves, in which O-ring seals are positioned, have to be cleaned
thoroughly and checked for foreign body or damage on the groove edges.
Minor edge damage can manually be smoothed out by means of emery
cloth (grain size 400 according to DIN 69176, part 1 or finer) and a
scraper.
Residues from liquid sealing have to be removed completely before the
pump can be remounted using a new sealing agent.
2. Gear shafts
2.1 Tooth system

1 Tooth flanks
2 Axial butting face
3 Crest of the tooth

Figure 1. Gear shaft

The replacement of gear shafts due to damage in the area of the tooth
system is only necessary if it is determined that material has broken off the
crest of the tooth > 3 mm in longitudinal direction.
Further use of the gear shafts is possible in case of
- scores or scratches on tooth flanks, even if they can be distinctly seen
or felt. Sharp-edged burrs on the tooth system which might exist,

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 102/ 05

 especially on the crests of the teeth, should, as far as possible, be
removed or smoothed by means of a scraper, oil stone or emery cloth
to such an extent that a smooth meshing of theeth with the second
gear shaft is possible, if such a gear shaft is to be re-used.
- individual indentations < 1 cm2 on tooth flanks.
- chip-off of material particles < 1 cm2 in the area of the transition
between axial butting face and tooth flank
2.2 Bearing journal

4 Bearing journal

Figure 2. Bearing journal

Further use of the gear shafts is not possible due to damage in the area of
the bearing journal if
- scores, scratches or chip-offs are found on the bearing journal which
are so deep that they can be made out by touching with the finger nail
or the tip of a pencil.
- material changes due to overheating or distinct blue discolorations are
found on the bearing journals.
2.3 Axial butting faces

2 Axial butting faces

Figure 3. Front surface of the gear shaft

A further use of the gear shaft and/or bearing support due to damage in
the area of the axial butting faces is not possible if
- scores or scratches are found on the axial butting faces which are so
deep that they can be made out by touching with the finger nail or the
tip of the pencil.
Important! Gear shaft and bearing support are adapted to each
other. It is, therefore, not possible here to replace individual components.
It is recommended to replace the lube oil pump and to have the damaged
one repaired by MAN B&W Diesel or by an authorised service center.

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 103/ 05

 3. Bearing bushes
3.1 Structure and wear characteristics
The bearing bushes of the lube oil pumps consist of a steel bush onto
which a bronze layer is sintered. The bronze layer contains a mixture of
PTFE and lead in the pores in way to the shaft which form a grey-green
glimmering slide layer as against the bearing journal of the gear shaft.
During the course of pump operation, the slide layer is gradually worn off
and the bronze layer lying underneath becomes more and more visible.
After a short running-in phase, during the course of which slight deposits
from the slide layer may occur on the bearing journal (harmless), the slide
layer is further worn off approximately analogously to the operating time, if
the stresses acting on the bearing and the operating conditions remain the
same.

3.2 Visual inspection of the bearing bushes

6 Bronze layer
7 Slide layer

Figure 4. Bearing bush in new condition

The bearing bushes are to be replaced when on approx. 70% of the

internal face of the bush the metallic bronze layer is visible.
Further use of the bearing bush is possible if
- the visible bronze portion is less than 35% of the running surface.
- the bearing bushes are otherwise in a good condition, i.e. there are
neither scratches nor scores which penetrate the grey-green slide layer
down to the bronze layer.
- the next maintenance interval corresponds to the operatingt time of the
preceding maintenance interval.

3.3 Bearing bush assessment based on the measurement of the

bearing clearance

A Inner diameter of the

bearing bush
B Outer diameter of the
bearing journal

Figure 5. Diameter for determining the bearing clearance

If there is uncertainty concerning the assessment of the wear condition

based on visible indicators, the measurement of the bearing clearance can

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 104/ 05

 provide more precise information regarding the condition of the bush.
For this purpose, the inner diameter (A) of the bearing bushes and the
outer diameter (B) of the appertaining bearing journals (4) have to be
mesasured.
Further use of the bearing bush is possible if
- in case of a shaft diameter of 60 mm: A -- B < 0.36 mm
- in case of a shaft diameter of 50 mm: A -- B < 0.34 mm

C,D Measuring level

Figure 6. Measuring levels for determining the bearing clearance

Important! Measuring the diameter has to be carried out at both

measuring levels (C, D) of the bearing bush and bearing journal. In case
the limiting value for further use is exceeded, even if this is only the case
on one of the two front surfaces, the bush has to be replaced.

