KSZ 70-125B

OPERATING MANUAL
0
FOR DIESEL ENGINE S
TYPE
KSZ 70/125 B
SERIAL NO.
0 135 0 0 1 . 6
MAN B&W DIESEL AKTIENGESELLSCHAFT

STADTBACHSTRASSE 1
D-86153 AUGSBURG
0
2 0. JAN. 2006
INTRODUCTION
0
Our Diesel engines are the result of decades of systematic research and development
__w_or_k . They will meet all service requirements at any time to the full satisfaction
- of th e
owner, provided they are properly serviced . Timely execution of the specified
maintenance work will ensure efficient operation and long life . The OPERATING
MANUAL is intended to help achieve this object .
The Operating Manual contains all necessary information for planned maintenance as
well as for the general overhaul of the Diesel engine and should therefore be placed in
the hands -of the operating personnel . A thorough study and repeated reading to
commit the instructions to memory will enable the personnel to gain complete
understanding of the engine . With this knowledge the personnel will be in the position
to run the engine properly, recognize possible irregularities at an early stage and rectify
them before serious damage occurs .
Proper maintenance and overhaul of the Diesel engine definitely require skilled
personnel . It is understood that the personnel assigned to this work has had the
necessary training and no further mention will be made of it in this operating manual .
We shall not entertain any guarantee claims based on a lack of particular instructions in
this manual in the event of damage caused by faulty handling . is
Individual parts of the Diesel engine may be altered due to technological development
without corresponding changes being made in this operating manual . The text and all
data apply at the time of going to print .
Letters and enquiries relating to the Diesel engine should include the type and serial
number which will be found on the name plate .
This publication is copyright . Reprinting and other duplication and for-

warding to third parties may only take place with our written approval .
M/E 40
INHALTSVERZEICHNI S KSZ 70/125 B
0
TABLE OF CONTENTS D 36 5612- 2
Abschnitt 1 TECHNISCHE DATEN TECHNICAL DATA

Section 1 1
I
Typenbezeichnung, Kurzbeschrei bung Type designation, brief descriptio n
Leistungsongaben, Verbrouchsongaben Output, consumptio n
Motorabmessungen Engine specifications
Zundfol ge, Firing order,
Betriebstemperaturen und Drucke Services temperatures and pressure s
Gewichte, Spiele Weights, clearance s
Qualittitsonforderung fur Kraftstoff, Quality requirements for fuel ,

Schmierdl und KUhlwasser luboil and wate r
" .-
Absc' hnitt 2 SC n1:
HMABESC HREI BUNG E N D ESCRIPTIONS OF SYSTEM S
2
0 Section 2
Kraftstoffschema Fuel syste m
SchmierdIsthema Luboll syste m
Kuhlwosserschema Cooling water syste m
AnIaBschema Starting syste m
Regelschema Regulation
Abschnitt 3 BETRIEB
Section 3
OPERATIO N 3
Inbetriebsetzen Starting
Abstellen Taking out of operatio n
Oberwachung Monitorin g
Motoreneinlauf Engine break-i n
Allgemeine Anweisungen fur Schwerbl, General instructions for heavy oil ,
Schmierbl, Wasser luboil, wate r
0 Betriebsstbrungen Operating difficulties
Abschnitt 4 WARTUNG MAINTENANCE

Section 4
Wartungsplan Maintenance schedul e
Arbeitskarten Work cards
D36 5612 - 2 D+E

0
0
M+A&*14 TECHNISCHE DATEN
TECHNICAL DAT A
KSZ 70/125 B
I
0
Inhaltsverzeichnis Abschnitt 1 Table of contents section I I Blatt Shee t

Typenbezeichnung, Kurzbeschreibung , Type designation, brief description , I
Motorschnitte . . . . . . . . . . . . . . . . . . . . . . . engine sections . . . . . . . . . . . . . . . . . . . 2-4
Leistungsangaben, Verbrauchsangaben . . . Output, consumption . . . . . . . . . . . . . . . 5
Motorabmessungen, Zundfolge . . . . .. . . . . . Engine specifications, firing order . . . . 5
Betriebstemperaturen, Betriebs- und Pro- Service temperatures, service and tes t
bedrucke . . . . . . . . . . . . . . . . . . . . . . . . . . . pressures . . . . . . . . o . . . . . . . . . o . . . . 0 . 6
Gewichte . . . . . . . . . . . . . . . . . . . . . . . . . . . Weights . . . . . . . . . . . . . . . . . . . . . : . . . . . 7
Spiele . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearances . . . . . . . . . . o . . . 0 . . . . . . . . . 10- 1 2
Motorbenennungen . . . . . . . . . . . . . . . . . . . Definitions . . . . . . . . . . . . . . . . . . . . . . . . 20
0 Qucl ittitsanforderung an Dieselkraftstoff . . Quality requirements for Diesel fuel . . . . 21
Qua I i tu tsonforde rung an Schwer5l . . . . . . . Quality requirements for heavy fuel oil . 23
Viskositdts-Temperatur-Diagromm . . . . . . . Viscosity-temperature diagram . . . . . . . . 25
Qualittitsonforderung an Schmierdl . . . . . . Quality requirements for lubricating oil 34
Qualittitsonforderung an Kuhlwasser . . . . . Quality requirements for cooling water . 4 1
M .A . N .-Abgosturbolader M .A .N . exhaust turbocharger
Kurzbeschre i bung, Betriebsdaten . . . . . . . . Brief description, operating data . . . . . . 51

Rohranschlusse, Gewichte . . . . . . . . . . . . . Pipe connections, weights . . . . . . o . . . . . 52
Spalte und Spiele . . . . . . . . . o . . . . . . . . . o Gaps and clearances . . . . . . o . . . . . . . . . 53
0
C14
~ D36 5612 D+E 1 .1-2
0
0
TECHNICAL DATA 1
M*AL*M Type Designation,Brief Description KSZ 70/125 B
2
0
Type Designatio n
The type designation of the engine is KSZ 70/125 B or BL, a short form for :
K = Crosshead engin e
S= Easy-to-maintain
Z= Two-stroke cycle
90 = Cylinder bore in cm
160 = Piston stroke in c m
B = Box-type frame
L = Low spee d
The number of cylinders in the engine is placed between the letters K and S . The complete
type designation of a six-cylinder low speed engine will thus be K6SZ70/125 BL . The B L
i is of the some design as the B engine, except for the turbochargers which have been
engine
matched to correspond with the lower speed .
0 Brief Descript io n
The KSZ engine is a supercharged, low-speed, single-acting, two-stroke engine of crosshead

design with solid fuel injection, loop-scavenging and the necessary equipment for operation
on heavy oil .
The fabricated and welded bedplate (010) of the larger engines, by their number of cylinders,
is split in the middle and, ending the length of the engine, serves at the some time a s
oil sump . The mono-block thrust bearing is welded to the bedplate .
The enq ;ne frame (01 2) is a fabricated box-type frame construction made'either in one piece
for five .and six-cylinder engines, or in two pieces, vertically split in the middle for seven
and more cylinder engines . The cylinder blocks, mounted on top of the frame, are bolted
together to a single beam and are held down, together with the frame, on the bedplate by
long tierods .
The cast-iron cylinder blocks (014) contain the cylinder liners (050) of special alloy with
0 carefully designed ports . The lands between the scavenge and exhaust ports as well as the
liner f lange are water-cooled . The liner f lange seats on a supporting ring on the cylinder
block .
The two-piece cylinder covers (055) are made of a thin-walled lower part of steel and a
cast-iron upper part for transmission of the occurring forces . Each cover is equipped with a
fuel injection valve, a starting valve, a relief valve and an indicator valve .
The crankshaft (020) is of the semi-built type, i .e . the shaft journals are shrunk into the
forged cranks .
Connecting rods (030) are of the marine type construction . The bolted-on bearings with
bearing shells receive the lubricating oil from the main bearings through drilled passages
in the crankshaft and the rifle-drilled connecting rod . The crosshead bearings receive
additional lubricating oil from the force-feed crosshead lubricators .
The crosshead (031 ) consists of a throughgoing pin which carries the guide shoe and the piston
0
01 rod which are bolted to the top - and the bracket for the telescopic pipes of the piston cooling
N
CY)
system bolted to the side .
D36 5612 E 1 .2-2 p .t .o .
The piston rods (033) arerifle-drilled for the supply and return of piston cooling water/
and are flange-mounted on the guide shoe . A stuffing box seals the passage of the piston 0
rod through the bottom of the cylinder j acket . The composite piston (034) is fastened to
the piston rod by long waisted bolts .
The camshaft (209) is seated at about mid-height of the engine and is driven through
a
gear train which also serves to drive the cylinder lubricators, the governor and the monitoring
instruments . The fuel injection pumps (200) are combined into one block in the case o
f
five and six cylinder engines, whereas 7-12 cylinder engines use two pump blocks, on e
on each side of the timing gear drive . The starting air pilot valves (160) are arranged in the
shape of a star and are accommodated in a common casing . The engine is reversed by the
reversing gear (120) which shifts the camshaft in axial direction so that the corresponding
set of cams ~Fthe double cams for the injection pumps and the starting air pilot valve s
are placed under the pumps and the valves respectively .
The Woodward governor (1 40) is linked up to a hydraulic-pneumatic positioner (125) which

incorporates, amongst other control instruments, a power booster that transmits the movement
of the governor to the fuel control linkage of the injection pumps .
0
All manoeuvres, i .e . starting, reversing, stopping and load-control are effected throug
h
a corresponding movement of a single-control lever in the engine control stand . The engine
control system is designed for the connection of a remote automatic control system .
The constant pressure system has been adopted for turbocharging the engine . On start-up
and low power operation additional scavenge air is supplied by auxiliary blowers connected
in series with the turbochargers .
The electrically driven turning gear(026) for turning the eng ine in the course of overhauls
is mounted on the bedpl ;te at the driving end .
The_fuel oil system and all parts related to the combustion system are designed for operation
on heavy oil .
Cooling of cylinders, cylinder covers, pistons, fuel injectors and of turbochargers is by

.means of freshwater, whereas the intercoolers, the fresh water and the oil cooler are cooled
by seawater .
ID
All parts requiring lubrication are connected to the force-feed lubricating system - except
a few joints that are equipped with self-lubricating Tushes (fuel control linkag~~)_ _-Cylinder
liners are lubricated by special cylinder lubricators which are driven from the camshaft
.
All important screw connections of the engine are tensioned and released by . means-of
hydraulic tools and a high-pressure pump so that maintenance and overhaul work is
comparatively easy in spite of the large size of the components involved .
Note : The numbers listed with the individual engine components denote the component/assembly
concerned . This facilitates finding individual parts in the work sheets of section 4
(Maintenance) and in the spare parts catalogue .
D36 5612 E / 1 . 2-2

MOTORQUERSCHNITT 1
KSZ 70/125 B
ENGINE CROSS SECTION 3
0
0
r" I
r':
0% D36 5612 D+E 1 .3-2
0
0
MOTORQUERSCHNITT 1
M *Atk* KSZ 701125 B
ENGINE CROSS SECTION 3
0
D36 5612 D+E 1 .3-3

0
0
M*A&*M MOTORLXNGSSCHNITT
KSZ 70/125 B
1
ENGINE LONGITUDINAL SECTION 4
0
(0
0
01 D3.6 5612 D+E 1 .4-2 siehe Ruckseite - p .t .o .
AusfUhrung bei 7-10 Zyl . %toren Steuerungsantrieb in der t1itte des Motors Ausfuhrung bei 5 u . 6 Zyl . tbtoren Steuerungsantrieb auf Kupplungsselte
Timing gear drive of 7 to 10-cyl . engines arranged in the middle of the engine Timing gear drive of 5 and 6-cyl . engines arranged on the coupling end
- -VI
NA^
IJCDD OCDOGUft
onn
ir
11
36-40 524
MOTORLYNGSSCHNITT
KSZ 70/125 B
ENGINE LONGITUDINAL SECTION 4
0
N
Pl~
D36 5612 D+E 1 .4-3 siehe Rijckseite - p .t .o .
AusfUhrunq bei 7-10 Zyl . Moren Steuerungsantrieb in der I-Mitte des t .btors AusfUhrung be! 5 u . 6 Zyl . Moren Steuerungsantrieb auf Kupplungsseite
Timing ge .,;r drive of 7 to 10-cyl . engines arrangpd in the middle of the engine Timing gear drive of 5 arid 6-cyl . engines arranged on the coupling end
8 01 F AA^1111A
j MIC J!Q(DN
mi r u jFii 0
I . %
L V
oil
7
4LU [if J.-
L
:1777
36405
0
TECHNICAL DATA I 1
M *Aftk* M Output and Consumption K SZ 70/125 B
0 Engine Specifications, Firing Order I 5
0 u t p u t of engine type . . . . . . . . . . . . . . . . . . . . . . . . . . .
serial number . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine output MCR . . . . . . . . . . . . . . . . kw . . . . . . . . . . . . . . . . . . HP I
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm
Mean effective pressure . . . . . . . . . . . bar
Firing pressure . . . . . . . . . . . . . . . . . . . . bar
Mean piston speed . . . . . . . . . . . . . . . . . m/s
C ansum p tian
Fuel consumption at -MC R
(plus 3 % guarantee margin) . . . . . . . . . 9/1<Wh . . . . . . . . . . . . . . . g/HPh
Cylinder lubricating oil . . . . . ... . . . . . . . 1 .4-1 .5 9/'kWh . . . . . . . . 1 .0-1 . 1 g/HPh
Tur b achar g in g
0 Manufacturer of exhaust gas turbocharger . . . . . . . .
Type of turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . constant pressure with auxiliary blowers
Criti ca I Speed s
The barred speed ranges are marked in red on the tachometer and are named on a plate .
Engine Specif i cation s

Number of cylinders, see type designatio n
Swept volume of one cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481 dm3

Compression ratio . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 12 .39
Tota I swept volume

5-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o . . . 3
2405 dm
6-cylinder engine . . . . o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2886 dm3
7-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3367 3
0 dm
8-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3848 dm
9-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4329 dm
1 0-cylinder engine . . . . . . . . . . . . . . . o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481 0 dm
3
Overhead required (from center line crankshaft) mm

piston and piston rod (without suspension device) . . . . . . . . . . . . . . . 9600
tierods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12543
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . 700
Piston stroke . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250
Diameter of main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
crank bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
crosshead bearing . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . . . . . . 400
camshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 and 280
D36 5612 E 1 .5-2 p .t .o .

0
Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Relief valve (cylinder cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Torsion vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300
Injection pump plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Supporting width o f
main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
crank bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
crosshead bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
camshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 90, 118 and 14 8
Width of torsion vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Length of piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1285
connecting rod (middle of bearing) . . . . . . . . . . . . . . . . . . . . . . 2250
cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . 2427
Width of compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lift of starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
relief valve (cylinder cover) . . . . o . . . . . . . . . . o . . . . . . . . . . . 8
fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .6 0
fuel cam . . . . . . . . o .. . . . . . . . . . . . . . . *. . . . . . . . . . . . . . . . . . . . 53
starting air pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . 5
Axial movement of camshaft, reversible engines . . . . . . . . . . . . . ... . . . . . 165

Distance between cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 and 2070
Fue I Inj ection Pumps See Acceptance Records for Beginning of Delivery
Firing 0r d er
Sense of rotation of crankshaft when looking on the drive flang e
Number of cylinders Clockwise - ---counterclockwise Firing Interval s
5 1-5-2-3-4-1 even
6 1-6-2-4-3-5-1 even
7 1-6-3-4-5-2-7-1 even 40
8 1-8-2-6-4-5-3-7-1 uneven
9 1-7-5-2-8-4-6-3-9-1 uneven
10 1-10-4-7-2-9-5-3-8-6-1 uneve n
Step-up ratio of mounted instruments n engine n instrument
Woodward governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6, 8
SEL speed transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5
Siemens tachogenerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 .55
BBC tachogenerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 .55
Jungner tachogenerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I
Deuta pulse generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I
40
D36 5612 E/1 .5-2
TECHNICAL DATA
1
M+AL*M Service Temperatures, Service an d
Test Pressures
KSZ 70/125 B
0 6
Service Temperatures (atMCR )
The temperatures stated are guide values . The exact temperatures are listed in the
Acceptance Records of the engine . (cf ef 3 . 8) .
0C
Scavenge air before cylinder (cf sheet 3 .26) . . . . . . . . . . . . . . . . . . . .approx. 45
.
Exhaust gas before turbocharger . . . . . . . . . . . . . . . . . . . . . . . o . . . . . . .approx . 470
after cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .up to ~. 450
Cooling water inlet on cylinder . . . . . . . . . o . . . . . . . . . . . . . . . . . . . . . 66
outlet on cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .approx . 78
outlet land cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -< 75
inlet piston cooling, . . . . . . . . . . . . . . . . . . . . . . . . . . . > 58
outlet from pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
inlet nozzle cooling . . . . . . . . . . . . . . . . . . . . . . . . . .. . approx . 60
Lubricating oil inlet crankgeor lubrication . . . . . . . . . . . . . . . . . . . . . approx . 42
0 outlet on thrust bearing . . . . . . . . . . . . . . . . . . . . . . . . approx . 45
Heavy oil, see viscosity-temperature diagram (sheet 1 .25)
Service and Test Pressures (bar-kp/cm2 )
service pressure I opening pressure I test pressur e

bar bar ba r
Cooling water (spaces) Cylinder cover 2,3-2,8 - 10
Cylinder block 2,3-2,8 - 7
Cylinder liner 2,3-2,8 - 7
Piston 3,5-4,5 - 10
Fuel injector 3,3-3,8 - 15
Charge-air cooler 1,5-2,0 - 4
Lubricating oil Bearing lubrication 2,3-2,6 - -

