Table of contents

Introduction

Work cards, arranged by subjectslkey words

Work cards, arranged by subassembly groups

Intended f ~ ...r

Table of contents

Intended for

...

How the working instructions/work cards

are organised, and how to use them
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 detailsltechnical 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:

I
How to find the work cards
required

Counting number (card 2)

Subassembly group (crankshaft)

The work cards are contained in the lists of Section 2 and 3. The list, Part
1 is a summary of work cards by subjectslkey 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 inforrnation. The following are
used:
A A A Danger! Imminent danger.
Possible consequences: Death or most severe injuries, total damage
to property.

A A Caution! Poten tially dangerous situation.

Possible consequences: Severe injuries.
A Attention! Possibly dangerous situation.
Possible consequences: Slight injuries, possible damage to
property-

AA

Important! For calling attention to error sourcedhandling errors.

A Tip! For tips regarding use and supplementary information.

General

Table of contents

001

Operating media systems1Pipes

Flushing and cleaning

000.16

Replacement
Pipes
Cleaning, Acid Bath Treatment and Preservation

000.18

Solderless screwed pipe unions

Additional parts

002

Operating medidAuxiliary agents

000.04

Lubricating oil
Assessing and Treating
Lube oillfuel
Cany out drop test
Cooling water

000.05
000.07
000.14

Engine or components
Preservation treatment

003

Machine elements

000.11

Galvanized bearings
Assessing
Bimetal bearings (without a third layer)

000.11

Seals made from elastomer

Storage, cleaning, mounting
Threaded inserts
Use
Tightening of bolted connections
Tightening torques (illustrated)
Tightening of bolted connections
Tightening torques (table)
Tightening of bolted connections
Tightening torques (turning moment)
Tightening of bolted connections
General remarks
Surface examination by means of
penetration methods
Surface examination by means of
magnetic flux leakage methods
004

Hydraulic tensioning tools1 High-pressure pump

Working and safety regulations

Using high- pressure toolsf hydraulic tensioning tools
Hydraulic hand pump
Use
High-pressure hoses
Use
Hydraulic tensioning tool
Use
Hydraulic tensioning tool
Venting, checking, replacing of sealing rings
Hydraulic tensioning tool
Use
Hydraulic tensioning tool
Venting, checking, replacing of sealing rings
Dial gauge (measuring device)
Checking the bolt elongation
005

Operating valuesIOperating results

000.25

Ignition and compression pressures

Determination
Charge air cooler/crankcase
Measuring the differential pressure

000.40

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Cooling water system

Cleaning
Purpose of jobs to be done
Free operating media systems from contamination/residues,
ensurelrestore operational reliability.
Brief descri~tion
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.

Cleanins
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 cooiing system. Only in the event that procurement d the services of a
specialist firm is not possible, the cleaning should be performed by the
engine operator.
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 frssh 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 instructionsfor use are to be strictly observed.

Oil sludge

Manufacturer
Drew
Nalfleet
Uilitor
Vecom

Product

Concentration

HDE - 777
Nalfleet 9 - 010
Aquabreak
Ultrasonic
Muiti Cleaner

4 - 5%
2-5%
0.05 - 0.5%

4%

Duration of cleaning procedure /

temperature
4 hrs at 50 - 60 "C
4 hrs at 60 - 80 "C
4 hrs at ambient temperature
12 hrs at 50 - 60 "C

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

i
.
L

Pipes
Cleaning, Acid Bath Treatment and
Preservation
Pumose of iobs to be done
Keeping operating systems free from contamination and residues,
ensuring/restoring of operational reliability.

Pipes, which are replaced or supplemented, must after

manufacture/processingbe 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 cleanina
Scale and welding pearls rr~ustbe 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.

General

Solderless screwed pipe unions

Mounting
Purpose of jobs t o be done
Insert/replace components,
proper processing and installation.

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 worWsteps include:
proper processing and
proper installation.

No.

Quant Denomination

Availability

1 Tools, basic scope

000.002

1 Pipe cutter

lnventory

1 Spot facer

lnventory

1 Machinery oil

Inventory

e
Advantaaes of solderless screwed ~ i o 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.
Seauence of o~erations

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 oiied
(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

Loctite Products
Use
Pumose of iobs to be done

Use of auxiliary materials,

proper processing and mounting.

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 worwsteps 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.
A Attention! LOCTITE must not be used inside the crankcase as a
substitute for locking fasteners, feather keys etc. provided for in the
design.