3.4 Evaluation of the bearing bushes regarding scores or scratches

Individual scores and scratches, which are located within the grey-green
slide layer, permit the further use of the bearing bushes, unless the
assessment criterion mentioned under 3.2 is not complied with.
In case, however, there are scores or scratches in the internal face of the
bush which distinctly extend into the bronze layer or into the steel jacket,
the bushes have to be replaced.

6682 300.02--01 E 06.00 32/40, 40/45, 40/54, 48/60, 58/64 105/ 05

Charge air cooler

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

6682 322--06 E 07.99 101/ 01

Charge air cooler
Checking and cleaning 322.01

Purpose of jobs to be done

Carry out work in time according to the maintenance schedule,

permit/support economic operation,
prevent operating problems/damage.

Brief description

The charge air cooler has a decisive influence on the operating values and
thus the performance of the engine. It is, therefore, necessary to check
and clean the charge air cooler at regular intervals.
The work/steps concern:
checking the operating values,
removal of components,
chemical/mechanical cleaning 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 Digital pressure gauge Digima--Premo 009.090 Optional
2 Shackle A1.6 002.454 Standard
1 Open--jaw and ring wrenches (set) -- Standard
1 Receptacle -- Inventory
1 Pipe brush -- Inventory
1 Lifting tackle with rope -- Inventory
1 Cleaning agent -- Inventory
1 Cleaning trough -- Inventory
1 Safety goggles -- Inventory
1 Protective gloves -- Inventory
1 Sealing compound (silicone) -- Inventory
1 Grease (acid--free) -- Inventory
1 Copper paste Molykote 1000 -- Inventory

6647 322.01--01 E 07.02 48/60 101/ 05

Related work cards

Work card Work card Work card

000.08 000.40

Technical details

Term Information
Test pressure cooling element (water side) 6 bar
Cooling element 1000 kg

Operating sequence 1 -- Checking the charge air cooler

Cleaning the charge air cooler depends on the degree of contamination.

Therefore, connect the digital pressure gauge (009.090) upstream and
downstream of the charge air cooler at regular intervals and carry out
000.40).
measurements (see work card 000.40

▲ Attention! Cleaning the charge air cooler on the air side is

necessary whenever the pressure differential in the upper load range
has reached 50 mbar!

Check the cooling water inlet and outlet temperature during operation, at
the same time, note down the charge air temperature upstream and
downstream of the charge air cooler in order to keep the charge air cooler
rating under permanent control.

Check the pipe connections for tightness.

Verify air tightness between charge air cooler casing and cooling element.
Inspect the charge air cooler for leakages.

Operating sequence 2 -- Removing the cooling element

Starting condition Cooling water cooled down to at least 50ƒ C.

Steps 1. Drain the cooling water from the cooling water supply and drain pipes
(2).
2. Put the receptacle underneath the charge air cooler.
3. Remove two covers (8) at the bottom of the charge air cooler casing
(20).
4. Screw out the screw plug (14) at the drain connections (13) and drain
the cooling water from the cooling element (approx. 130 litres).
Important! In the case of charge air coolers without permanent
venting, open the venting screws (12) on the upper water box (5).
5. Screw the screw plug (14) including seal (15) back into the drain
connections (13).
6. Remove the cooling water supply and drain pipe (2) and the venting
pipes (if fitted) from the upper water box.
7. Unscrew hexagon bolts (1).
8. Unscrew the hexagon bolts (9) on the charge air cooler bottom side.