Fuel Supply, Heavy Oil 3,5-4,5 + - -
0 Injection pipe - 1200
Injector - 275 (300+++) 100-0
Charge-air Charge-air cooler 2
Pressure air Pressure air receiver 30 60
Starting pipe 30 60
Exhaust backpressure after turbine up $to 0 .025
Relief valve
in crankcase I 0.05
in cylinder head cf A-cceptance Records
+ A higher pressure may be required to prevent golification of fuel at very high fuel
temperature .
Measured at pipe connection bar at camshaft level
+++ - with new sprin g
0
r.4
Co
L~ D36 5612 E 1 .6-2
0
0
M*Ak* TECHNICAL DATA
Weights
KSZ 70/125 B
7
0
Weights of Essential Components (approximations in kg )
Piston and piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2180

Crosshead, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o . . 1290
Guide shoe . . . . . . . . . . . o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
Connecting rod with bearing . . . . . . . . . . . . . . . . . . o . . . . . . . . . . . . . . . . . . 0 . . . . . . . 3500
Connecting rod shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o . . . o . 1570
Crosshead bearing with bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . o . . . . . . o . . 520
Crankbearing with bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o . . . . . . . . . 870
Main bearing, I bearing cover . . . . . . . . . . . . . . . . . . . . . . . . o . o . . . . . . . o . . . o . o . 15 0
1 bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2230
Cylinder jacket without cylinder liner, . . . . . . . o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8000
Cylinder liner with supporting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200
Tierod . . . . . . . . . . . . . . . . . o . 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
0
Torsion vibration damper (crankshaft), complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 0
flyrim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5160
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Fuel injector . . . o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o . . . . 33
Charge-air cooler, complete . . . . . . . . . . . . . . . . . . . . . . . . . o . . . . . . . . . . . . . . . . . . . . 2980
cooling element . . . . . . . . . o . . . . . . . . . . 0 . . . . . . . . . . . . . . . . . . .
Exhaust-gas turbocharger M .A .N . (e .g . NA 57) . . . . . . . . . . . . o . 0 . . . . . . . . . . . . . . 2820
BBC (e .g . VTR 631) . . . o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4100
Complete engine 5 cylinder . . . . . ... . .... . .. . .. . . . .. . ... . .. ... . . . . . . . . . . 310000

6 cylinder . . . . . ... . .... . .. . .. . . ... .... ... .. . . . . . . . . . . . 360000
7 cylinder . . . . ... . ... . . .. . .. . . . ... . .. ... ... . . . . . . . . . . . 430000
8 cylinder . . . . ... . ... . . .. . . .. . . .. . ... ... .... . . . . . . . . . . 475000
9 cylinder . . . . ... .... . . .. . .. . . ... . .. . .. . .. . . . . . . . . . . . . 520000
10 cylinder . . . . .. . . .. . . . .. . ... . ... .... .. . .. . . . . . . . . . . . . 570000
0: D36 5612 E 1 .7-3

0
0
TECHNISCHE DATEN I
TECHNICAL 'L"'AT A I
SSp i eel KSZ 70/125B
0 1 10
Fertigungs- Spiel
MeBstelle NennmaB spiel flax . clear , Bil d
reasuring po .,nt Dimension Clearance ance Figur e
when n e
Kolbenstangen-Stopfbuchse A 220 H7 -
(015) B 1,5 tO,3* -
C 0,8 10,3* -
Piston rod stuffino bo x
D 2,5 ±0,3* - -
(01 5)' K
0,0 1 1 B,
E -14,96 + - - H
- 0 , 02
N
0
StoBsplel neu und F 0,11 0,18 0,40
E-
minimales Sto8spiel G 15,08 +0,02
+0,0 2
Gap clearance new and H 11,86 R
-0 , 01
admissible minimum i - 0,10 0,1, 0,3 0 T
.K 11,98 +0,02 - C
L 2
2 36403461 2
0 3
0 2, 5
P 4
R 17,05 +0,02 -
S - 0,21 0,29 0,40
17 -0,1 6
T -
-0 , 22 f I
Kurbelwelle (020) Wancenatmung max . zunssig 0,45 mm, slehe Arbeitskarte 000 .1 0
Crankshaft (020) Crank web deflections nax . admissible 0 .45 see work card 000 .1 0
Drucklager (017) A 550 -0,0 5

(500 -0,06) -
Locating bearing -
B 0,15-0,175 0,2 5
(0,14-0,19) - c
VaB in ( ) bei 5+6-2y- . LA -
C - 0,30-0,3 5 0,4 5
linder-Motor - -
(0 , 28-0 , 38)
Dimensions in with D - 1,00 1,50
5+6 cylinder engine E 194 2:0,05 - -
(230 ±0,05) - - B J
0 - -
F 1180 ±0,5
(1066 ±0,5) - - D E
36 40 346/2
Kurbelwellenlager (021) A 550 -0,06 - -

6 - 0,15-0,225 0,3 0
F-lain bearino (021)
C - 0,30-0,45 0,60
- 0 0
D 330
c
R 0 A 0 e
r
B
36 40 346/2
0
C-4
Co siehe ROckseit e
LO D36 5612 D+E 1 .10-2 p .t .o.
kertigungs -
VeBstelle NennmaB spiel 11-ax . Spiel Bil d
Veasuring point Dimension Clearance ~,ax . clear- Figure
when new 3nce
0
Trelbstangenlager (030) A 550 - 0,06 -
B - 0,215-0,28 * 0,3 5
Connecting rod bearing
C - 0,32-0,45 0,6 0
(030)
D 312 C~j
* 50 mm unterh2lb de r rIN
C
Trennfuge gemessen CD
Measured 50 mm lower 'A
8 B
than parting lin e
Kreuzkopflager (030) A 400 +0,06 - -

+0104
Crosshead bearing (030) B - 0,11 - 0,19 0,2 5
0,18 - 0,21 0,25
* gemessen in Lagerschale C
C 0,24 - 0,38 0,50 E -
measured in shell D 178 - a - L -
F F~
oemessen im Lagerdeckel E 760 ±O, 2 PIN
measured in cover B a
F - 0,10 - o,6o 0,8 A
i
0
G 760 ±0,2 -
G 'le -itschuh (031 ) A 500 +0,06 -

B - 0,10 - 0,14 0,20 j E
Cuide shoe (031)
C 499,8 -0,02 F',
D 65,05 +0,05 - I!
C
0,20 - 0,27 0,30 B
F 64,85 -0,02 -
Kolben (040) A 694,5 10, 1

B 698,0 -0,2 - - rG
Piston (040) - M H
C 699,0 -0,1 0,3*
D 698,6 -0,1 - -
max . VerschleiB
1 220 f7 - H
B K j
admissible max . wear F 0,15 -0,20 - - 2
G 12,4 H7 - 2,0* K is
H - 0,416-0,461 1,2 L
~, 4
J 12 f8 -
K 12,3 H7 -
L - 0,316-o,361 1,0
M 5,7 +0,5 20
N 3 x 17 -
40
1 x 29 C-
P
IR
0 12,15 +0,1 -
P - 0,166-0,293 0,4
R 12 f8
KolbenringUberl2uf A 93 +0, 3 A
Top ring-travel position B
130 <
C 12,4
C3
7
0
L~~364170611
D36 561 2 D+E/I . 1 0-2
TECHNISCHE DATEN
I I
TECHNICAL DATA
M *Ak* 14 KSZ 70/125 B
S pie l e
0 Clearances 11
Fertigungs- I
MeBstelle NennmaB spiel Max . Spiel Bil d
Measuring point Dimension Clearance M2X . clear- Figure
when new ance
Zylinderbuchse (050) A 704, 2

A
P3 0
Cylinder liner (050) B 40 10,20
C 700 H9 4, 5
max . VerschleiB /_c _
1 ,5
0:* Z5
max . wear Z5
D 2, 1
max . Ovalit9 t
max . ovality
0 COD
OR
Steueruncsantrieb (100) A 280,1 H6 -

B - 0,156-0,240 0,35
Camshaft drive oear (100) JH G
C 280 f7 -
A l
D 200,4 H 7 - 13 - D
E K
E - o,4oo-o,475 0,60 C IF L
F 200 h6 -
G 150 H7 -
H - 0,04-,;-0,123 0,2 0
J 150 f7 -
K - 0,16-0,27 0 .4 0
L 200 h6 -
M 120 H7 - 0
N - 0,06-0,10 0,20
N M x
0 200 H7 -
P - 0,100-0,192 0,30 0
0 R 200 e7 - F717
+o,65 R v
S 370 +0,45 - -
- V
T 0145-0,85 1,2 0
U 370 -0,2 - -
- U T S
• Zahnspiel V - 0,2,;4 35*
• Gear backlash W - 0,20-0,30* -
X - 0,15-0,20* -
I I
AnlaBschieber (160) A 24 H7 -
B - 0,025-0,030 0,050
Starting air pilot valve B
C 24*
(160) D 50 H7
- 0,40 D
E 0,200-0,325 E
F 49,8 -0,1 - F
G 40 H7 - -
• eingepaBt H 0,0504,100 0,1 5
• fitted by hand 1 40 - -
** mit Gleitlack beschicht K 18 D 7 H
L - 0,027-0,056 0, 15
with antifriction M 18 n6 - - a~j ::I- KJL
overlay N M
N - 2,5
0 0 - 0,1-0,3 36 40 346/ 3
C%4
0~ siehe RUckseite
to I D36 5612 D+E 1 - 1 1 .11-2 , I p.t .o .
fertigungs - Max . Spi e l
MeBstell e Nennma B spie l
Max . clea r - Bil d
Measuring point Dimension Clearanc e ance rigur e
when new
165 +0,1 5 0
A
Umsteuervorrichtung (120) -0,1 0
B 350 H7 - L M
Reversing gear (120) -
C 0,500-0,607 - H,
- JA
D 349,5 -0,05
K'
E 8 f7 -
F - 0,038-0,075 0,1 5
G 8 E8 - S
H 4 E8 -
J - 0,03-0,06 0,10 B
- 0
K 4 f7
X.
L 160 H7 w
A
M 0,30-0,4 4
TU V
160 -0,3
N
4
0 50 H7-0 , C A7,7 1
P - 0,025-0,075 0,15 E F G 36 40 346/ 3
R 50 f7 -
S 35
T
U
33 +0,1 3
- 0,2M,38 0,50
40
-0,2
V 33 -0,25 -
W 120 E7 -
X - 0,072-0,129 0,2 0
Y 120 h6 -
Einspritzpumpe (200) A 50 H7
B 0,023-0,02 5
Injection pump (200)
C 50
D 104 D6
E - 0,120-0,164 0,30 A
B
F 104 h6 - C
F
G 91 D6 - - D_
H - J G
0,120 -0,164 0,30 H
J 91 h6 - -
K 15
+0,12
+0,10
-
K
0
L LL
0,10-0,15 0,20 im
F, 15 -0,03 -
beide Teile sind zu- N 4, 6
sammengel~ppt 0 15H7 (14, 9+0 , 1 ) -
P 8 +0,0 1 -
both parts are lapped
R 45 H7 - N
S - 0,05-0,10 0,2 0 9 P
T 45 e7 - i l
S
Tt* R
36 40 346/3
40
D36 5612 D+E/1 . 11-1 1
TECHNISCHE DATEN I
TECHNICAL DATA 1
M *A&* M KSZ 70/125 B
Spiele
0 Clearances 12
Ferzigungs -
VeBstelle NennmaB spie l Max . Spiell Bil d
Mle2surino point Dimension l Clearance Max . clear Figur e
1when new ;,nr p
Antrieb der EinspritZ- A 195 -010,10

0094 -
pumpe (201)
B 0,1016-0,321 0,50
A
Injection pump drive (201) 195 -0,30 B
C
-0,33 C F
• MeBbereich +0,24 - G - D
D 75 +0,21
• Rance of measure
E - 0,177-0,220 0,3 0
F - 36 40 346/3
75 n5
G 0,4 - 0, 9
H 14
i 85 +0,1 - F j!
- E
K 0,4-0,6 1,0
0 L 84,6-0,1 - LK J
Antrieb fUr Zylinder- A 1,0 1,5 S-

schmierpumpen (302) - C
B 60 +01099
0 D1 -
Cylinder lubricator drive C - 0 , 1~1-0 , 27 0,30 A
(302) D 60 d9 -
E 45 H7 -
- tE
F 0,025-0,075 0,10
F
• Zahnspiel G 45 f7 - 'G
• Gear baci,lash H - 0,4-0,9 1,5
*J - 0,10-0,24 -
J
0 Schmierpresse fUr Kreuz- A 3,5

kopilacer (303)
B 2,5 +1,0
Pressure lubricator for -0,5 A
crosshead bearing (303) C 28 , 7
B
D 26 H7 c
K
E 0,010-0,020 -
D
F 26 -
E
G 30 E8 - F X
H 0,0112-0,058 0,10
* beide Teile sind zu- J 30 n6 \III
sammencel"oppt K 25 E8 -
GJ
L 0,025-0,071 0,10 H
both parts are lopped -
M 25 k6
L
K
G Hi GH J
Oz D36 5612 D+E 1 .12-2

0
0
M .A . N . 2-stroke 1
M *AGk* P4 DEFIN IT IONS Diesel Engines
0 20
D ef initians
The terms commonly used in the engine building industry are defined in sheet 6265 DIN
Standards and the international standards ISO 1205-1972 and ISO 2276-1972 as well as I
in sheet Q1 0 . 09211 -1050 M .A . N . Quality Standards . A definition of some of thes e
terms as far as they are used in the printed material of our Diesel engines is given hereunder .
Designation of the Cylinder s
The cylinders are designated by numbers only, numbering is consecutively 1, 2, 3 etc .

starting from the coupling end .
In-line engin e
Designation of the Direction of Rotatio n
The direction of rotation of the crankshaft is clockwise when it is rotating in the direction
of rotation normal for the hands of a clock when looking on the coupling end, and it is
counterclockwise when it is rotating in the direction opposite to clockwise . In the case of
reversible marine engines, the designation of the direction of rotation is determined by the
direction of rotation at ahead way of the ship .
Definition of Left-Hand and Right-Hand Engin e

0 For the definition of "Left-hand engine" and "Right-hand engine", the location of the
exhaust side of the engine is the deciding factor . The engine will beknown as a left-hand
engine when the exhaust manifold is mounted on the left side, or as a right-hand engine
when it is mounted on the right side when looking on the coupling end .
To p
r1i lefthand '. engine righthand engine engine sides

N
D36 5600 E 1 .20-2
P .t .o .
Designation of Crankpins, Shaft Journals and Bearings
Crankpins and crank bearings are designated by numbers (numbering consecutively 1, 2, 3,
etc .), starting from the coupling end in the same way as the cylinders, the shaft journals 0
and main bearings by 1, 11, 111, etc . Journals of locating bearings and bearing shells are
designated by a combination of the figures zero and the respective Roman numeral, e .g .
01, 011, (cf drawing) . Special attention is directed to the fact that Roman numerals (1, 11, 111)
are used for shaft journals and main bearings, whereas Arabic numerals (I , 2, 3) are use d
for the designation of crankpins and crank bearings .
coupling flange connecting flange K S
thrust bearing flange connecting flange
KG S
I
01 011 1 av vi, _V1Y7-r)Vn1_
W
N'-~_L/ 1-/
thrust bearing pin crankpin No .
shaft journal No .
0
Design with I bearing only
\-~_L/
Designation of Engine Side s
The coupling end of the engine is the end where the main power is taken off, connecting the
propeller shafting, a generator, etc .
The free end of the engine is the front side of the engine opposite the coupling end .
The left side of the lefthand engine is the exhaust side .
The_right side of the righthand engine is the exhaust side .
The control side is the side where the injection pumps and the camshaft are mounted (opposite
tz) the exhaust side) .
The exhaust side is the side of the engine where the exhaust pipes are located (opposite to
40
the control side) .
0t h e r T e r m s
Reversible engine- The direction of rotation of the crankshaft can be reversed . This is
normally achieve by axial displa6ament of the camshaft by a reversing mechanism so that
another set of cams is being engaged .
Supercharged engine . One or more turbochargers (consisting of a turbine and a compressor),
driven by the engine exhaust gases, supply the air required for combustion at greater than
atmospheric pressure . Non -supercharged engines are no longer included in our building program .
Dual fuel engine . It can be operated on liquid fuel or on gas (natural gas, city gas, sewe r
gas, etc .) . When run on gas, burning is initiated by the injection of a small charge of liquid
fuel, the so-called pilot fuel .
Gas-Otto-engine . The engine is operated on gas (natural gas, city gas, sewer gas, etc .)
ignited by an electric spark .
0
D36-5600 E / 1 .20-2
1
M+Ak*F4 QUALITY REQUIREMENTS FOR
M .A .N . DIESE L
DIESEL FUEL 21
0
Diesel fuel is a comprehensive term for gas oil and Diesel oil . Diesel oil is also known as
Marine Diesel Fuel, MDF, li .qht boiler oil, or heavy distillate . The usability of a fuel in
a given engine depends on the engine design and the fuel characteristics . The fuel should
meet the limiting requirements listed below, which conform to international specifications
and apply to the condition of the fuel on delivery .
Diesel oil can be used if the engine and fuel treatment facilities are designed accordingly .
Designation Gas Oil Diesel Oi l
Densit at 150 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g/ml < 0 . 86 < 0 .91 5

Viscosity at 20' C . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm2/s <8 <1 7
cst <8 <17
Behaviour in the cold Pourpoint . . . . . . . . . . . . . . 0 C a+ - 6 a+ - 6

0
Cloudpoint . . . . . . . . . . . . . 0 C ++ +-F
FlashpLint as per Abel-Pensky . . . . . . . . . . . . . . . . . . 0 C > 55 > 55

(fire safety regulations must be observed )
Distillation range, Vol . recovered at 3600 . . . . . . . . % Vol > 90 > 70
End point . . . . . . . . . . . . . . . . . . . . . . . . . 0 C <38 5
Percentage of Sediment . . . . . . . . . . . . . . . . . . . . . . . % wt < 0 .01 < 0 .05
Water . . . . . . . . . . . . . . . . . . . . . . . . . mgAg < 500 < 2500
Sulphu . . . . . . . . . . . . . . . . . . . . . . . . % wt < 0,5 < 1 .80
Ash . . . . . . . . . . . . . . . . . . . . . . . . . . . % wt < 0 . 02 < 0 .02
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nil ni l
Conradson Carbon Residue (CCR) . . . . . . . . . . . . . . . % wt < 0 .15 < 1 .50
(Gas oi I on 1 0% Bottoms )
Cetane number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . > 40 .. > 35
0 Specifications . . . . . . . . . . . . . . . . . . . . . . . . ASTM D 396-67 T . . . No 1+2 No 4

D 975-68 T . . . No I D+2D No 4D
BS 2869: 1967 . .. CI .A1+A2 CI .B1+B 2
IS 1460: 1968 ... Grade A Grade B
+ a = Temperature at which fuel is stored .