In the case of screwed connections requiring tightening to a given torque,

LOCTITE 222 and 243 may be used as the case may be, since the
lubricity of these two products corresponds to that of the lubricating oil.
The curing time which LOCTITE requires can be reduced by adding the
accelerator T or by warming up the joint to elevated temperatures. For
recommended products, please see Tables 1 ... 3.
Attention! The shelf life of LOCTITE is limited to approximately
I 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.
A

Operating Sequence 1

Steps

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

Table of contents

List of Assemblies
Work cards, arranged by s~~bassembly
groups

3.2

...

009

Foundation/resilient mounting/ alignment of the engine

000.09

Position of the crankshaft flange in relation to the driven flange

Determinelcheck
Check the foundation bolts
Align the engine on the foundation

012.01

012

CrankcaseIBearing bolts/Cross tierodst Cylinder head bolts

012.02

Main bearing bolts and cross tierods

Checking, untightening and tightening
Cylinder head bolts
Removal and installation

012.03

020

Crankshaft/Coupling bolts

000.10
020.01

Crankshaft
Measure the crank web deflection
Balance weight bolts

020.02

Oil bore of the crankshaft

020.03

Gearwheel on the crankshaft

Removing and installing
Coupling bolts

020.04

Intended for

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020.05 Balance weight

Removing and installing
Main bearing/ Thrust bearinglflange bearing

021

021 .O1 Main bearing cap with lower bearing shell

Lowering and checking

021.02 Upper main bearing shell

Removing and installinglchecking

021.03 Main thrust bearing

Measuring axial clearance1checking locating bearing rings

021.04 Main flange bearing1Bearing shells

Removing, refitting, checking

021.05 Main bearing cap

-

027

Removing and installing

Torsional vibration damper

027.03 Torsional vibration damper of the crankshaft

Removing and refitting

030

Cor~nectingrod/Big-end bearing

030.01 Con-rod shank bolts

Checking, untightening and tightening

030.02 Big-end bearing bolts

Checking, untightening and tightening

030.03 Big-end bearing cap - lowering Big-end bearing bolt - removal

Lower big-end bearing shell - checking

030.04 Upper big-end bearing sheli

Removing and installinglchecking

030.05 Big-end bearing

Removing and installing

034

Piston/piston rings

034.01 Piston

300.02

Lube oil pump

Assessing the individual components
350.01 Cooling water pump
Disassembling and assembling

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322

Charge air cooler

434

Fuel injection pipe

434.01

Fuel injection pipe

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

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434.02

.: 1CI

434.03

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434.04

609-01.00(07H) Functional test and adjustment of safety, alarm and

monitoring equipment
609-05.00(05H) Adjustment and test of onloff differential pressostate
609-05.01(04H) Adjustment and test of onloff therrnostate
609-05.02(04H) Function and test of level switch (LAL25)
609-05.03(04H) Adjustment and test of pressure transmitter
609-05.04(04H) Adjustment and test of analogous temperature transmitter
609-05.05(01H) Function and test of leakage alarm (lAH42)
609-1O.OO(15l-l) Adjustment of lambda con
610-05.00(01H) Retightening and mounting of coupling bolts
61 1-05.00(01H) Retighten and mounting of foundation bolts
614-01.15(02H) Fuel oil split filter
615-01.05(04H)
615-01.20(03H)
615-06.00(03H)
615-15.00(05H)

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Prelubricating pump
Lubricating oil, therrr~ostaticvalve
Lubricating oil cooler
Centrifugal bypass filter

619-03.00(18H) Fitting instructions for resilient mounting of gensets

619-03.00(19H) Fitting instructions for resilient mounting of gensets
619-03.00(20H) Fitting instructions for resilient mounting of gensets
6 19-03.05(02H) Replacement of conicals
619-03.10(02H) Maintenance of conicals
Top of the page

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Foundationhesilient mounting1
alignment of the engine

CrankcaseKie rod/solts
CrankshaftlCoupling bolts
Main bearinchrust bearinplange bearing
Torsional vibration damper
Connecting rodlsig end bearing
PistonlPiston rings
Cylinder linermop land ring
Cylinder headlsafety valve
Dead centre indicatorlSpeed pick-up
Crankcase coverlCovering
Camshaft drive
Camshaftrrhrust bearing
Torsional vibration damper
Rocker armmocker arm casing
Cam follower/Push-rod
Inlet and exhaust valve
Camshaft adjusting device
Operating device
Speed control
Starting air pilot valvelStarting valve1
Main starting valve
Fuel injection pumplControl linkage
Fuel injection valve
Charge air and exhaust pipe
Lube oil and cooling water pipe
Charge air cooler
Fuel injection pipe