6647 322.01--01 E 07.02 48/60 102/ 05

 9. Using the shackle (002.454), fasten the rope to the suspension ribs
on the upper water box (5) of the cooling element and attach it to the
lifting tackle.
▲ Attention! The integrally cast suspension ribs on the upper water
box (5) have only been provided for suspending the cooling element
and may not be used for removing the complete charge air cooler!
For the removal of the complete charge air cooler, separate, lateral
suspension fixtures have been provided on the charge air cooler
casing!
10. Cautiously pull the cooling element out in upward direction, and put it
down into the cleaning trough.

Operating sequence 3 -- Cleaning the cooler bundle (on the air side)

Brush the finned tubes with cleaning fluid or spray them with undiluted
solvent. Refer to Table 1.

▲▲ Caution! Some cleaning agents have an etching effect on the

skin if undiluted, therefore, wear safety goggles and plastic gloves
when using them.
Observe the instructions of the manufacturing firm!

Important! In case the finned tubes are severely contaminated or

covered with incrustations, the deposits have to soak in cleaning fluid for
several hours. For this purpose, put the cooling element vertically into the
cleaning trough, closing the openings for the cooling water pipes on the
upper water box (5) in order to prevent penetration of the cleaning fluid
into the interior of the cooler bundle.

If a water-soluble detergent is used, flush the cooling element amply with

water and/or purge it with compressed air after cleaning.

Designation Manufacturing firm

Air Cooler Cleaner Unitor Ship Services AS, Mastermyr
Kolbotn/Norway
Air Cooler Cleaner HD Vecom B. V.,
Maassluis/Netherlands
Ameroid ACC-9 Drew Chemical Corp.,
Boonton, New Jersey/USA
Atlas D.G. Cleaner Atlas Mc Alpine LTD, Erith,
Kent/Great Britain
Nalco 161-AC Nalco Chemical Comp.,
Oak Brook, Illinois/USA
Norus Degreaser Norus Sales Co.,
Stabekk/Norway
Table 1. Cleaning agent/manufacturer

Operating sequence 4 -- Cleaning the cooler bundle (on the water side)

Steps 1. Remove the upper and lower water box (5 and 17).
2. Loosen the deposits in the finned tubes by means of a pipe brush
and flush them with a strong water jet.
000.40.
For removal of calcareous deposits, see work card 000.40

6647 322.01--01 E 07.02 48/60 103/ 05

 1 Hexagon bolt 8 Cover 15 Seal
2 Cooling water pipe 9 Hexagon bolt 16 Seal
3 Seal 10 Hexagon bolt 17 Lower water box
4 Hexagon bolt 11 Connection for pressure 18 Hexagon bolt
5 Upper water box differential measurement 19 Seal
6 Connection for pressure 12 Venting screw 20 Charge air cooler casing
differential measurement 13 Drain connection 21 Cooler bundle
7 Hexagon bolt 14 Screw plug

Figure 1. Charge air cooler, two-stage

6647 322.01--01 E 07.02 48/60 104/ 05

Operating sequence 5 -- Installing the cooling element

For the installation, proceed in the reverse order followed for removal,
paying special attention to the following:

Steps 1. Always mount the upper and lower water box (5 and 17) with new
seals.
2. Carefully clean the contact face between charge air cooler casing and
cooling element.
3. Coat the seals with copper paste Molykote 1000 or acid-free grease
prior to inserting them.
4. If the cooler bundle (21) has been cleaned on the water side
(operating sequence 4), it is recommended to carry out a pressure
test prior to the installation of the cooling element.
5. Make sure that all other seals are in perfect condition.
6. Before installing the cooling element, apply temperature-insensitive
Silicone to the upper sealing face of the charge air cooler casing.
7. Prior to lowering the cooling element into the charge air cooler
casing, pay attention to the correct position of the reversing water
chamber.
8. After opening the supply and drain connections of the cooling water
pipes, open the venting screws (12).
Important! Keep the venting screws open until the air has
completely escaped from the cooling element.
9. After taking into operation, check all pipe connections for tightness.
10. Verify air tightness between charge air cooler casing and cooling
element.
11. Inspect the charge air cooler for leakages.