Heat fuel if the stated pourpoint cannot be maintained .
++ Cloudpoint below fuel temperature before inlet to filter .
A Cetane number of > 45 is desirable, particularly at low ambient air temperature and
at high altitudes .
Against reimbursement of the net cost, our

0 chemical laboratory will analyse fuel oil sent
in by our customers . A sample of about 1 litre
is required.
D36 5600 E 1 .21 -1
0
0
QUALITY REQUIREMENTS FOR KSZ
M*J3L*M HEAVY OIL FOR TWO-STROKE
0 ENGINES 23
(Heavy oil is also . known as furnace oil, boiler oil, fuel oil,
intermediate fuel, bunker oil C, mazout lourd )
Heavy oil generally consists of distillation or cracking residues of crude oil blended with
distillation products .
The mixture should be homogeneous and stable even after long storage, and it must not have
any corrosive effect on the injection equipment .
The following specifications refer to the properties of the heavy oil as supplied .
Recommende
~1 d Spec.-limi t
.) (2. )
Densit at -.1 -59C 9/m1 0.980 0.990

2 380 600
Viscosity mm /Pcst/00C
(3500) 000)(3 .)
(sec .Redw .VIWF )
Sulphur content wt percent 3.0 4. 0
Conradson Carbon Residue
10.0 15 .0
wt percent
Vanadium content ppm - -
Sodium content ppm -
Water content vol percent cO . 2 1 .0 (4. )
Cetane number ofdistillation a-40 3-35
pi~oduct adaed
Flashpoint in closed cup OC z-65 -65 (5 .) -
int (6.) (6.)
I .) The recommended values are based on experience gained with various ensine. models .
In general, they will ensure economical engine operation .
2 .) Heavy oils coming close to the sip ecified limits should, if possible, only be used under
favourable service conditions ( continuous operation without extreme cr frequent load
changes, close attendance and careful malntenance~ otherwise the intervals between
necessary maintenance operations will become shorter and wear, i .e. extent of spare
parts required, wl I I become greater .
CD
92.
S-
3 .) The admissible maximum viscosity of the'heavy oil intended for use in a given plant de-
pends on the existing fuel heating facilities and fuel treatment plant (Separator plant) .
Recommended heavy oil viscosity range at inlet of injection pumps :
V)
mm2~s = cSt sec

.Redw . I E
Two-stroke engines 12- 16 60-75 2.0-2. 5
If the heavy oil quality reaches the limiting specifications stated in the table above,
the fuel viscosity is to be kept at the low limit .
p. t. 0.
0 Against reimbursement of the net cost, our chemical
laboratory will analyse heavy oil sent in by ou r
%0 D36 5600 E 1 .23-1 customers. A sample of about 1 litre is required.
4 .) The water content must be less than 0 .2 % by vol . Every effort should be made to re- 0
move the water, particularly as it is frequently sea water, to the best possible degree
(most effectively with centrifugal separators) .
5.) Fire safety regulations must be observed .
6 .) The lowest permissible temperature for heavy oi I is I OOC above the pour"06irit' 0 C) to,
ensure troublefree fuel delivery .
Genera I
If the density of the heavy oi I exceeds 0.99 g/cm3 , the separator (centrifuge) will no
longer be able to remove particularly water and, to a certain degree, solids effectively .
Careful treatment of fuel oils having a high viscosity is, therefore, all the more essential .
The flow rates through the separator, which are dependent on the viscosity and temperature
at the point of separation, specified by the engine builder and the separator manufacturer
should not, under any circumstances, be exceeded (also see sheet D36 5600 E/3 .22) . Special
care should be used in the case of asphalt ~-bcse oils as are sold, for example, on th e
West Coast of the United States . is
The use of changeable tanks is not recommended . If fuel storage tanks in ships are used as
changeable tanks for trimming and stabilizing purposes, a demulsifier must be added to the
heavy oil either when bunkering or separating the oil to prevent the seawater from forming
an emulsion with the heavy oil .
For additional information write to M.A . N . Augsburg, Abtei lung QB (our department for
fuel and lubricants) .
D36 5600 E~l

VISKOSITXTS-TEMPERATUR-DIAGRAMM ,,,.
I J .A .N .-DIESEL
M *Atk* M VI.SCOSITY TEMPERATURE DIAGRAM
0 (VI 70 - 80) 25
AS* 0 1/z 0" POPPOMA *14mmuf)l - 9SP-IA 014--CIAP-IA 01PI D1 - 04PYlA "Jw-ul)l
I
0
Co Beispiel siehe RUckseite
N~
rz D36 5600 D+E 1 .25-1 Example please turn over
Bestimmung der Anwörm- und Separiertemperatur von Schweröle n
Beispiel : Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KSZ 901160 B

40
Empfohlene Viskositat . . . . . . . . . . . . . . . . . . 16 mm2/'S .. a cSt
Schwerbiviskosittit . . . . . . . . . . . . . . . . . . . . . . 180 mm2/s 4 cSt/509C
Anwörmtemperatur . . . . . . . . ca . 1 150 C (388 K)
Separiertemperatur Purifikator . . . . . . . # .00 .9#40 . ca . 940 C (367 K)
Klarifikator . . . . . . . . . 0 . . . 0 .4 . ca . 97 0 C (370 K)
Pumpfuhigkeit noch bei . . . . . . . . . . . . . . . . . . . . . . . ca . 240 C (297 K)
Hinweis fUr Projektierung

Das Viskositöts-Ternperatur-Diaqramm ist fur einen Viskosittits-Index (V1) von 70 - 80 auf-
gezeichnet .
Fer die Auslegung des Enderwarrners nur dieses Diagramm verwenden . Zu der ermittelten
Anwörmtemperatur abhönaig von der Viskositöt, dann 109C hinzurechnen . Damit ist End-
erwörmer so groß ausgelegt, daß Verminderung der Hetzleistung durch Ruckstandsbildung
0
sowie Temperaturabfall* in langen Leitungen vom Enderwörmer zum Motor oder höhere
Schwerölviskositat als bei der Projektierung zugrunde gelegt wurde, ausgeglichen werden
können .
Determinatton of temperatures of heavy fuel oil for separation and heating
Example : Diesel engine .. . . . . . . . . . . . . . ......... KSZ 901160 B

Recommended viscosity . . . 16 mm F/s A cSt
Heavy fuel oil viscosity . . . . . . . . . 180 mml/S . cstl5ec
To be heated up to . . . . . . . . . . . . . . . . . . . approx . 0
115 C (2309F)
Requisite temperature forpuriffer . . . . . approx . 940 C (20doF)
c1crifier . . . . . approx . 97 0 C (2060F)
Can stil I be pumped at o a e . . . 00 . . . approx . 240. C t750F)
0
Planing not e
The viscosity-tempercture diagram is based on the viscosity index (VI) of 70 to 80 .
Only this diagram should be used when choosing the rating of the final fuel heater . The
temperature to which the oil is to be heated up should be determined as a function of its
viscosity and 109C then added . Sufficient allowance is thus made when choosing the heater
rating so that compensation can be made for any diminution of heating capacity due to the
formation of residues, for any drop in temperature in long pipes running from the heater to
the engine or for a higher viscosity than was anticipated during the planing stage .
40
D36 5600 D+E / 1 .25-1 .
QUALITY REQUIREMENTS FOR LUBE 1
0 M *AGk* M OIL FOR TWO-STROKE ENGINES KSZ
RUNNING ON HEAVY OIL 34
The following lubricating oiles are used in two-stroke engines :

I . Running Gear Lubrication
I
A straight mineral lubricating oil or premium oil, highly resistant to ageing and comply-
ing with the specifications given overleaf in the paragraph on base oil, should be used .
We have no objection to the use of a multi-purpose oil having a mild cleaning (detergent)
and a distinct neutralizing effect (this oil type has been specially developed for piston-
cooling of more highly supercharged two-stroke crosshead engines) . The oil must not form
an emulsion with water . Use of this oil is advisable if appreciable amounts of leakage oil
seeping from the diaphragm of the entablature into the crankcase oil are to be anticipated,
promoting corrosion of bearings, journals and crankpins .
Lubricating oil of the SAE Class 30 should be used .
2 . Cylinder Lubrication
0
An alkaline lubricating oil should be used . When engine operation is changed over to
Diesel oil (Marine Diesel Fuel = MDF) for a short period of time, the cylinder oil need
not be changed . However, if the engine is run on a fuel with a sulphur content of less
than 1 .0 percent by weight (as is often the case with fuels bunkered in ports of the
People's Republic of China) for an extended period of time, cylinder lubrication must be
changed over to HD oil . Operation with highly alkaline cylinder oil in conjunction with
fuel of low sulphur content may lead to undue wear of cylinder liners and piston rings .
Lubricating oil of the SAE Class 50 should be used .
The alkalin!ty of a lubricating oil is indicated by the Total Base Number (TBN)'in accord-
ance with such standards as ASTM D 664 or D 2896 and DIN 51 596 . However, the power of
an oil to -neutralize acids cannot be inferred merely from the TBN unless additives of the some
~D
composition and concentration as in the reference oil are added to the oil in question . The
Le; high clka line reserve is necessary to neutralize the . sulphuric acids produced by the combus-
tion of heavy oi I (su lphur content up to 4 . 0 percent by weight). The neutralizing buffer ef-
fect not only reduces wear but also provides effective protection of the oil film and thus
curbs deposit formation on pistons and liners and In liner ports .
Fq
0
to
Lubricating Oil TBN
HD oil, normal additive level . . . . . . . . . . . . . . . . . . . . mg KOH/g 6 -1 0
HD oil with a higher additive level (SI to S3 oils) . . . mg KOH/g 10 -1 5
Medium alkaline oil mgKOH/g 25 -35
I.- Highly alkaline oil ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . mg KOH/g 60 - 100
The tendency of forming additive ash in the combustion space should be as low as possible
and the additive ash should be of soft texture, otherwise a higher wear rate and fouling of
liner ports are to be expected .
patoo .
Against reimbursement of the not cost our chemical laboratory

will anitlyse lubricating oil sent in by our customers. A sample
La
of about 1 litre is required. ,
I D36 5600 E 1 .34-1
Alkaline oils of differing structure and composition should never be mixed . If a changeover
is made from one type of oil to another, the cylinder lubricating oil pumps must be com- 0
pletely drained, otherwise damage may be caused due to the incompatibility of the different
components .
Oils are classified as follows, in accordance with their structure :
I . Single-phase Oi l
The alkaline reactive is completely dissolved in the base oil .
Appearance: lucid, dark .
2 . Dispersion Oil, Peptisation Oi l
The alkaline reactive is added to the base oil in a finely dispersed solid or gelatinous
form .
Appearance : opaque, turbid .
When using these oil types, observe suppliers' instructions for use . The composition of the
oil must be such that no seggregation of components will occur in service, otherwise cyl-
inders may not get enough oil or reactives, or pumps and tubes may become obstructed .
The lubricating oil must not form a stable emulsion with water .
Foaming characteristics (ASTM D 892) after 10 minutes < 20 m l
The base oil (premium oil or alkaline oil = base oil + additives) should meet the below
listed analytical minimum values, particularly in respect of its resistance to ageing . The
base oil should have been refined by means of an up-to-date solvent extraction process .
Crankgear Cylinder
Designation
Lubrication Lubricatio n
Viscosity at 500 C . . . . . . . . . . . . . . . . . . . mml/s !_t cst 60 -70 115 - 150

. E 8 - 9. 3 15- 20
Viscosity class SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 50
Viscosity index (VI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 98
Behaviour in the cold . . . . . . . . . . . . . . . . . still fluid 0 C -15 -15
flash2oint as per Marcusson . . . . . . . . . . . . 0 C > 200 > 200
Water content . . . . . . . . . . . . . . . . . . . . . . . . vol percent < 0.10 < 0 .10
Ash content . . . . . . . . . . . . . . . . . . . . . . . . . . wt percent < 0.02 < 0 . 02
Conradson Carbon Residue . . . . . . . . . . . . . wt percent < 0.50 < 0.50
Mineral acids and fats . . . . . . . . . . . . . . . . . . . . . . . . . . . . nil nil
Distillation loss as per Noack (DIN 51 581)wt percent 8 < 8
Ageing test . . . . . . . insolubles in normal pentane after 50 hours heating in the M . A . N .
age i ng box to 135110 C wt percent < 0 . 02
3 . Lubrication of BBC Exhaust Gas Turbocharger s

For lubrication of BBC turbochargers, observe manufacturer's instructions (see sheet
D36 5600E/I .36) . Usuall , age-r6sistant lubricating oils, predominantly turbine oils of
a viscosity of 30 - 76 =~s -t cSt or 4 - 10 E (depending on the charger speed) are re-
commended . Oils with a high additive package, e .g. alkaline lubricating oils, are un-
suitable .
4 . The Woodward governor and the hydraulic pneumatic positioner uses the some oil as is
used for cranl;j~r ubrication .
40
D36 5600 E / 1 .34-1
0 QUALITY REQUIREMENTS FOR FOUR-STROKE
'
COOLING WATER AND
MALM COOUNG WATER TREATMENT ENG INES
41
(
1 1A
0 BLW
ILI,4
I .GENERAL
The engine cooling water, like the fuel and lubricating oil, is a medium which must be carefully selected,
treated and controlled . Otherwise, corrosion . erosion and cavitation may occur on the walls of the cooling
system in contact with water and deposits may form . Deposits impair the heat transfer and may result in
thermal overload on the components to be cooled . The treatment with an anti-corrosion agent has to be
effected before the first commissioning of the plant . During subsequent operations the concentration
specified by the engine manufacturer must always be ensured . In particular, this applies if a chemical additiv e
is used.
2 . REQUIREMENTS FOR UNTREATED WATER

The characteristics of the water used must be within the following limits :
Note 1*dH (German hardness)
Type of water . . . . . . . . preferably distilled = 10 mg CaO in I litre of water
water, freshwater. = 17 .9mgCaCO3Aitre
0 free from foreign 0.357 mval/litre
matter 0,179mmoLlitre
Total hardness . . . . . . . max. 10*dH
pH value . . . . . . . . . . . . 6 .5- 8
Chloride ion content . max. 50 mgAitre
Not to be used : Sea water . brackish water, river water, brines, industrial waste water and rain water .
The MAN B&W watertest kit includes devices permitting, La ., to determine the above-mentioned water
characteristics in a simple manner . Moreover, the manufacturer of anti-corrosion agents are offering test
devices that are easy to operate . As to checking the cooling water condition, refer to work card 000 .07 .
SUPPLEMENTARY INFORMATIO N
If a distillate (from the freshwater generator for instance) or fully clesalinated water (ion exchanger) is
available, this should preferably be used as the engine cooling water. These waters are free from lime and
metal salts, i .e . major deposits affecting the heat transferto the cooling water and worsening the cooling
ef fect cannot form . These waters, however, are more corrosive than normal hard water since they do not
form a thin film of lime on the walls which affords a temporary protection against corrosion . This is the
reason why water distillates must be treated with special care and the concentration of the additive is to be
periodically checked .
0 The total hardness of the water is composed of temporary and permanent hardness . It is largely determined
by calcium and magnesium salts. The temporary hardness is determined by the hyd rogen-carbon content of
the calcium and magnesium salts . The permanent hardness can be determined from the remaining calcium
and magnesium salts (sulphates) . The decisive factor for the formation of calcareous deposits in the cooling
system is the temporary (carbonate) hardness .
Water with more than I O*dH (German total hardness) must be mixed with distillate or be softened . A
rehardening of excessively soft water is only necessary to suppress foaming if an emulsifiable corrosion
inhibiting oil is used .
3 . DAMAGE IN THE COOLING WATER SYSTE M

Corrosion is an electro-chemical process which can largely be avoided if the correct water quality is selected
and the water in the engine cooling system istreated carefully .
Flow cavitation may occur in regions of high flow velocity and turbulance . If the evaporation pressure is
fallen below, steam bubbles will form which then collapse in regions of high pressure, thus producing
material destruction in closely limited regions.
Erosion is a mechanical process involving material abrasion and destruction of protective films by entrapped
solids, especially in regions of excessive flow velocities or pronounced turbulences .
Corrosion fatique is a damage caused by simultaneous dynamic and corrosive stresses . It may induce crack
formation and fast crack propagation in water-cooled, mechanically stressed components if the cooling water
0 is not treated correctly .
D36 5600 E 1 .41-1 04 .97 Page 1 of 5

4 . TREATMENT OF THE ENGINE COOUNG WATER
0
Thepurposeof engine cooling water treatment is to produce a coherent protective film onthewallsofthe
cooling spaces by the use of corrosion inhibitors so as to prevent the above-mentioned damage . Asignificant
prerequisite for the corrosion inhibitor to develop its full effectivity is that the untreated water is satisfying
the requirements mentioned under point 2 .
Protecting films can be produced by treating the cooling water with a chemical anti-corrossive or emulsifiable
corrosion inhibiting oil.
Emuhlifiable corrosion inhibiting oils fall more and more outof use since, on the one hand, their use is heavily
restricted byenvironmental protectlion legislation and, onthe other hand the suppliers have, forthese and
other reasons, commenced to take these products out of the market.
Treatment of an anti-corrosive agent should be done before the engine is operated for the first time so as to
prevent irreparable initial damage .
It is not allowed to operate the engine without cooling water treatment .
S . COOUNG WATER ADDITIVE S

No other additives than those approved by MAN B&W and listed in Tables 8.1 to 8.4 on pages 4 and 5 are
permitted to be used . The suppliers are to warrant the effectivity of the cooling water additive .
Additives can only be used in closed circuits where no appreciable consumption occurs except leakage and 0
evaporation losses.
A cooling water additive can be approved for use if it has been tested according to the latest rules of the
Forschungsvereinigung Verbrennungskraftmaschinen (FVV), 'Testing the suitability of coolant additives for
cooling liquids of internal combustion engines' (FVV publication R443/1986) . The test report is to be pre-
sented if required . The necessary testing is carried out by Staatliche MaterialprOfanstalt, Department
Oberflachentechnik, GrafenstraBe 2, 64283 Darms.Tadt on request.
5.1 Chemical additives

Additives based on sodium nitrite and sodium borate, etc. have given good results . Galvanised iron pipes or
zinc anodes providing cathodic protection in the cooling systems must not be used . Please note that this kind
of corrosion protection, on the one hand, is not required since cooling water treatment is specified and, on
the other hand, considering the cooling water temperatures commonly practiced nowadays, it may lead to
potential inversion. if necessary, the pipes must be de-zinced .
S.2 Anti-corrosion oi l
This additive is an emulsifiable mineral oil mixed with corrosion inhibitors . A thin protective oil film which
prevents corrosion without obstructing the transfer of heat and yet preventing calcareous deposits forms on
the walls of the cooling system .
The manufacturer must guarantee the stability of the emulsion with the water available or has to prove this
stability by presenting empirical values from practical operation . If a completely softened water is used, the
possibility of preparing a stable non-foaming emulsion must be checked in cdoperation with the supplier of
the anti-corrosion oil or by the engine user himself. Where required, it is recommended adding an anti-foam
agent or hardening (see work card 000 .07) .
Antit-corrosion oil is not suitable if the cooling water may reach temperatures below O*C or above 90'C . Ifso,
an anti-freeze or chemical additive is to be used .
53 Anti-freeze agen t
If temperatures below the freezing point of water may be reached in the engine, in the cooling system or in
parts of it, an anti-freeze agent simultaneously acting as a corrosion inhibitor must be added to the cooling
water. Otherwise the entire system must be heated .
Sufficient corrosion protection will be afforded if the water is mixed with at least 35% of these products. This
concentration will prevent freezing down to a temperature of about- 220C The quantity of anti-freeze
actually required, however, also depends on the lowest temperatures expected at the site .
Anti-freeze agents are generally based on ethylene glycol . A suitable chemical additive must be admixed if
the concentration of the anti-freeze specified by the manufacturer for a certain application does not suffice
to afford adequate corrosion protection . The manufacturer must be contacted for information on the
40
D36 5600 E 1 .41-1 04 .97 Paq,~ 2. o f 5
compatibility of the agent with the anti-freeze and the concentration required . The compatibility of the
0 chemical additives stated In Table No . I with anti-freeze agents based on ethylene glycol is confirmed.
Anti-freeze agents may only be mixed with each other With the supplier's or manufacturer's consent, even if
the composition of these agents is the same .
Prior to the use of an anti-freeze agent the cooling system it to be cleaned thoroughly .
If the cooling water is treated With an emulsifiable anti-corrosion 61, no anti-freeze may be admixed, as
otherwise the emulsion is broken and oil sludge is formed in the cooling system .
For the disposal of cooling water treated with additives, observe the environmental protection regulations .
For information, contact the suppliers of the additives .
6 . PREREQUISITES FOR EFFICIENT USE OF A CORROSION INHIBITOR
6 .1 Clean cooling system

Before starting the engine for the first time and after repairs to the piping system, It must be ensured that the
pipes, tanks, coolers and other equipment outside the engine are free from rust and other deposits because
dirt will reduce the efficiency of the additive. The entire system has therefore to be cleaned using an
appropriate cleaning agent with the engine shut down (refer to Operating Instructions, Section 3, Sheet 28,
'Flushing the Engine Supply Circuits' or to work card 000-08).
Loo~e solid particles, in particular have to be removed from the system by intense flushing beca6se otherwise
0 erosion may occur at points of high flow velocities.
The agent used for cleaning must not attack the materials and the sealants in the cooling system . This work is
in most cases done by the supplier of the cooling water additive, at least the supplier can make available the
suitable products for this purpose . If this work Is done bythe engine user it isadvisable to make use of the
services of an expert of the cleaning agent supplier. The cooling system is to be flushed thoroughly after
cleaning . The engine cooling water is to be treated with an anticcorrosive immediately afterwards . After re-
starting the engine, the cleaned system has to be checked for any leakages .
6.2 Periodical checks of the condition of the cooling water and cooling syste m
Treated cooling water may become contaminated in service and the additive will loose some of its effectivity
asaresult . it is therefore necessary to check the cooling system and the condition of the cooling water at
regular intervals .
The additive concentration is to be checked at least once a week, using the test kit prescribed by the supplier.
The results are to be recorded.
The concentrations of chemical additives must not be less than the minimum concentrations stated in
Table 8 . 1 on page 4.
0 Concentrations that are too low may promote corrosive effects and have therefore to be avoided . Concen-
trations that are too high do not cause damages . However, concentrations more than double as high should
be avoided for economical reasons.
A cooling water sample is to be sent to an independent laboratory or to the engine supplier for making a
complete analysis every 3 - 6 months.
For emulsifiable corrosion inhibiting oils and anti-freeze agents the suppliers generally prescribes renewal of
the water after approx. 12 months. On such renewal, the entire cooling system is to be flushed, or if required
to be cleaned (please also refer to work card 000.08) . The fresh charge of water is to be submitted to treat-
ment immediately.
If excessive concentrations of solids (rust) are found . the water charge has to be renewed completely, and the
entire system has to be thoroughly cleaned.
The causes of deposits in the cooling system may be leakages entering the cooling water, breaking of the
emulsion, corrosion in the system and cal cartous deposits due to excessive water hardness . An increase in the
chloride ion content generally indicates sea
, water leakage . The specified maximum of 50 mg/kg of chloride
ions must not be exceeded since otherwise the danger of corrosion will increase . Exhaust gas leakage into the
cooling water may account for a sudden drop in the PH value or an increase of the sulphate content.
Water losses are to be made up for by adding untreated waterwhich meets the quality requirements
according to item 2 . The concentration of the anti-corrosive has subsequently to be checked and corrected if
necessary .
D36 5600 E 1 .41-1 Page 3 of 5

LneCK$ OT tne cooling water are especially necessary whenever repair and servicing work has been done in
connection with which the cooling water was drained .
7 . PROTECTIVE MEASURES 0
Anti-corrosive agents contain chemical compoundswhich may cause health injuries if wrongly handled . The
indications in the safety data sheets of the manufacturer are to be observed .
Prolonged, direct contactwith the skin should be avoided . Thoroughlywash your hands after use . Also, if a
larger amount has been splashed onto the clothing and /or wetted it, the clothing should be changed and
washed before being worn again . 1. 1
if chemicals have splashed intothe eyes,washwith plentyof waterand consult a doctor .
Anti-corrosive agents area contaminating load for the water in general . Cooling water must therefore not be
disposed off by pouring it into the sewage system without consulting the competent local authorities priorly .
The respective legal regulations have to be observed.
S . PERMITTED COOLING WATER ADDITIVES
8.1 Chemical additives (Chemicals) - containing nitrate
initial Minimum concentratio n

Manufacturer Product designation dosifica- ppm
tion per Nitrite Na-Nitrit e
1000 litre Product 0
W02) (Na N02 )
DrevvAmeroid Int . Liquidewt 15 1 700 1050
Stenzelring 8 Maxigar d 40 1 133 0 2000
21107 Hamburg DEWT-NC 4, 5 kg 2250 3375
nitor Chemicals Rocor NB Liquid 21,S I 1500 3600
KJEMI-Service A . S . Dieseiguard 4,8 kg 4800 3600
P. 0 . Box 49/Norway
3140 Borgheim NNW
Vecorn GmbH CWT Diesel/QC-2 16000 40000o. ,
161 600 0
Schlenzigstr. 7 1 N",V.I '
21107 Hamburg V
NalfleetMarine NalfleetEWTUq 31 3000 1000 .1" ':Y-5
Chemicals (9-108)
P.O. Box I I Nalfleet EWT9-131C 10 1 10000 100 0
Northwich Nalfleet EWT 9-111 10 1 10000 100 0
Ch eshi re CW8DX, Nalcool 2000 30 1 30000 100 0
U .K_
Maritech AS Marisol CW 12 1 12000 2000 300 0
PO BOX 143
S-29122 Kristiansta d
0
Mo-te* The values in the marked areas can be determined with the test kit of the chemical manufacturer. .
8.2 Chemical additives - free from nitrat e
Manufacturer Prod u ctdesig nation Initial dosification Minimum concentratio n

per 1000 litre
Texaco Havoline Extende d

Technologiepark Life Corrosion inhi- 751 7.5 %
B-9052 Zwijnaarde bitor (ETX 6282 )
Belgium
I I I I
0
D36 5600 E 1 .41-1 04-97 Page 4 of 5
8 .3 Emulsifiable anti-corrosion oi l
0
Manufacturer Product (Designation)
BP Marine, Breakspear Way . Hemel Hempstead, Diatsol M

Herts HP2 4UL Fedaro M
Castrol Int ., Pipers Way, Swindon SN3 IRE, UK Solvex WT 3
DEA Mineraldl AG, Oberseering 40,22297 Hamburg Targon D
Deutsche Shell AG . Oberseering 35,22284 Hamburg Dromus 6
Oil 9156
Texaco Soluble Oil CX
Technologiepark - Zwijnaarde 2 Soluble Oil D
8 9052 Gent/Zwijnaarde
I
8 .4 Anti-freeze agents with corrosion inhibiting effec t

0
Manufacturer Product (Designation)
BASF, Carl-Bosch-Str ., 67063 Ludwigshafen/Rhein Glysantin G 48

Glysantin 931 3
Glysantin G 0 5
Castrol Int ., Pipers Way, Swindon SN3 I RE, UK Antifreeze
BP, Britannic Tower, Moor Lane, London EC2Y 98U, UK BP KOhlerschutz
BPAnti-frost
DEA Mineral6l AG, Oberseering 40,22297 Hamburg DEA K(jhlerfrostschutz
Deutsche Shell AG, Oberseering 35,22284 Hamburg Glycoshel l
H6chst AG, Werk Genclorf, 84508 Burgkirchen Genatin extra (8021 S)
I Mobil Oil AG, SteinstraBe 5,20095 Hamburg Frostschutz 500
D36 5600 E 1 .41-1 04 .97 pa .je 5 of 5

0
0
ABGASTUIRBOLADER
EXHAUST-GAS TURBOCHARGER
TURBOCOMPRESSEUR A GAZ WECHAPPEMENT
TURBOSOBREALIMENTADOR DE GAS DE ESCAPE
SOBREALIMENTADORES
0 TURBOSOMANTI A GAS D1 SCARIC O
50
TECHNISCHE DATEN
TECHNICAL DATA
CARACTERISTIQUES TECHNIQUE S
DAMS TECHNICOS
DADOS TtCNICOS
0
DATI TECHNIC I
D36 5650 1 .50-1 11 .78

0
.j:;!" !11,,L" ~
0
TECHNICALDATA 1
NA 57
M *AOL* M Outline, Operating Data 51
0
Outlin e
Exhaust gas turbocharger with a single-stage axial-flow turbine and a single-stage radial-
I
flow compressor - two centrally located plain bearings with the turbine wheel and th e
impeller overhung - turbine wheel with rotor shaft is one-piece, impeller mounted - air
intake casing or silencer - compressor with one outlet socket - bearing lubrication
connected to engine circuit - bearing casing water-cooled .
Exhaust gas turbocharger . . . . . . . . . . . . . . . NA 57/M O

NA 571N0
NA 57/r O
Operating Dat a
Maximum permissible operating speed . . . . NA 57/MO . . . . . . . I/rpm 1430 0
NA 571NO . . . . . . . I/rpm 15000
is NA 57/rO . . . . . . . ]/rpm 15000
Exhaust temperature before turbine (see operating manual for .engine )

Lubricating oil pressure at inlet of bearing casing . . . . . . . . . . . . bar 1 .3-1 . 5
Required oi I flow rate (SAE 30/55 0 C or SAE 40/650C) . . . . . . . . M 3A 4 .6-5 . 2
Filtration of lubricating oil to contaminants smaller than . . . . . . mm 0.05
Highest admissible oil temperature at engine inlet . . . . . . . . . . . . ~C 65
Highest admissible cooling water temperature at outlet . . . 0 . . . 0 0 C 9 0
Cool i ng water flow rate at a t = 10 0 C . . . . . . . . . . . . . . . . . . . . . . m 3/h 4.1-5 . 6
See engine Acceptance Records for further operating data .
CN
9
~0
D36 5645 E 1 .51-2

0
0
1
M+A&* M TECHNICAL DATA
Pipe Connections, Weights . NA 57
52
Pipe Connect ion s
Type of turbocharger NA 57
Exhaust gas Inlet mm I x 500 dia .

Outlet mm 1370 x 540
Air Inlet (intake casing) MITI 1370 x 390

Outlet mm 1 x 350 dia .
Lubricating Inlet on bearing casing mm 38 x 2 . 5

oil Outlet on bearing casing MIT) 76 .1 x 2 . 9
Cooling water
Inlet on bearing casing ITIM 30 x 2
Outlet on bearing casing mm 30 x 2
W e i g h t s (approximations) kg
Gas admission casing with nozzle ring . . . . . . . . . . . . . . . . 395
Gas outlet casing . . . . . . 6 . .. ... 1120
-Bearing casing, complete . * * o s * . . . . . . . 6-00 . . . . 790
Bearing casing with rotor, complete . . . . . . . . . . . . . . 960
Compressor casing . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 800
Diffusor, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 a . . . . 400 140
Nozzle ring . . . . . . . . . . . . @ . .Of* 35
Rotor, complete . . . . . . 0 . . . . . v00** .* .0*.** . 170
Rotor,,,, . . . . . . . 0 0 . 0 . 6 0 0 . . . . . . . 0 . . . . & 0 0 0 . . . . . . . . . . . . . 0 . .' 105
-impeller o o o . . . . 0 . . . . . . 0 . . . . . 0 . 0 0 0 . 0 . 0 0 . . . 0 0 . . . . . . . . 06e . .e . 48
.Sj lencer.;~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . 0 . . . . . . . . . . . . 720
0 Casing feet . . . . . . 0 . . . *0 . . . . 0 . . . . 0 .0 * . . 0 . . 6 . 0 . . . . 0 . . . . * 170
.
Oiltank . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . 0 .00 60
Turbocharger complete with silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4365
Tools box with content . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 70
Spares box with content . . . . . . . . . . . . . . . . .. ..... 21
0
C)
Co
r4 D36 5645 E 1 .52-2 .
0
0
TECHNICAL DATA
..
M*J&+ IQ .. .1 . NA57
Gaps and Clearances ':--: 53
Radial
do - di (mm)
2
Clearance = do - di (mm )
do = outer diameter
di = inner diameter
10 If wear at point (8) has been
checked and found to be in
order, dimension (10) need no t
be taken . The exact dimensio n
is obtained by means of a sof
t
metal imprint .
Check on each assembl y
Pos. in When now Replace or re-

fig. Designation of parts Part No. Gap Cl earance machine parts
min max. min. max . min. max .
+ 520 .035
Locating ring - sealing cover 0 .15 0.195 0 0 . 25
517.086
+ 5)7*075
2 Locating bearing - rotor shaft - - 0 .140 0 .182 - -
520 .001
(radial )
3 Radial bearing - rotor shaft 517 .055 -
- - 100180 0 .222
(radial) 520 .061
+-
4 Labyrinth ring (rotor shaft) - 520 .01 8
sealing cover 0 .15 0 .195 0 0 .25
517 .064
+ .520,!-001- 1
5 Turbine wheel - end cover 1 .0o 1 .1 0 0 .70 1 .50
501 .143 1
0 520 .001
6 Turbine wheel - shroud ring 0.70 0.90 0 .70 1 . 20
513 .008
+ 520 . 0~57
7 Turbine wheel - end cover 040 0 .50 0 0 .60
517 .067
8.Locating bearing - locating 517 .075 - 0 .230 0 .322 7 -
- ring (axial) 520 .035 - 1
9 + Impeller - labyrinth disc 5TOM-
.049
0.75 0 .85 - - 0 .75 1 .1 0
517 .089
520 .048
10 Impeller - Insert piece (axial) 1 .90 2.10 - - 2 .50
546 .051
11 Impeller- insert piece 520 .048
(radial) -546 . MI , 1 .10 1 .20 1 .5a
Admissible aberration from the plane of rotation of impelle r
(measured with dial -gouge at largest radial distance) 0 . 08 mm
Admissible eccentricity of turbine shaft (measured with dial gauge with the rotor
supported at centering points - first check the latter for cleanness) . 0 .02 m m
C)
~Q36 5645 E 1 .53- 2
0
0
SCHEMABESCHREIBUNGE N
KSZ 70/125 B
DESCRIPTIONS OF SYSTEMS
0 I
Inhaltsverzeichnis Abschnitt 2 To bl e of con-t ents section 2 Blatt Shee t
Kraftstoffschema . . . . . . . . . . . . . . . . . . . . . Fuel system . . . . . . . . . . . . . . . . . . . . . . 2 - 4