6647 322.01--01 E 07.02 48/60 105/ 05

Fuel injection pipe

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

6682 434--06 E 07.99 101/ 01

Fuel injection pipe
Removing and refitting
Disassembling and assembling 434.01

Purpose of jobs to be done

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

check state/wear condition of components,
ensure/restore operational reliability.

Brief description

Fuel injection pipes are to be dismounted for maintenance and repair

work.
Fuel injection pipes are to be disassembled for checking and
reconditioning the sealing faces of the delivery pipe.
The work/steps include:
removal of components,
disassembly and assembly,
mounting of components.

Safety requirements

- Engine shut down

- Engine secured against starting
- Operating media systems closed/depressurised

Tools/appliances required

Qty Designation No. Availability

1 Open--jaw and ring wrenches (set) -- Standard
1 Lubricant (containing molybdenum disulphide) -- Inventory
1 Lubricating oil, clean -- Inventory

Related work cards

Work card Work card Work card

000.30 221.01 434.02

Operating sequence 1 -- Removal of the fuel injection pipe

Steps 1. Close the shut-off valve on the fuel supply pipe.

2. Loosen the hexagon bolts (10 and 16) on the threaded piece (2), and
loosen and remove the fuel injection pump (12).
3. Loosen and unscrew the hexagon bolts (6), paying attention to the
disk springs (7).

6701 434.01--01 E 06.02 L 40/54 101/ 03

 4. Push the flanges (5, 8 and 15) back.
5. Pull the delivery pipe (9) off the threaded piece (2).
6. Take the complete fuel injection pipe off.
Important! In case several fuel injection pipes have to be removed,
mark them so as to ensure that each fuel injection pipe will be refitted to
the cylinder from which it has been removed.
7. Take the flange (5) off.
8. Clean the fuel injection pipe on the outside.
9. Clean the sealing faces on the delivery pipe (9) and check them for
damage. If necessary, disassemble the fuel injection pipe, and re-
work the sealing faces (see operating sequence 2).

Operating sequence 2 -- Disassembly of the fuel injection pipe

Starting condition The fuel injection pipe has been removed.

Steps 1. Push the flanges (8 and 15) back, and screw off the nuts (3 and 14).
▲ Attention! The nuts have left-hand threads!
2. Pull the flanges (8 and 15) off.
3. Clean all the individual parts, and check them for damage. Replace
parts if necessary.
4. If required, rework the sealing faces on the delivery pipe (9) - see
Work Card 434.02.
434.02

Operating sequence 3 -- Assembly of the fuel injection pipe

Starting condition All individual parts cleaned. Possibly damaged sealing faces on the
delivery pipe reworked.

Steps 1. Insert new O-ring seals (11) that have been coated with clean lubri-
cating oil into the ring grooves, making sure that they are not twisted.
2. Push the flanges (8 and 15) onto the delivery pipe (9).
3. Screw the nuts (3 and 14) onto the delivery pipe (9) to such a degree
that the snap rings (4) contact the delivery pipe. Refer to Figure 1 .
▲ Attention! The nuts have left- hand threads!

▲▲ Caution! If the nut is not tightened to the point where the snap
ring contacts the delivery pipe, the connection between the delivery
pipe and cone may not be tight!

Operating sequence 4 -- Refitting the fuel injection pipe

Starting condition The fuel injection pipe has been cleaned.

Steps 1. Clean the sealing faces on the threaded piece (2) and on the fuel in-
jection pump (12), and check them for damage.
2. Insert new O-ring seals (13) that have been coated with clean lubri-
cating oil into the ring grooves, making sure that they are evenly ten-
sioned over the entire circumference and not twisted.
3. Push flange (5) over flange (8).
4. Verify that the nuts (3 and 14) have been screwed onto the delivery
pipe (9) to such a degree that the snap rings (4) contact the latter.
Refer to Figure 1 .
▲ Attention! If the nut has not been tightened to the point where the
snap ring contacts the delivery pipe, the connection between
delivery pipe and cone may not be tight!