Schmierölschema (Motor) . . . . . . . . . . . . . . Luboi! system (engine) . . . . . . . . . . . . . 5 +6
Schmierölschema (Zylinder) . . . . . . . . . . . . Luboil system (cylinder) . . . . . . . . . . . . 7+ 8
Schmierölschema (M .A .N .-Turboloder) . . Luboil system (M .A .N . turbocharge~ . 9
Kühlwasserschema . . . . . . . . . . . . . . . . . . . . Cooling water system . . . . . . . . . . . . . . 10- 13
Anlaßschema . . . . . . . . . . . . . . . . . . . . . . . . Starting system . . . . . . . . . . . . . . . . . . . . 14+15
Regelschema . . . . . . . . . . . . . . . . . . . . . . . . . Regulation . . . . . . . . . . . . . . . . . . . . . . . . 16+17
Seewasserschema . . . . . . . . . . . . . . . . . . . . . Sea water system . . . . . . . . . . . . . . . . . . 20+21
0
M .A . N .-Abgasturbolade r M .A .N . exhaust turbocharger
Schmiertslscherna . . . . . . . . . . . . . . . . . . . . . Lubricating oil circuits . . . . . . . . . . . . . 51 +5 2

Kuhlwasserschema . . . . . . . . . . . . . . . . . . . . Cooling water circuits . . . . . . . . . . . . 52
.
Yorgeblasesteuerung . . . . . . . . . . . . . . . . . Control of auxiliary blowers . . . . . . . . 95-97
Woodward-Regler I Woodward govemor
D36 5612 D+E 2 .1-2

0
0
DESCRIPTION OF SYSTEMS
M*A&*M Fuel System
KSZ - B
2
0
Fuel Syste m
The following description together with the two illustrations is intended to show the
general operating principle of a typical fuel system . Insofar it does not take into
account plant-inherent requirements and any changes in the layout due to differing
design features of the appliances of the various manufacturers . The actual arrangement
of the appliances and the pipe layout will be seen in the plant drawing .
The Diesel oil is conveyed from the storage tank through a separator, in which it is
cleaned, to the Diesel oil day tank (32) . The heavy oil from the storage tank is first
conveyed to the settling tank (33) and from the latter to the heavy oil separators, in
which it is cleaned, and further to the heavy oil day tank (36) . Both the settling and
the day tank have heating facilities (38) . The three fuel tanks (32, 33 and 36) are
equipped with a sludge drain valve (41) at the lowest point .
Either Diesel oil or heavy oil, depending on the switch position of the four-way cock (40)
0 is supplied from one of the day tanks to the mixing tank (37) . The fuel is pumped by the
supply pump (43) through an end-preheater (44), a filter (45) and the viscosity measuring
device (46) to the admission surge tank (17) on the engine . Admission surge tank and
excess fuel surge tank (16) form a single unit with a common partition separating the one
from the other . A small tube connecting the two tanks permits any air or gas bubbles that
may have formed in the admission surge tank to escape into the excess fuel surge tank .
From the admission surge tank the fuel is passed through the header pipe (13),to the injection
pumps (I ) . Only part of the fuel supplied to the injection pumps is delivered by the pump s
to the injectors (I I ), the remaining portion is returned through the excess fuel pipe (1 2
the excess fuel surge tank (16) and the pressure retaining valve (15) to the mixing tank (37) .
This excess fuel serves to heat the fuel injection pumps, which are not equipped with heating
facilities, and thus to help maintain the required viscosity of the heavy oil .
The header pipe (13), the excess fuel pipe (12) and the injection pipes (7) are jointly
insulated with heating tubes (4 and 6) arranged in parallel . Either four or six buffer pistons
(3), depending on the number of cylinders in the engine, are provided in the surge tanks
and the supply pipes to reduce pressure pulses . Leakage fuel from the buffer pistons, the
0 pressure retaining valve and from the injection pumps is discharged through the leakage
pipes (20),and the leakage fuel from the fuel injectors through .the leakage pipe (10) .
If required, depending on the viscosity of the fuel intended for use, the leak fuel pipes and
the drip pans will also be provided with heating facilities .
Depending on plant requirements, the injection pipes may be of the jacket type . With
these pipes, leakage fuel from leaky injection pipes (7) will be collected in the jacket (8)
and drained through leak oil pipes (19) into a collecting tank which may be equipped with
a level switch for releasing a leak oil alarm .
The fuel supply pump sets (43) are duplicated, one to serve as a stand-by set . A single
filter is provided as a stand-by unit for the automatic service filter (45) .
Engines designed for operation on Diesel oil only are not equipped with heating facilities
and have no heavy oil tanks, no mixing tanks, no change-over cocks and no viscometer .
0
CD
OD
oZ D36 5610 E 2 .2-2
0
0
KRAFTSTOFFSCHEMA (MOTOR) I
FUEL OIL SYSTEM (ENGINE) I KSZ- B
3
0
11
1 Einspritzpumpp
2 Absperrventil
3 Pufferkolben
4 Heizleitun g
5 Abzweioleitunq
6 Heizleitun g
7 Einspritzleitun g
2 umrantelung ( HEnspritz- und
he i z le it unQ )
9 ~bströmIeitung (Heizleitung) 8
10 Leckleitung (Einspritzventil)
11 Einspritzverti l
12 lulbers'römleitunz
13 Verteilerleeitung M
1' . .',laufleiturg (Druckhalte-
ven' il )
0
15 '
Druckhalteventil
16 L',be r s-, rönwi ndk esse ',
17 Zulaufwindkessel
18 Zulaufleitun g
l'- (Einsprit,-lei-
unce r„,
20 Leckleitun,- (Einspritzpur,
pen2n'Lrieb und PL~fferkclbe,-.);
II Inject-ion pump
2 Stop valv e
3 Buffer piston
4 Heating tube
51 r5ranch (heating tube)
6 Fe2tina tub e
0 7 Injection pipe
8 Jacket (injection pipe and heating tube)
9 Discharge pipe (heating tube )
10 Leak oil pipe (injector)
11 In4ecto r
12 Excess
J fuel pip e
13 Feader pipe 26
14 D.,sch2rge pipe (pressure retaining valve )
15 Pressure retaining valve
16 Excess fuel surge tank
17 Admission surge tank
18 Supply pip e
19 Leak oil pipe (fuel injection pipes )
-270 Leak oil pipe (injection pump drive and buffer pistons )
D36 5610 D+E 2 .3-2

0
0
KRAFTSTOFFSCHEMA (ANLAGE) 2
M+Aak+m KSZ - B
FUEL OIL SYSTEM (PLANT) 2
4
0
31 Leitung vom Se rator 1 Pipe from separator

32 Dieselöl-Tagesrehälter 2 Diesel oil daily tank
33 Absetzbehälte r 33 Settle tan k
34 Leitung vom Vorratsbehälter 34 Pipe from storage tank
'z5
1 Leitung vom Separato r 35 Pipe from separato r
6 Schweröl-Tagesbehälter Heavy oil daily tank
7 Vdschbehlälte r ; 76 Mixing tan k
38 Heizleitung 38 Heating pipe
39 Dreiwegenahn 39 Three-way cock
40 Dreiwegeheh n 40 Three-way cock
41 Schlammablaßventil 41 Sludge drain valve
42 Leitung zum Separator 42 Pipe to separator
43 Förderpump e 4~ Supply pum p
44 Endvorwärmer 4 End pre-heater
45 Kraftstoffilte r 45 Fuel filte r
0 46 ViskositUtsmeßgerä t 46 Viscosity measuring equipment
031 D36 5610 D+E 2 .4-2

0
0
M*AAL*M Lubricating Oil System - K SZ 7-0/125 B
KSZ 78/155 B 5
0
Lubricating Oil System (Engine )
The bedplate (21 ) serves as collecting tank for the lubricating oi I dripping from the points
of lubrication . The oil is returned to the service tank (26) through two oil drain holes (22),
one on the drive end and one on the free end, in the case of 5 and 6-cylinder engines and,
in the case of engines with 7 or more cylinders, through an additional third drain hol e
which is arranged in or near the middle of the engine .
An electrically driven pump (28) draws the lubricating oil from the service tank (26) and de-
livers it through the cooler (29) and/or a by-pass pipe to the temperature regulator (30) and
further through the filters (31 and 37) to the header pipe (25) . The filter (37) is an indicator
filter monitoring the line filter (31 ) . The pressure regulating valve (27) is provided in a branch
pipe and has a drain pipe connecting the service tank (26) . The header pipe (25) of 5 and
6-cylinder engines extends the length of the engine, whereas two header pipes, one for each
engine half, extending to the left and to the right from the camshaft drive gear are provided
for engines with 7 or more cylinders . From the header pipe there is a branch pipe (24) to each
main bearing (23) . From the main bearings, part of the oil is passed through drilled passage s
0 in the crankshaft to the crank bearing (14) and further through the rifle-drilled connecting rod ~
to the crosshead beaflngs (12) and to the sliding surfaces of the guide shoe (13) . Crosshead
bearings require a high oil pressure to be able to develop the load-carrying fluid film as the
crosshead pins in the bearings perform an oscillating motion only . The high-pressure lubricators
(I I) provided for this purpose on each connecting rod receive the lubricating oi I through
transverse drill holes and deliver it through short delivery pipes (10) and drilled passages to
the crosshead bearings .
The thrust bearing (17) which runs in an oil both, receives the lubricating oil through the
supply pipe (15) branched off from the header pipe (25) . The oil level in the thrust bearing is
determined by the installation position of the oil return pipe (20) . The oil flow rate is set
during the test run by means of a throttling disc (16) fitted in the supply pipe (15), and the oil
f low can be checked at the sight 41ass (19) in the return pipe . Leak oi I from the crankshaft oi I
sea I is returned to the bedp late through the pipe (18) .
The pipe (7), branched off from the header pipe (25), connects the following branch pipes :
(33) to the bearings of the intermediate wheels, (8) to the entrainer bearings, (3) to the cam-
shaft bearings, cam tracks and roller tappets of injection pump drives, (2) to the injection
0 pumps, (I ) to the reversing Sear, and (5) to the governor and auxiliary gear drive . Branched
off from the pipe (32), which is also connected to the header pipe (25), are the oil supply
pipes to the spray nozzles (9) for the lubrication of the teeth of the timing gear wheels at the
point of mesh .Bearings and the teeth of the gearwheels of the driving gear of speed transmitter
and stroke counter are lubricated by splash oil flung from the timing gear into the drive gear
casing . The oil is returned to the timing gear casing through an overflow pipe and a short
drain pipe . The oil flowing from the drive gear of the injection pumps and from the camshaft
bearings is drained through the leakoil pipes (34 .and 35) into the crankcase and further into
the bedplate . The oil pressure in the luboil system is indicated by the pressure gouge provided
in the engine control stand and connected through the gouge tube (4) to the pipe (7) . The oil
temperature is monitored by temperature sensors and indicating instruments in the engine con-
trol stand . The fitting (6) in the branch pipe (7) serves for the connection of a control gouge .
The arrangement of the electrical supply pumps, coolers, filters and of the pressure regulator
differ from plant to plant and will be'seen in the layout plan .
The duplicated electrical oil supply pump ensures that should one set be failing the oil supply
can be switched to the other set so that the lubricating oil supply to the engine is largely en-
9 sured .
Co
Pl~
le D36 5612 E 2 .5-2
0
0
1
SCHMIERÖLSCHEM.A. (MOTOR)
M *Aftk+ M LUBOIL SYSTEM (ENG INE)
KSZ - B
1
6
0
35
34
I
0 33
32
31
30
29
1 Abzweigleitung I Supply pipe

(Umsteuervorrichtung ) Rocklaufleitung (reversing gear) 20 Return pipe
0 2 Abzweigleitung Grundplatte 2 Supply pipe 21 Bedplate
(Einspritzpumpe) Ulablauf (Grundplatte) (injection pump) 22 Oil discharge (bedplate)
3 Abzweigleitung (Nocken- Kurbelwellenlager 3 Supply pipe Main bearing
23
wellenlager, Nockenlauf- kzweigleitung (camshaft bearing, cams $ 24 Supply pipe (main bearing)
bahnen, Rollenstößel ) Verteilerleitung roller tappet) '25 Header pipe
4 Manometerleitung BetriebsbeWter 4 Gauge pipe 26 Service tan k
5 Zbzweigleitung Druckregelventil 5 Supply pipe 27 Pressure regulating valv e
(Hilfsgeräteantrieb) Pumpen (auxiliary drive) 28 Pumps
6 Anschlu ß Kohler 6 Connection (pressure 29 Coolers
(Kontrollmanometer) Temperaturregler gauge for checking) 30 Temperature regulatin g
7 Abzweigle4tun g Betriebsfilter 7 Supply pipe device
8 Zulaufleitun g Leitung (Spritzdasen) 8 Supply pipe 31 Service filte r
9 SpritzdUse (Zahnräder) Zwischenradlager 9 Spray nozzles (gear wheels) 32 Pipe (spray nozzles)
10 Druckrohr Leckleitung 10 Pressure pipe Intermediate wheel bearing
33
11 Schmierpresse (Nockenwellenlager) 11 Lubricator 3 4 Leak pipe (camshaft bearing)
12 Kreuzkopflager 35 Leckleitung 12 Crosshead be .aring 35 Leak pipe (pump drive)
13 Gleitschu h (Pumpenantrieb) 13 Glide shoe 36 Suction filte r
14 Trelbstangenlage r 36 Saugfilte r 14 Crank bearing
15 Zulaufleitung (Drucklager) 37 Indikatorfilter 37 Indicator filte r
15 Supply pipe (thrust bearing )
16 Drosselscheibe 16 Throttling disc
0 17 Drucklager 17 Thrust bearing
.,118 Leckleitun g 18 Leak pipe
V-
0] D36 5610 D+E 2 .6-2

0
0
KSZ 70/125 B
M *AfL* M DESCRIPTION OF SYSTEMS KSZ 78/155 B
Lubricating Oil System 7
0
Lubricating Oil System (cylinder)
Pistons and cylinder liners are lubricated with fresh oil supplied to the individual
lubricating points in the cylinders by individual pumps .
For each cylinder there is one lubricator (19) mounted on the control side of the engine
and driven through a small gear from the camshaft end through the rod (14), the common
drive shaft (16) and the link rod (13) . Each lubricator has 10 pump elements which supply
lubricating oil through the delivery pipes (24) and the 8 lubricating fittings (1) at the top
and the two lubricafing fittings (3) at the bottom of the cylinder liner (2) . The amount of
oil delivered depends on the engine load and is adjusted through the regulating shaft (15)
via the telescopic member (10) and the control shaft (11 ) . The delivery volume can be in-
creased or reduced for a I I pumps in common by means of the tommy screw (1 2) . The delivery
volume of the individual pump elements can be adjusted at the pumps (see work sheet in
section 4) . Delivery of the pumps can be checked at the flow gauges (23) fitted in the delivery
pipes (24) . Cylinder lubricators may furthermore be equipped with electronic flow controls,
0 releasing an alarm in the event of a pump failing .
The lubricators are continuously filled with lubricating oil from an overhead tank through
the supply pipe (25) . The oil level in the pumps can be checked at the sight glass (21 ) . Leak
oil, if any, is collected in the bracket (18) which is also designed to serve as an oil pan .
A drain pipe (17) with stop cock serves for draining the oil pan .
The lubricating fittings (1 and 3) in the cylinder liner (2) are designed as non- return valves
and thus prevent compression and combustion gases from entering the cylinder' lubricators
' .
The lubricators can be manually operated by means of the hand crank (20) for venting the
delivery pipes and for priming the engine after an extended period of standstill .
Each lubricator is equipped with a venting screw (22) at the top of the casing cover which
must be unscrewed when the oil consumption of the individual pumps is being measured .
0
P~
CIO LDU,
0
0
I
SCHMIEROLSCHEMA (ZYLINDER)
KSZ- B
LUBOIL SYSTEM (CYLINDER)
0
I Schmieranschiu3, oben 1 Lubricating fitting

2 Zylinderbuchse 2 Cylinder line r
3 SchmieranschluB, unten 3 Lubricating fitting
10 112Stisches FedergliedJO Telescopic membe r
11 Verstellwelle 11 Control shaf t
12 Knebelschraube 12 Ton, m y scre w
13 Verbindungsstange 13 Link rod
14 Stange (Antrieb) 14 Rod (drive)
15 Regelwell e 15 Regulating shaf t
16 Antriebswelle 1 0 Drive shaft
17 klauf roh r 17 Drain pipe
18 Konso l 18 Bracket
19 Schmierpumpe 19 Lubricator
20 Handkurbel 20 Hand crank
21 Schauglas mi t 21 Sight glass wit h
Keßskal a gaug e
22 Entloftungsschraube 22 Vent screw
0 23 Druckflu3kontrolle 23 Flow gauge
24 Druckleitung 24 Delivery pipe
25 Zulaufleituno 25 Supply pipe
0
0
DESCRIPTION OF SYSTEM S
M *Ak* P4 Lubricating Oil System KS Z
L u b r i c a t i n 9 0 i I S y s t e rn (Exhaust-Gas Turbocharger )
M .A . N . exhaust-gas turbochargers are connected to the lubricating oil circuit of the

engine (see sheet 2 .51 of this section) .
BBC exhaust-gas turbochargers have their own internal lubricating oil circuit (see separate
operating manual) .
I D36 561 .Q-E --- 22 -

.9-1
0
0
M*AIL*M DESCRIPTION OF SYSTEMS
Cooling Water System
KSZ- B
0
10
Cooling Water Syste m

The cylinders and cylinder covers are cooled by freshwater supplied to the individual
cylinders through a common header pipe (17) . Within the cylinders, the cooling water
is circulated round the cylinder liners, guided by ribs, in upward direction up into the
supporting ring and further through a bend (10) into the cylinder cover from which it is
discharged through the pipe (13) to the manifold (12) .
A small part of the cooling water is lead through the pipe (15) directly into an annular
channel in the I iner f lange from which it is discharged through the pipe (I I) into the pipe
bend (10) .
The cooling water from the lands (9) of the scavenge and exhaust ports is collected in an
annular space below the port belt and is returned through the pipes (18) and a manifold (16)
.to the el&vated tank (32) . Gate valves in the supply and discharge pipes driable the indi'vidual
40 cylinders to be* drained in the case of repairs through the drain pipe (19) after opening the
corresponding cocks .
The manifold (12) carries the cooling water to the electrically driven pump (35) for recircu-
lation via the temperature regulator (34) and the cooler (33) or, in the case of the cooling
water temperature being low, through a bypass pipe to the engine . The jacket-water pump
(35) is connected to the elevated tank (32) . The venting pipes (30) from_the cylinders,the dis-
charge pipes from land cooling and from the turbochargers empty visibly into the elevated
Jank .
Exhaust-gas turbochargers i both the engine mounted and the separately mounted, are
cooled by freshwater branched off from the manifold (12) . The cooling water is returned,
from each turbocharger separately, through the pipes (31 ) to the expansion tank .
The pistons are cooled by freshwater supplied through the header pipe (2) and passed through
the surge t nk (4) and delivered through one of the two telescopic pipes(6) and the telescopic
pipe carrier (7) into the crosshead (20) whence it is passed through the hollow-drille d
piston rod (8) into the cooling water space of the piston (14) . From the piston the cooling
0 water is returned through a pipe fitted in the center of the hollow-drilled piston rod to the
crosshead and via the telescopic pipe carrier, the second telescopic pipe and the discharge
surge tank to the . manifold (I) . Gate valves in the supply and discharge pipes at the bottom
of the surge tanks and a drain cock permit the individual pistons to be drained of cooling
water in the case of repairs .
The pressure pulses produced by the acceleration -and decebratior~ 'of the water columns?
as a result of the reciprocating movement of the telescopic pipes-inside the surge tank are
dampened by an air pad . The air necessary to build up and always maintain this air pa
d
is supplied by an-el'e-c'616ally driven water ring pG`mp_~vhich coHfinuoOtly-i.7eplai~6s-thd-cii~-
swept away by the water current . The air is supplied from the pump through the air supply
pipe (3) and the branch pipes with non-return valves to the surge tank of each cylinder . The
air supplied by the pump contains some of the sealing water of the liquid ring pump . To preven
sealing water from accumulaling and interrupting or cutting off the flow of supply air to the
surge tanks, there is a water trap provided at the lowest point of the air supply pipe .
is
0111 D365610E 2 .10-3 P .t .0 .
The cooling water is carried by the manifold (1) to the elevated tank (39) in which the
trapped air is expelled . From the elevated tank the cooling water is conveyed to the
electrically driven pump (38) which forces it through the temperature regulator (37) 0
and the cooler (36) or a by-pass pipe back into the header pipe (2) . See separate print
"description of air supply to piston cooling syste .m',' .
Separated corrosion inhibiting oil, if any, can be seen as a layer on top of the cooling
water through the sight glass (41 ) on the elevated tank (39) and should be drained into
the sludge tank through the discharge connection (40) .
The fuel injectors(66) are also cooled by freshwater . The water is supplied to the injectors
through the hea pipe (51 ) and branch pipes (67) and is passed through dri I I holes i n
the casing down to the injector nozzle . From the injectors the cooling water is returned
through individual discharge pipes (52) to the elevated tank (59) in which any leak fuel
the water may contain is separated from the water . The cooling water discharge from
the individual fuel injectors can be checked at the sight glass (58) . From the elevated
tank the water is conveyed to the electrically driven pump (64) which forces it through
the cooler (65) and/or the temperature regulator (56) and a bypass pipe back tothe
header pipe (51 ) . The cooling water supply and discharge pipes are provided with cocks
to facilitate repairs . * 40
The venting pipe (61 of the cooler empties into the elevated tank . Drain pipes (63)
provided at the lowest points of the cooling system as well as on the cooler and elevated
tank permit the system to be drained . Leak fuel or corrosion inhibiting oil separated from
the cooling water will show as a layer on the cooling water and can be seen at the
second sight glass (58) . It can .be drained through the discharge (62) into the sludge tank .
Each of the three cooling systems (cylinders, pistons, fuel injectors) have a stand-by
circulation pump . The elevated tanks are equipped with heating coils for heating the cooling
water and are provided with filling socket .
0
D36 5610 E / 2 .10-3
KUHLWASSERSCHEMA
(ZYLINDER + KOLBEN)
M*Ak* M COOLING WATER SYSTEM
KSZ 70/125 B
0
(CYLINDER + PISTON) II
1 Sammelleitung
(Kolbenkühlung )
12 13 14
2 Verteilerleitung
(KolbenkUhlung)
3 Belüftungsleitung
4 Windkessel
5 Stopfbuchse
6 Poswenrohr
7 Posaunenträger
8 Kolbenstange
9 Stegkühlraum
10 Ubertrittskrommer
(Zylinderkopf)
11 Ablaufroh r
(Bundkühlung)
12 Sammelleitung
13 Ablaufleitung
14 Kolbe n
0 15 Zulaufleitung
(BundkUhlung)
16 Sammelleitun g
(StegkUhlung)
17 Vertellerleitung
(ZylinderkUhlung )
'18 Ablaufleitung
(Stegkühlung)
19 Intleerungsleitung
20 Kreuzkop f
1 Manifold
(piston cooling )
2 Header pipe
(piston coolin o
3 Air supply pipe
4 Surge tan k
5 Stuffing bo x
6 Telescopic pip e
0 Telescopic pipe carrier
7
8 Piston ro d
9 Land cooling space
10 Bend (cylinder head)
11 Discharge pip e
(liner-collar cooling)
12 Manifol d
13 Discharge pipe
14 Pisto n
15 Supply pipe
(liner-collar cooling)
16 Manifold (land cooling)
17 Header pip e
(cylinder cooling )
18 Discharge pipe (land cooling)
19 Drain pip e
20 Crosshea d
D36 5612 D+E 2 .11-1

0
0
KUHLWASSERSCHEMA (MOTOR)
KSZ - B
COOLING WATER SYSTEM (ENGINE)
0
41
42
39
40
43
38
37
36 2 1
1 Sammelleitung (Kolbenkühlung ) I Manifold (piston cooling )

0 2 Verteilerleitung (Kolbenkühlung) 2 Header pipe (piston cooling)
12 Sammelleitung (Zylinderkühlung) 12 Manifold (cylinder cooling)
16 Sammelleitung (Stegkühlung ) 16 Manifold (land cooling )
17 Verteilerleitung (ZylinderkUhlung) 17 Header pipe (cylinder cooling)
30 EntlUftungsleitung (Zylinder ) 30 Venting pipe (cylinder )
31 Ablaufleitung (Turbolader ) 31 Discharge pipe (turbocharger)
32 Hochbehälter (ZylinderkUhlung) 32 Elevated tank (cylinder cooling)
33 Kühle r 33 Cooler s
34 lemperaturregier 34 Temperature regulating device
35 Pumpe n 35 Pump s
36 Kühle r 36 Cooler s
37 lemperaturregier 37 .Temperature regulating device
38 Pumpe n 38 Pump s
39 Hochbehälter (KolbenkUhlung) 39 Elevated tank (piston cooling)
40 Glablauf zum Schlammbehilter 40 Discharge to sludge tan k
41 Schauglas 41 Sight glas s
42 Uberlauf zum Sammelbehälter 42 Overflow to-collecting tank
43 Intleerung zum Sammelbehälte r 43 Discharge to collecting tank
I D36 5610 D+E 2 .12-4

0
0
KUHLWASSERSCHEMA
(EINSPRITZVENTILE )
M *Atk* M KSZ
COOLING WATER SYSTEM
(INJECTORS ) KEZ 13
67
66
I
0
63 65 - 64
51 Vertellerleitung 51 Header pipe

52 Ablaufleitun g 52 Discharge pip e
53 Druckluftanschluß (falls vorhanden) 53 Air pressure connection (if provided)
56 Temperaturregle r 56 Temperature regulating devic e
57 Uberlauf zum Sammelbehälter 57 Overflow to collecting tank
58 Schaugla s 58 Sight glas s
59 Hochbehälter 59 Elevated tank
60 Heizleitun g 60 Heating pipe
0 61 Dauerentlüftun g 61 Permanent ven t
62 Ulablauf zum Schlammbehälter 62 Discharge to sludge tan k
63 Intleerung zum Sammelbehälter 63 Discharge to collecting tank
64 Pump e 64 Pum p
65 Kühle r 65 Cooler
66 Einspritzventil 66 Injector
67 Abzweigleitun g 67 Supply pipe
c~ I D36 5610 D+E 2 .13-3

0
0
DESCRIPTION OF SYSTEM S KSZ- B
Starting System
14
0
S t a r t i n g S y s t e m
The engine is started with pressure air supplied from pressure air receivers through a main
starting valve and pneumatically operated starting valves in the cylinder covers .
The supply pipe (12) connects the pressure-air receiver with the main starting valve (2) on
the engine . The header pipe (6) with branch pipes carry the air to the starting valves (3)
in the cylinder covers . Part of the air is branched off and passed through the connecting
pipe (I I) to the starting pilot valves (10) arranged round the camshaft in the form of a star .
Each starting pilot valve connects through the control pipe (5) a starting valve (3) in the
cylinder cover . The gauge tube (8) branched off ahead of the main starting valve connects
a pressure gauge in the engine control stand .
When the shut off valves on the pressure air receivers are opened, pressure air is present at
the main starting valve . At the same time, control-air is supplied through control pipe (I
0
to the control piston of the main starting valve and holds the valve in closed position .
When the control lever in the engine control stand is moved into the range STARTING
(AHEAD or ASTERN), control pipe (1) is vented which causes the main starting valve (2)
to open . Pressure air is thus allowed to flow through the pipes (6 and 4) to the starting
valves (3) and through the connecting pipe (11) to the starting pilot valves (10) . The
starting pilot valves, which in the inoperative position are held off the common cam by
springs, are pushed down on the cam by control air pressure . The pilot valves',that are
standing over the flat part of the cam are pushed down so for that control-air pressure is
allowed to flow through pipe (5) to the connected starting valve (3) . The valve is opened
by control-air pressure and pressure air flows into the cylinders and forces the piston down
with the result that the crankshaft begins to turn . Thus, the camshaft is turned too and the
starting cam pushes the piston of the control valve towards the outside with the result that
control-air pressure to the starting valve is cut off and the control pipe (5) vented . The
pressure on the valve piston is released and the valve closed by spring force . The starting
periods of the individual cylinders are designed to overlap to ensure smooth rotation of the
crankshaft .
The starting valve (31 in the cylinder cover acts'as a non-refurn valve and closes when the
0
pressure rises at the beginning of combustion .
Depending on engine requirements, the system may be equipped with various interlocking
valves to prevent engine start-up, e .g . when the turning gear is engaged .
D36 5610 E 2 .14-3

0
0
ANLASSSCHEMA
M*A&*P4 STARTING SYSTEM
KSZ - B
15
7A
12 8
0
1.Steuerleitung (Hauptanla3ventil) 1 Control pipe (main s ttarting valve)

2 HauptanlaBventi l 2 Prain starting valve
3 AnlaBventi l 3 Starting valv e
4 Abzweigleitun g 4 Branch pip e
5 Steuerleitung (AnlaBventil) 5 Control pipe (starting valve)
6 Verteilerleltun g 6 Header pip e
7 En'LlOftunosleitung 7 Venting pipe
8 Manometerleitung 8 Gauge tub e
10 AnlaBsteuerschieber 10 Starting pilot valve
11 Verbindungsleitun g 11 Connecting pip e
12 Zustrbmleitung (Druckluftbe~~lter ) 12 Supply pipe (air receiver)
D36 5612 D+E 2 .15-2

0
0
KSZ- B
Da *A4!L* M Regulation
16
4
Re 9 u I a t i a n
Injection pump setting is controlled via the pump rocks and the fuel control linkage from th e
positioner (I I ) (see separate pamphlet " Engine Control and Monitoring System") . Th e
positioner is controlled from the Woodward governor, from the engine control stand and from
the automatic remote control system, and it can also be directly operated in an emergency,
the lowest setting overriding all others . The positioner incorporates various switches and
valves for monitoring and safe operation of the engine .
The pump rack (19) of each injection pump (20) is connected to the regulating shaft (9)
through the linkrod (18) and the hinged lever (17) . The hinged lever is designed in suc h
a way that it will give way in either of the two directions of movement when a given force
rating is exceeded . The lever thus prevents sticking of the fuel control linkage and thus of
all other injection pumps should one injection pump be sticking or seizing . The regulating
sbaft is seated in self-lubricating bushes and is connected via the lever (22) and the ro d I
~1 3) to the positioner (11) mounted on the gearbox of the camshaft drive gear . The positioner
0
is connected via the lever (10) and the rod (6) to the lever (3) of the Woodward governor (2) .
The pneumatic speed setting device (4) for presetting the desired speed is mounted besid e
the governor and is connected with it through the rod (5) . The Booster Servomotor (I ),
connected to the Woodward governor (2) supplies the governor with pressure oil during
start-up to enable the governor to assume its function as quickly as possible . The lever (7)
with the telescopic member (8), clamped onto the shaft (9),has the purpose of controlling
the delivery volume of the cylinder lubricators (see lubricating oil system) .
The shut-down cylinders (21 there is one on etich injection pump, serve to stop the engine
quickly and independently of other control gear settings in the case of emergency conditions
in response to a signal from the monitoring instruments mounted on the engine . In response to a
signal from one of the monitoring instruments, e .g . at failing lubricating oil pressure, pressure
air is admitted via corresponding control valves to the s hut-down pistons and the latter move
the pump racks (19) to STOP position . At the same time a signal is relayed to a solenoid moun .-
ted in the positioner (I I) so that also the fuel control linkage is moved to STOP . Should the
fuel control linkage for some reason not be moving to STOP, the hinged levers provided in
the linkage give way and thus take up the movement of the fuel control linkage acting'in--
0 the opoosite direction .
For running the engine by speed control, set control valve in engine control stand to maximum
setting and set desired speed to be maintained by the governor at the precision regulating
valve . The pump setting required to obtain the preset speed will then be controlled by the
governor .
When it is intended to run the engine by load control, the Woodward governor should be set
via the precision regulating valve in the engine control stand to rated speed and will then act
as a safety governor against overspeed . Now the control valve will give control of the in-
jection pump setting and can be set to the desired range .
In either case, control settings are relayed to the control valve in the positioner (I I) . Over-
run devices in the control valve linkage of the positioner allow for different pump settings
from the various control systems (Woodward governor, pneumatic setting from engine control
stand, electrical setting from automatic system and from the emergency control gear), with the
lowest setting' overriding all others .
0
N
t`1
CN 1 D36 5610 E 2 .16-2 p . t . 0.
Turnbuckles provided in the lever linkage from the Woodward governor to the positioner, in
the linkage connecting the latter with the regulating shaft, and in the linkage connecting a
the shaft with the injection pumps permit . accurate adjustment of the whole linkage . All
shofts and linkpins of the fuel control linkage are seated in self-lubricating bushes .
Caution 1
No attempt should be made to tamper with the fixed setting of the spindle (16) of the
emergency manual control as any changes of the setting will partially or completely blot out
control signals relayed via the positioner (I I) with the result that the Woodward governor,
acting as overspeed governor, and the shut-down devices acting via the positioner are out
of operation . The some holds when the turnbuckles are maladjusted .
As to the use of the emergency manual controls at the spindle (16) and the emergency control
gear (23) see section 3 .
40
0
!15o 5610 E / 2 .16-2
5 .77
01 8 9 10 11 12 13 14 15 16 17 .- 18 19 20 2 1
U1 - 3
C)
T
M ------- 0
43 -
z
7
6-- 23 22
1 Booster-Servomotor 1 Booster servomotor
2 Woodward-Regler 2 Woodward governor n
0 ;0
3 Rogler ebel 3 Governor lever M
5 z G)
4 Drelizahlstellger5t 4 Speed setting device 5J M
4 r-
5 Stange 5 Rod 0 V)
6 Verbindungsstange 6 Link rod r- 0
2-
3 7 Klemmhobol
!~ 7 Clamping lever r*vl
8 Elastisches Federglied 8 Telescopic member CA
9 Regolwelle 9 Regulating shaft
10 Hobel 10 Leve r
11 Slellger~t 11 Positione r
12 Wdhlhebel 12 Selector lever
NORMALBETRIEB-NOTBETRIEB NORMAL OPERATION -
13 Stange EMERGENCY OPERATION
3640342
111 Zeiger 13 Ro d
15 Verschalung 14 Pointer
16 Spindel(Nothandverstellung) 15 Cove r
17 Knickhebel 16 Spindle (emergenc y
18 Verbindungsstange manual control) 7K
19 Regelstange 17 Hinged lever (A
20 Einspritzpumpe 18 Link ro d
21 Abstellzylinder 19 Pump rac k
22 Hobe] 20 Injection pum p
23 Notbodienung 21 Shut-down cylinder
22 Leve r
23 Emergency controls
a,
0
DESCRIPTIONS OF SYSTEMS KSZ
M*AL*M Sea Water System
KEZ
20
5 e a Water Syste m
The sea water system is normally not included in the M .A . N . scope of supply . We recommen d
the system be designed as described below and shown in the schematic drawing . But as to
the actual design features and data, see description of the shipyard .
The purpose of the seawater system is to cool the lubricating oil, the jacket cooling water
and the charge-air by means of various heat eichangers . The two pumps (I I ) draw the sea--
water through a common suction pipe with filter (1 2) from the water chest (I ) . Normally,
(:Tiy one of the two pumps will be operating while the other serves as a stand-by set . Non-
return flaps on the delivery side of both pumps prevent the water from flowing back through
the pump which is not in operation . A pipe line from the common delivery pipe carries the
water to the charging air coolers (4) mounted on the engine . Part of the cooling water for I
the charge-air coolers can be branched off from this line and passed to the fresh water
40 generator (2) . Other water lines connect the coolers for lubricating oil (9) for cylinder
cooling water (8), injector cooling water (6) and piston cooling water (5) . The sea water
is finally discharged outboard through a common discharge pipe .
The temperature is regulated by a motor-driven valve (7) provided in the discharge pipe
and operated by a PI regulator (10) and a temperature sensor installed in the delivery pipe .
If the sea water is too cold, heated sea water from the discharge pipe is returned to the
suction side of the sea water pump .
de N
D36 5610 E 2 .20-2