6701 434.01--01 E 06.02 L 40/54 102/ 03

 5. Place the delivery pipe (9) onto the sealing face on the fuel injection
pump (12), and insert it into the sealing face on the threaded piece
(2).
6. Push the flanges (8 and 15) forward until they contact the nuts (3 and
14).
7. Coat the threads and seating faces of the hexagon bolts (10 and 16)
with MoS2 lubricant, screw the bolts in and tighten them by hand
(approx. 30 Nm) using the open-end wrench.
8. Push the flange (5) all the way to the front.
9. Screw the hexagon bolts (6) including the disk springs (7) in, and
tighten them.
Important! If required, loosen the hexagon nuts on the fuel injection
valve, align threaded piece (2) and delivery pipe (9), fasten the fuel injec-
tion pipe in place by means of the bolts, and alternately tighten the hexa-
gon nuts on the fuel injection valve to the specified torque in several
stages (see Work Card 221.01 and 000.30).
000.30
10. Open the shut-off valve on the fuel supply pipe.

1 Cylinder head 7 Disk spring 13 O-ring seal

2 Threaded piece 8 Flange 14 Nut
3 Nut 9 Delivery pipe 15 Flange
4 Snap ring 10 Hexagon bolt 16 Hexagon bolt
5 Flange 11 O-ring seal
6 Hexagon bolt 12 Fuel injection pump

Figure 1. Fuel injection pipe

6701 434.01--01 E 06.02 L 40/54 103/ 03

Fuel injection pipe
Sealing faces on the delivery pipe
Grinding 434.02

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 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 Designation No. Availability

1 Grinding device for delivery pipe 434.043 Optional
1 Locating plate 434.043--1 Optional
1 Threaded ring 434.043--2 Optional
1 Bearing ring 434.043--3 Optional
1 Bearing flange 434.043--4 Optional
1 Adapter flange (delivery pipe) 434.043--5 Optional
1 Spacer ring 434.043--8 Optional
2 Bearing block 434.043--10 Optional
1 Swivel arm 434.043--11 Optional
1 Bracket 434.043--12 Optional
1 Stop 434.043--13 Optional
1 Stop gauge (delivery pipe) 434.043--14 Optional
1 Grinding wheel 434.043--16 Optional
1 Base plate 434.043--17 Optional
1 Sliding carriage 434.043--18 Optional
1 Shaft 434.043--19 Optional
1 Stop 434.043--20 Optional
1 Counter flange (delivery pipe) 434.043--21 Optional
2 Ball bearing 434.043--24 Optional
2 Ball bearing 434.043--25 Optional
1 Hook spanner 434.043--37 Optional
1 Face spanner 434.043--38 Optional
2 Clamping lever 434.043--41 Optional

6701 434.02--02 E 08.06 L 40/54 101/ 06

 Qty Designation No. Availability
5 Emery paper 434.043--44 Optional
1 Hexagon screw driver 5 000.294 Standard
1 Hexagon screw driver 4 000.293 Standard
1 Tommy bar, 8 mm 000.262 Standard
1 Electric angle grinder -- Optional
1 Safety goggles -- Inventory
1 Cleaning agent -- Inventory

Related work cards

Work card Work card Work card

434.01

Operating sequence 1 -- Attaching the delivery pipe to the grinding device for delivery pipe

Starting condition Fuel injection pipe removed, disassembled and cleaned (see work card
434.01).
434.01

Important! The grinding device for the delivery pipe must be

installed and operated on a solid support. Vibrations of the grinding device
have an influence on the surface quality of the sealing faces to be ground.
The delivery pipes to be ground must be absolutely free from lube oils and
greases. Any kind of contamination, especially lubricants, reduce the
service time of the emery paper considerably.