0
0
SEEWASSERSCHEMA
M*Abk* M SEA WATER SYSTEM KSZ
KEZ
21
--0-
1 Seewasserkaste n 1 Sea water ches t

2 Frischwassererzeuger 2 Fresh water generator
0 3 Moto r
4 Ladeluftkühle r
5 Kühler für Kolbenkühlun g
3 Engin e
4 Charging air coole r
5 Cooler for piston coolin g
6 Kühler für Einspritzventilkühlung 6 Cooler for injection nozzle cooling
7 Motorventi l 7 Valve, motor drive n
8 Kühler für Zylinderkühlung 8 Cooler fo~ cylinder cooling
9 Schmierölkühle r 9 Lubricating oil coole r
10 PI-Regle r 10 PI regulator
11 Seewasserpumpe 11 Sea water pump
12 Saugfilte r 12 Suction filter
D 36 561 0 D+E 2 .21-2

a
it
0
ABGASTURBOLADER
EXHAUST-GAS TURBOCHARGE R 2
TURBOCOMPRESSEUR A GAZ WECHAPPEMENT
SOBREALIMENTADORES 50
A TURBOSOFFIANT1 A GAS D1 SCARIC O
SCHEMABESCHREI BUNG EN
DESCRIPTIONS OF SYSTEMS
DESCRIPTIONS DES CIRCUIT S
DESCRIPCIONES ESQUEMATICAS
DESCRI(;OES DE ESQUEMAS
DESCRIZIONE SCHEMI
9
D36 5650 2 .50-1 04 .82
0
0
M*AL*14 L System, Cooling Water System
51
Lubricating Oil Syste m

The bearings of the turbocharger are connected to the lubricating oil system of the engine .
The lubricating oil is branched off downstream of the lubricating oil filter (7) of the engine
and is carried through the pipes (200 and 201 ) and a distributor piece in the bearing casing
to the two bearings and to the reserve tank (14) of each turbocharger . Each of the suppl y
pipes (201 ) is fitted wilh a non-return valve (I I) . Another dosing valve (13) is fitted in the .'
pipe (202) to the reserve tank . The oil flowing from the bearings is drained through the pipe s
(207 and 208) into the discharge funnel (21) with sight glass and is returned through the pip e
(209) to the lubricating oil tank (1) from which it is drawn and recirculated by the pumps (4 -
and 5) .
The lubricating oi I pressure is monitored by a contact pressure gauge (19) and a pressure switc h
(20) in the supply pipe (201) . A pressure gouge (15) is also provided on each turbocharger .
The oil discharge from each turbocharger can be checked at the sight glass in the discharge .
funnel (21) .
Some of the oil supplied to the turbochargers is conveyed vio a dosing valve to the reserv e
.1 tank mounted at the top of the turbocharger . The oil delivered by the lubricating oil pumps
after the tank has been filled up is returned through the overflow into the bearing casing o f
the turbocharger where it is discharged through the discharge pipe .
The reserve tank provides continued lubrication of the turbocharger bearings for about 20 min .
after the lubricating oil pumps are switched off aft&r the engine has been shut down . As th e
lubricating oil pumps are switched off, the non-return valve (11) in the supply pipe (202) wil l
close, whereas the dosing valve (13) under the reserve tank will open to allow oil to flow t o
the bearings . After-lubri cation of the turbocharger bearings must be kept up for a somewha t
longer period than after-I ubri cation of the engine because the lubricating oil has also th e
task of cooling the bearings . Heat must especially be carried off from the bearing on the
turbine side . The comparatively slight pressure head resulting from the difference in heigh t
between reserve tank and bearings is yet sufficient as the special bearings (multiple wedg e
bearings) have a certain pumping effect . This suction effect increases with the speed of th e
turbocharger .
-Additional Luboi I Filte r

This additional edge-type filter serves to retain dirt and solids the pipes may contain whe n
the engine is still new or has undergone extensive repairs . This filter should only be switche d
in during the first 24 hours of operation . --Th .er.eafter, the filter should be by-passed by
opening the shut-off cock, after which only'-very little oil will be passed through the filte r
to prevent the fi Iter e 1'ement from gumming up .
I ndicati'ng Instrument s
per charger . I pressure gouge (15) ahead of turbocharger bearings
I contact pressure gouge (19) in engine control stand
I oil pressure switch with two alarm outputs (in plants arranged ~
- for unmanned operationt instead of the contact pressure gouge) .
I funnel (21) with sight glass for oil return pipes (208) and vent
pipe (217) .
Cooling Water System '
. The turbochargers are connecte he engine cooling water system . The cooling water is
admitted at the bottom of the bearing casing, flows through the cooling spaces on turbine an d
.1
compressor side
i and is discharged at the
1 top of the casing into a pipe .
D36 5645 E 2 .51-2 P .t .o .

R o hr I e i t u n a e ri Pi p i n a s
Nr . Matrrial/Polir 0 Leitung von nach

No . Materizl/pipe dia-i . Pipe f rom to, 0
200 STR 57 x 2-19 -- Druck Motoralleitung Uber Schieber Lel tung 20 1
Pressure Luboil pipe Pipe 20 1
201 STR 44,5 x 2-,6 Druck Leitung 200 Leitung 202
Pressure Pipe 200 Pipe 202
202 STR 30 x 2 - ~ Druck Leitung 201 Turbolader einzel n
Pressure Pipe 201 Turbocharger separat e
205 STR 57 x-Z,9 Druck Leitung 200 Uber Filter Leitung 200
Pressure Pipe 200 via filter Pipe 20 0
207 STR 76j-1 x"2,9 Ab. lauf Turboloder einzeln . - Leo tung 20 8
Outlet * Turbocharger separat Pipe 208
208 STP, 76, 1 x 2,.~Z Ablauf Leitu ng 207 Ablauftrichter
Outlet Pipe ,207 Discharge funne l
209 STR 108 x .3,6 Ablauf
Outlet
Ablauffrichter
Discharge funnel
SchmierbibehUlte r
Lubricating oil tan k
t.
213 STR 8 x I Druck Leitung 201 Klemmleiste
Pressure Pipe 201 Terminal ba r
214 5-FR 3 x I I Druck Klemmleiste Kontaktriianomete r
Pressure Terminal bar Contact pressure goug e
217 STR44,5x-2-;6 Entluftung Ablauftrichter Entluftung (Schmier5lbehaljter )
Vent Discharge funnel Vent (lub6l tank)
0
SCHMIEROLSCHEMA
M*AL*M LUBOIL SYSTE M
NA
52
4
1 SchmierölbehUter (etor) 1 Luboil tank (engine)

2 EntlUftungsleitun g 2 Venting pip e
3 Saugfilter mit Magnet (0,5 mm) 3 Suction filter with magnet (0 .5 mm)
4 Reserve-Schmierölpumpe 4 Stand-by luboil pump
5 Schmierölpumpe 5 Luboil pump
6 Schmierölkühle r 6 Luboil coole r
7 Motor-Schmierölfilter (0,05 mm) 7 Engine luboil filter (0 .05 mm)
9 Zulaufleitung (etor ) 9 Supply pipe (engine )
11 RUckschlagventi l 11 Non,-return valve
12 Abgasturboloder (I+II) 12 Exhaust-gas turbocharger (I+II)
13 Dosierventi l 13 Throttle valve
14 Reservebeh31ter 14 Stand-by tank
15 Manomete r 15 Pressure gauge
17 Schmierölfilter (Turbolader) 17 Luboil filter (turbocharger)
18 Absperrbahn 18 Shut-off cock
19 Kontaktmanometer 19 Contact pressure gauge
20 Druckschalter 20 Pressure switch
21 Ablauftrichter 21 Discharge funnel
D36 5645 D+E 2.52-1

a
0
SCHEMABESCHREIBUNGEN
*AO=1%k* 1119rhIld KSZ-B
Vorgeblasesteuerung
95
Dieselmotoren . . .. . . . . . . .. . . . K7 SZ 70 /125 BL - Werk-Nr .

Abgasturbolader . . . . . . . . . . . NA57/MO Werk-Nr .
Abnahme . .. . . . . . 4 . . . . . . . .
V o r 9 e b 1 a s e mit Antrieb ohne ZwischenUbersetzung durch Elektromoto r
Fabrikat und Typ Pollrich , BS 56AE 450M/5

GesamtdruckdIfferenz PI/P2 . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 76,52/44,'] 5 . mbar
Durchsatz. VI/V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .~,.~2 /6, 78 'M3/s
Leistungsaufnahme . o . . . . 0 .0 . . . . . . . . . . . « . . . . . . . . . . 9 . . . . * . . . -,- 41 kW
Drehzahl riv . o . . . . . . . . . to 0 . . . . . . . . . . Ilmin
Reservetetiumfang je Schiff . . . . . . . . . . . . la' frad
u
.
E 1 ektromotor Baufonn B3, Schutzart IP 44, Raumtemperatur 65oC, Isolierstoffklasse
mit 3 eingebauten KaltleitertemperaturFUhiefn .
AEG AM 250 MV2
Fabrikat und Typ . . . . . . . . . . . . Frequenz . . . . .. . . . . 60 Hz
. Spannung . . . . . . . . . . . . . . . . . . .440 -V~ Nennstrom . . . .-. . . . . . . # . . . 93 A
Nerinleistung . . . . . . . . . . . . . . . 55 kW EinschaltungXM/direkt
Nenndrehzahl . . . . . . . . . . . .1~40 Ii/mi n
Hoch laufze it YXI direkt 2 s-
Sonderlaufer für Schweranlauf . . . . . . nein
.- ReserveteilumfangleSchiff .o . . . . . . . . . . . . . . . Elektromoto r
Satz Lager
Elektropneur.iatische Steuerung fur YA - Anlauf für Direktanlau f
Ze.ichnungs-Nr .-
Gesamtanlage . . . . . . . . . . . . . . . . . . . . . . . . . B I 1 . 12500- "4348
, -
Pneumatischer Teil . . . . . . . . . . . . . . .
Elektrischer Teil . . . . . . . . . . . . . . . . . . *. '. *. '.
Is
,Stromlaufplan . . . . . . . . . . . . . . . . . . . . . . . a . Al 1 . 12500- 4324
Anschlußplan . . . . . . . . . . . . . . . . . . . . . . . . . . Al 1 . 12500- 4353'
Einbauzeichnung . . . . . . . 11 . 12500- 4350
Instrumententafel . . . . . . . .» .* .0 *. *. . . . 64 ., . . C 1 1 . 12500- -',4330
Anschlußplan für Instrumententafel . . . : . . E 11 . 12500-,' -,4~25
Anschlußplan für Maghetfeldschalter . . . . . F11 .12500-3100
Reserveteilumfong . ... . . . ab . . . . . . . E 11 .99007-0784
F11 .99007-0652
I
41
Co
D36 5610 2 .95-3
0
(0
DESCRIPTIONS OF SYSTEMS KSZ 2
M*AL+M Auxiliary Blower Control
95
Diesel engine . . . . . . . . . . . . . . . . . . . . . Serial No . . . . . . . . . . . . .

Exhaust-gas turbocharger . . . . . . . . . . . Serial No . . . . . . . . . . . . .
Auxiliary Blower driven by electric motor without transmission gear .
Make and Typ e

Total pressure differential PI/P2 . . . . . . . . . . . . . . . . . . . . . . mbar
Flow rate Vl/V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/s
Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW
Spare part4 scopc per ship . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E I e c t r i c M o t a r design B3, protection type IP 44, for 65 0 C room temperature, I

insulation class F, equipped with 3 cold-junction thermo-couple s
419,
Make and Typ e
Voltage . . . . . . . . . . . . . . . V Frequency . . . . . . . . . . . cps
Rated output . . . . . . . . . . . kW Rated current . . . . . . . . A
Rates speed . . . . . . . . . . . I/min Starting . . . . . . . . . . . . direct
Running up time start . . . . s
Special type rotor for high starting torque . . . . . . . . . . . . . . . . . . . . . . . . . . yes no
Spare parts scope for vessel . . . . . . . . . . . . . . . . . . . . . . . . . . electric motor
Iset of bearing s
Electro-pneumatic control
Drawing No .
Total plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 11 .12500-
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . B I 1 .12500-

a Connection diagram . . . . . . . . . . . . . . . . . . . . . Al 1 .12500-
Instrument board . . . . . . . . . . . . . . . . . . . . . . . . Cl 1 .12500-

Connection diagram for instrument board . . . Ell .12500-
Connection diagram for magnetic fiel d
switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl 1 .12500-
Spare parts scope . . . . . . . . . . . . . . . . . . . . . . . El 1 .99007-
Fl 1 .99007-
0
C~
C I D36 5610 E 2 .95-3
a
ck,
a
DESCRIPTIONS OF SYSTEMS KSZ-B
M*A&*F4 Auxiliary Blower Control 96
I
Descri ptian
Motorised auxiliary blowers connected in series with the turbochargers supply additional
scavenge air during engine start-up and low power operation . Switching on and off of the
auxiliary blowers is automatic dependent upon the charge-air pressure (see electro-pneumatic
control of auxiliary blowers) .
The control gear comprises one switch cubicle with built-in contactor (for star-delta or direct
starting see sheet 2 .95) for each auxiliary blower, one common switch cubicle for the electro-
pneumatic control and an instrument board with auxiliary blower selector switch, push buttons
and indicator lamps for installation in the engine control stand .
The control gear provides for time and sequence control for running up the motorised
auxiliary blowers, for engaging the silencer inserts with the turbochargers and for switching I
4 off the motorised auxiliary blowers and disengaging the silencer inserts when a preset charge-
air pressure is exceeded . With dropping air pressure in the scavenge-air pipe, the auxiliary
blowers are restarted with time lag and in subsequent order and the silencer inserts are re-
engaged .
The operating method can be preset at the selector switch in the electro-pneumatic switch
cubicle . The selector switch has the switch positions :
1. OF F
2. AUTOMATIC
3. MA N UA L
To 1 . OFF
Control gear is cut off in this position .
a To 2 . AUTOMATI C
The motorised auxiliary blowers are normally set to operate automatically . When the
selector switch in the electro-pneumatic switch cubicle is set to AUTOMATI C
the indicator lamp AUTOMATIC ON in the control console lights up . The control
system of the motorised auxiliary blowers can now be switched on by actuating the
switch in the control console . The auxiliary blowers will then be run up in the correct
time and order. When the auxiliary blower is run up, the indicator lamp AUXILIARY
BLOWER IN OPERATION will show . The auxiliary blowers will be shut off in the
upper food range which is approx . above 50 % of engine MCR . Switching on and off
is automatically, depending upon the scavenge-air pressure before the cylinders .
1 D36 5610 E 2 .96-3 p . t .0.

a
Requirements for running up of auxiliary blowers are : sufficient oil pressure at the turbo-
.'chargers and a scavenge-air pressure below the switch point for OPERATION WITHOUT
AUXILIARY BLOWERS . The silencer inserts will be moved in position in the correct time
and order, depending on the operation of the auxiliary blowers .
To 3 . MANUAL OPERATIO N
When it is intended to run the auxiliary blowers independent of the prevailing
scavenge-air pressure, they must be controlled manually from the electro-pneumatic
control cubicle . With the selector switch in the position MANUAL, the auxiliary
blowers can be switched ON and 00 by means of the pushbuttons but it should
then be remembered that the second auxiliary blower should only be switched on
after the first blower has been run up and that can be checked at the ammeter pro-
vided in the instrument board . An essential requirement for running up the auxiliary
blowers is a sufficient oil pressure at the inlet of the engine .
The silencer inserts will be moved in the correct position at 1he correct time and in
the correct order of sequence depending upon the operational position of the it
auxiliary blowers and their position will be shown by the indicator lamps . A pressure
gouge showing the prevailing scavenge-air pressure helps determine the correct time
for switching the auxiliary blowers on and off .
Notel When passing from high to low food range it is essential that auxiliary blowers
be switched on I
Further information on the operation will be seen in the drawing showing the sequence of
operations of the auxiliary blower control .
Selector switch for operation of motorised auxiliary blower s
For emergency operation, in the case of one auxiliary blower being out of operation due
to damage, there is a switch in the engine control console with the following switch
positions :
0 = Emergency operation, high engine spee d