Steps 1. Loosen both clamping levers (434.043-41) and swivel out the electric
angle grinder (3) together with the bracket (434.043-12) up to the
stop.
2. Screw the adapter flange (434.043-5) onto the threaded ring
(434.043-2) by means of the hexagon socket bolts (2) and tighten
them. See Figure 1 .
3. Attach the stop gauge (434.043-14) to the adapter flange by means
of two hexagon socket bolts (6). See Figure 3 .
Important! 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 (434.043-21) onto the delivery pipe (1).
▲ Attention! The delivery pipe has left-hand threads!
5. Screw the delivery pipe (1) into the adapter flange by means of the
counter flange, until the cone of the delivery pipe contacts the stop
gauge.
6. Screw the counter flange onto the adapter flange and tighten it using
the face spanner (434.043-38) and hook spanner (434.043-37).
7. Remove the stop gauge (434.043-14).
8. Slip the tommy bar (000.262) radially into the threaded ring
(434.043-2), screwing the ring in until it contacts the locating plate
(434.043-1).
▲▲ Caution! It is important that every time a delivery pipe is to be
newly ground, the threaded ring is screwed in to such an extent that
it contacts the locating plate!

6701 434.02--02 E 08.06 L 40/54 102/ 06

 9. Press the yellow stop knob on the electric angle grinder (3), put
grinding wheel (434.043-16) together with emery paper (434.043-44)
onto the electric angle grinder and tighten by means of mounting nut.
10. Pull the sliding carriage (434.043-18) back by means of the support
adjusting crank (4).
11. Swivel the bracket (434.043-12) back in again until it contacts the
stop, blocking it on the sliding carriage by means of the two clamping
levers (434.043-41).

Operating sequence 2 -- Regrinding of the sealing faces on the delivery pipe

Starting condition Delivery pipe correctly attached to the grinding device for delivery pipe.
Grinding wheel with new emery paper mounted on the electric angle
grinder.

▲ Attention! The remachining of the sealing faces is intricate and

requires particular care! It is recommended to have this work carried
out in a service centre of by personnel from MAN B&W Diesel!

Steps 1. Swing the swivel arm (434.043-11) with the electric angle grinder (3)
to the right-hand stop (5). See Figure 2 .
2. Move the grinding wheel (434.043-16) towards the sealing face of the
delivery pipe (1) by means of the support adjusting crank (4) until the
grinding wheel touches the sealing face.
3. Move the swivel arm to the left-hand stop (434.043-13) so that the
front side of the grinding wheel faces the delivery pipe (1). See
Figure 4 .
▲▲ Caution! Wear safety goggles when grinding delivery pipes!
4. Establish the voltage supply for the electric angle grinder (3) and
switch the grinder on.
5. Turn the delivery pipe (1) evenly and, at the same time, move the
swivel arm with the electric angle grinder (3) around the sealing face
contour.
▲ Attention! The grinding wheel must not contact the adapter
flange!
6. The feed is effected at the threaded ring (434.043-2) 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 (4)! The adjusted position remains unchanged during the
whole grinding process!
Sealing faces are to be slightly remachined only, merely to be
smoothed, removing as little of the material as possible!
7. Move the swivel arm to the left-hand stop so that the front face of the
grinding wheel faces the delivery pipe (1). Turn off the electric angle
grinder (3).
8. Evaluate the result of the grinding process. Repeat the grinding
process until the sealing face has been ground evenly bright.
▲ Attention! In case the required contact pattern can no longer be
realised by means of the grinding device for delivery pipe, the grin-
ding device is to be sent to an MAN service centre for repair!

Important! Remove used up emery paper immediately and replace

by new emery paper.
9. Remove the delivery pipe (1) from the grinding device for delivery
pipe and take off the counter flange.

6701 434.02--02 E 08.06 L 40/54 103/ 06

 1 Delivery pipe 3 Electric angle grinder
2 Hexagon socket bolt M5x10 4 Support adjusting crank

Figure 1. Grinding device for delivery pipe with attached delivery pipe

6701 434.02--02 E 08.06 L 40/54 104/ 06

 2 Hexagon socket bolt
M5x10
5 Stop

Figure 2. Grinding device for delivery pipe

1 Fuel injection pipe

6 Hexagon socket bolt
M6x35

Figure 3. Attaching the delivery pipe to the grinding device for delivery pipe

6701 434.02--02 E 08.06 L 40/54 105/ 06

 5 Stop

Figure 4. Right-hand and left-hand stop for the swivel arm

6701 434.02--02 E 08.06 L 40/54 106/ 06

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