I = Emergency operation, with auxiliary blower 11, low engine speed
4L
2 = Normal operatio n
3 = Emergency operation with auxiliary blower 1, low engine spee d
With both auxiliary blowers in working order, the switch is to be set to position H . For
operation in switch positions 0, 1 and 3 see sheet 41 , section 3 (operation with damaged
turbochargers and auxiliary blowers) .
0
D36 5610 E / 2 .96-3
I
DESCRIPTIONS OF SYSTEMS 11 1
Na 4
2
Auxiliary Blower Control
KEZ
a 97
Emergency Operat io n
Should one motorised auxiliary blower be out of operation due to damage, engire operation
can be kept up with one auxiliary blower after controls have been set accordingly .
In addition to the controls of the auxiliary blowers, there is the control for air injection should
one of the auxiliary blowers be out of operation . Control of the system is by a pushbutton
AUXILIARY AIR FOR EMERGENCY OPERATION provided in the engine control console .
Fore ngine operation with a damaged auxiliary blower see instructions given in section 3
(Operating Difficulties) .
Monitoring and Safety System s
TheE-olarm 50-SR AUXILIARY BLOWER DEFECTIV E

40 monitors in the whole load range, i .e . also above the 50 % range in which the auxiliary
blowers are not running but must be in stand-by position, the following criteria :
Operational position of silencer insert s

Operational position of emergency operation switch
Temp--rature of the electric motor s
Voltage in control system .
The R-alarm [LO8~j ONE AUXILIARY BLOWER NOT STARTED signals within a load
range corresponding to a scavenge-air pressure of<0 .3 bar that one auxiliary blower has not
started or has been failing . The R-alarm will be cancelled when the emergency operation
switch is set to the position "emergency operation with one auxiliary blower" .
The S-alarm BOTH AUXILIARY BLOAE RS NOT STARTED signals within a load range
corresponding to a scavenge-air pressur e of <0 .3 bar that both auxiliary blowers have not
been started or are failing .
*0 The outgoing contact (working current) is connected to the automatic emergency shut-down
systern . Starting-up of the diesel engine with fuel admission but without supply of scavenge-air
from the auxiliary blowers is thus prevented .
The control system is designed in such a way that in automatic operation the electro motors
are automatically restarted after an adjustable lapse of time of from I - 30 seconds after a
black-out .
Provisions are made for the connection of a switch, supplied by the yard, for remote stopping
of the electric motors of the auxiliary blowers in the event of a fire in the engine room .
CDCo
0: D36 5610 E 2 .97-3
a
0
WOODWARD GOVERNOR COMPAN Y
MANUAL 36684J
WARNING
46
READ THIS ENTIRE MANUAL AND ALL OTHER PUBLICATIONS PERTAINING TO THE WORK TO BE
PERFORMED BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. PRACTICE ALL
PLANT AND SAFETY INSTRUCTIONS AND PRECAUTIONS . FAILURE TO FOLLOW INSTRUCTIONS CAN
CAUSE PERSONAL INJURY AND/OR PROPERTY DAMAGE .
TABLE OF CONTENTS
SECTION I - Installing and Adjusting a Two-Stage
GENERAL INFORMATION . . . . ... .... . . ... . . . . I Booster-Models 8901-091 and 8901-093 . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . ... .... . . .. . . . . . 1 SECTION 3
Description . . . . . . . . . . . . . . . . . . . .. . .... . . ... . . . . 1 PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . 13
Types of Boosters . . . . . . . . . . . . . .. . .... . . ... . . . . 1 How Single-Cylinder and Tande m
Single-Cylinder Booster . . . . . . . . .... . . . .. . . . . 2 Boosters Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tandem Booster . . . . . . . . . . . . . .. .... . . ... . . . . 2 First Phase of Single-Cylinder an d
Two-Stage Booster . . . . . . . . . ... .. . . . . ... . . . . 2 Tandem Booster Operation . . . . . . . . . . . . . . . . . 13
Second Phase of Single-Cylinder an d
SECTION 2 Tandem Booster Operation . . . . . . . . . . . ......1
INSTALLING AND ADJUSTING A How a Two-Stage Booster Operates . . . . . . . . . . . 1 440
BOOSTER SERVOMOTOR . . . . . . . . . . . . . . . . . . . . 6 First Phase of Two-Stage Booste r
General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Second Phase of Two-Stage Booste r
Oil Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . 6
Starting-Air Valve . . . . . . . . . . . . . . . . . . . . . . . . Third Phase of Two-Stage Booste r
. . . 6
Installing and Adjusting a Single-Cylinde r Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Booster-Models 8901-037 and 8901-051 . . . . ...6 SECTION 4
Installing and Adjusting a Tandem Booste r REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . 15
- Models 8901-065 and 8901-067 . . . . . . . . . . . .. .7 Ordering Replacement Parts . . . . . . . . . . . . . . . . . . 1 5
LIST OF ILLUSTRATION S
1-1 . Schematic of Single Booster Connections to PG-Type of Governor . . . . . . ......1
1-2 ., Schematic of Tandem Booster Connections to PG-Type of Governor . . . . . ..... 2
1-3 . Outline Drawing of Single Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . 3
1-4 . Outline Drawing of Tandem Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 4
1-5 . Outline Drawing of Two-Stage Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 5
2-1 . Governors Used With Single-Cylinder Boosters . . . . . . . . . . . . . . . . . . . . . . . . ..... . 9
2-2 . Governors Used With Single-Cylinder Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-3 . Governors Used With Tandem Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-4 . Governors Used With Two-Stage Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-1 . Single Booster, Phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
I 3-2 . Single Booster, Phase 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-3 . Two-Stage Booster, Phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-1 . Exploded View of Single Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-2 . Exploded View of Tandem Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-3 . Exploded View of Two-Stage Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
The letter designation following the manual number is changed to the next letter in alphabetical order
when an important revision is made to the manual .
TEXT CHANGES ARE INDICATED BY A BLACK LINE ALONGSIDE THE TEXT .
Woodward Governor Company reserves the right to update any portion of this publication at any time . Information provided by
Woodward Governor Company is believed to be correct and reliable . However, no responsibility is assumed by Woodward Governor
Company for its use unless otherwise expressly undertaken .
@Woodward Governor Company, 1984

All rights reserved 0
OODWAP D
SECTION 1
GENERAL INFORMATION
INTRODUCTIO N Compressed air applied to the side of the piston

opposite this oil forces the piston against the oil,
This manual covers the three types of Woodward which flows through ports at the other end of the
booster servomotors and consists of four sections : cylinder to the governor.
• General Informatio n When air is removed from the piston, the spring
• Installation and Adjustment Procedures returns the piston to its rest position . Reduced
• Principles of Operatio n pressure in the cylinder causes oil to flow into itfrorn
• Replacement of Part s the sump .
Check valves at all oil ports allow oil to flow in only

DESCRIPTIO N one direction . This prevents oil in the booster from
flowing back to the governor's sump when the
A booster servomotor supplies pressurized oil to booster operates, and oil in the booster outlet lines
mechanical-hydraulic governors and electro- from flowing back into the booster when it is
hydraulic actuators at the instant starting air reaches inactive .
0 the engine . This instant oil pressure eliminates the
time required for the rotary gearpump in the governor
to build up enough oil pressure to move the linkage . TYPES OF BOOSTER S
This produces afasterstart, which conserves starting
air and, in vessels with direct reversible engines, There are three types of boosters :
improves maneuverability .
• A low-volume, single-cylinder booste r
When the booster is inactive, a piston is held at one • A medium-volume, double-cylinder (tandem)
end of a cylinder byaspring, The cylinderisfull of oil booste r
supplied from a line from the governor's sump . A high-volume, two-stage booste r
booster outlet tubiog to

speedsetting servo speed setting servo pump oil pressur e
0
Eg intermediate oil pressur e
trapped oil and power
cylinder oil pressur e
sump oil pressure
povvpr servo booster outlet air pressure
/ I tubing t o
: governo r
pressure syste m
I
: booster inlet
I tubing to
governor sump
air supply up
to 500 ps i
__~11
adjusting screw to limi t starting air valv e
amount fuel pumps are
opened when starting
Schematic of Single Booster Connections to PG-Type of Governor
1
I
00DWAP173
0
Boosters are available with different air-to-oll of PGA, PGPL, and PGG governors equipped with
pressure ratios, making them suitable for both high any shutdown feature .
and low air pressure applications :
A single-cylinder booster has two air inlets, one
Model Type Pressure Ratio restricted and one unrestricted . Using the restricted
(Oil Out to Air In) air inlet results in slower movement of the fuel rack .
8901-037, 043 Single-cylinder 1 :1
8901-051 Single-cylinder 2 :1 TANDEM BOOSTER (Figures 1-2 and 1-4)
8901-065 Tandem 1 :1
8901-067 Tandem Tandem boosters have two cylinders and three oil
1 .61 outlets . Outlet no . 1 is unrestricted ; the other two
8901-091 Two-stage 2 :1 outlets are restricted by an adjustable needle valve .
8901-093 Two-stage 3 :1
Oil outlet no . 1 is connected to the governor's
Single-cylinder boosters supply enough oil fo r accumulator ; outlet no . 2, to the speed setting servo
governors with small and medium work outputs, (of PGA, PGPL, and PGG governors equipped with
such as UG-8 and -40, EGB-10 and -13,3161, and FIG any shutdown feature) ; and outlet no. 3, to a point
governors with outputs of 12 and 17 foot-pounds . directly under the power piston .
Tandem boosters, with larger volumes of oil and If outlet no . 2 is used, its needle valve determines the
three oil-outlets, are appropriate for PG-29 and -58,
EG-29 and -58, and PG-TM 58 governors . rate at which the speeder spring is compressed . The is
needle valve in outlet no . 3 controls the rate at which
Two-stage, high-volume boosters meet the boost- the power piston moves .
oil requirements for PG, EGB, and PG-TM governors
with 200, 300, and 500 foot-pound power cases .
TWO-STAGE BOOSTER (Figures 1-5,24, and
3-3)
SINGLE-CYLINDER BOOSTER (Figures 1-1 Two-stage boosters have three oil outlets, but a two-
and 1-3) stage feature allows oil to flow through outlet no . 2
Single-cylinder boosters have two oil outlets : one is before it flows through the other two outlets .
unrestricted and one has a built-in orifice-type In most applications, outlet no . 1 supplies oil to the
restriction . Outlet no . 1 (unrestricted) is connected power piston in the governor ; outlet no . 2, to the
directlyto the governor's oil pressuresystem . Outlet speed setting servo (of PGA, PGPL, and PGG
no . 2 (restricted) can be used to pressurize the speed governors equipped with any shutdown feature) ;
setting servo which compresses the speeder sprin g and outlet no . 3, to the relay piston .
TANDEM
BOOSTER
CONNECTION S
0 PUMP OIL PRESSURE
la
01
INTERMEDIATE OIL PRESSUR E
TRAPPED OIL III POWER CYLINDER OIL PRESSUR E

~Fk'12~
t
f
~101~ FLYWEIGHTS
0 SUMP OIL PRESSURE
SPEEDSETTING OIL PRESSUR E
OI L ACCUMULATOR f777xA--
PILOT NEEDLE
VALVE VALVE
PLUNGE R C NTRO L
L NO
PILOT VALVE
PUMP BUSHIN G
IN C
TO
SUMP W_ SIUMP 1111 Mmawle~ I
0 C,
BUFFER ROTAR Y
PISTON OUTPUT
SUMP
OR
SHAFT
SUPPLY
Figure 1-2 . Schematic of Tandem Booster Connections to PG-Type of Governor
2 0
25 .1
to (1 .000 )
T 564
(120 0)
38
(1 .4961
8 .7 ( .34 3) D I A H 0 L E (4)
192 (7 .560) 12( .473 )
218 (8 .584)
1/8"-27 NPTF OIL OUTLET H 2

WITH 0 .8 ( .032) ORIFICE TO GOVERNOR 1/8"-27 NPTF INLETWITH 0 .8 ( .032) ORIFICE FROM
SPEEDSETTING SERVO ENGINE AIR STARTING MANIFOLD
118"-27 NPTF INLET

STROKE LIMIT SCREW FROM ENGIN E
AIR STARTING MANIFOLD
FT' - , . 9' - -
82 5
(3248)
. * F- I . .. LIT
52 47.5
38 .5 (1 .870)
0 (2 .047) i [\ 10 -
11 .516) 1 ~ I 1
0~
1 K 4276)
VENT HOLE 19.5 ( .768)

NPTF OIL INLET 19
.5 ( .768 )
FROM GOVERNOR SUMP 1/8"-27 NPTF OIL OUTLET H I
TO GOVERNOR PRESSURE SYSTEM
0
MILLIMETER (INCH) 0
Figure 1-3 . Outline Drawing of Single Booster

VENTHOLE >
NEEDLE VALVE (RESTRICTED OUTLET #2)
ADJUSTING SCRM OIL VOLUME
OIL INLET .250-18 NPTF

AIR INLET .250 -18 NPTF
RESTRICTED OUTLET 2
.125-27 NPT F
--- F - -
39
0
.5 1 35) 113( .512) r"Ff;~
110 150 15
(59
11 .535)
399
75
(2953)
qj
-190(T.480)
~015155A,119
48
RESTRICTED OUTLET * 1~\
.125 -! 27 NPTF
8.5( .335)OTHRU(4)
OUTLET*1 .250-18NPTF 171 .669)OSPOTFACE TO CLEAN
NEEDLE VALVE (RESTRICTED OUTLET# 3)- (3.543)

90
of.315)
21916 .625)
-235(9.250)MAX
MILLIMETER (INCH)
re 1-4 . Outline Drawing of Tandem Booster

_t33 3
,1312) 9
SHUTTLE PISTON ADJUSTABLE STOP 14 4 (566) 0 THRU (4) M AX I
/-(I 4610 M'N
NEEDLE VALVE FOR OUTLET 01 3 (WR
12250)
177 S
7000)
57.2
(2 .2501
44
OUTLET # 3 : REDUCED FLOW TO GOVERNOR

562-18(ii,ch) UNJF STRAIGHT THREAD PORT 1~06)
241 3
L100100 r tq 50 01 ------------ BOOST AIR INLET SUPPLY AIR INPUT
438-2O(-h)UNJF STRAIGHT THREAD PORT (-04)
1 3 5 - OUTLET # I- FULL FLOW TO GOVERNOR
(5311- 35? 562-iS (-h) UNJF STRAIGHT THREAD PORT 06 )
(1 .4061 OUTLE T
2,7 # 2 : AUX . FLOW TO GOVERNOR 134
11.500) 562-1801,&) UNJF STRAIGHT THREAD PORT(-06) 15 31291 MAX
('141
'5511MAX,
120 G -(183 1
KP 7191 95 3
-a 91' - (37501
76 61 1 9
243 ) __T
t1476, I G ., 0.. 0-1
875
41 25,01 t
411 1 (IS 187) MA X
INLET . RETURN LINE FROM GOVERNOR \-1001TER STROKE ADJUSTMENT

750-16 Onehl UNJF STRAIGHT THREAD PORT (-081 250 0,ch) HEX SOCKE T
Ln
Figure 1-5 . Outline Drawing of Two-Stage Booster

WOODWA P ZED
SECTION 2
INSTALLING AND ADJUSTING A BOOSTER SERVOMOTO R
WARNIN G
The engine, turbine, or other type of prime

mover should be equipped with an overspeed
(overtemperature, or overpressure, where Purge air from the booster's oil chamber,
applicable) shutdown device(s), that operates the tubing, and the governor before you
totally independent of the prime mover control start the engine, by cycling the booster
device(s) to protect against runaway or piston with start-air or air f rom a separate
damage to the engine, turbine, or other type source. Failure to purge air completely
of prime mover with possible personal injury may result in sluggish governor response .
or loss of life should the mechanical-hydraulic
governor(s) or electric control(s), the
actuator(s), fuel control(s), the driving INSTALLING AND ADJUSTING A SINGLE- 16
mechanism(s), the linkage(s), or the con- CYLINDER BOOSTER - Models 8901-037
trolled device(s) fail .
and 8901-051 (Figures 1-3, 2-1, and 2-2 )
Refer to the general rules at the beginning of this

GENERAL RULE S section .
Observe the following rules when you install a Figures 2-1 and 2-2 show locations of inlet and outlet
Woodward booster servomotor . ports on Woodward governors with which a single-
cylinder booster can be used . Figure 1-3 shows
locations of ports and the adjustment screw on a
LOCATIO N single-cylinder booster.
Install the booster servomotor at a lower level than Install % inch (10 mm) steel tubing from the sump of
the governorto preventairfrom being trapped in the the governor to the oil inlet on the booster .
booster and oil lines .
Install 1/4inch (6 mm) steel tubing from oil outlet no . 1
on the booster to the power piston (the inlet marked
OIL LINES "OILFROM BOOSTER OUTLET-1") ofthegovernor.
0
Oil lines must slope up from the booster to the If the governor is a PGA, PGPL, or PGG equipped
governor with a minimum of loops and bends . with any shutdown feature, install 1/4 inch (6 mm)
steel tubing from oil outlet no . 2 on the boosterto the
speedsetting servo (the inlet marked "OIL FROM
STARTING-AIR VALVE BOOSTER OUTLET-2) of the governor . Otherwise,
leave oil outlet no . 2 plugged .
A starting-air valve (supplied by the customer) must
be installed in the air line to the booster . This valve Connect a line containing an air-starting valve from
must admit compressed air to the booster at the the starting-air supply to the appropriate air inlet on
same time that starting air is supplied to the engine, the booster . Use the inlet with the built-in orifice if
and it must vent the air cylinder of the booster to you want to move the fuel racks at a slower rate .
atmosphere when starting air is removed from the
engine . Air pressure at the booster air inlet must not Fill the governor with oil to the proper level (refer to
exceed 3500 kPa (500 psi) . the installation manual for the governor) .
6 Is
When all air and oil connections are secure, purge Fill the governor with oil to the correct level (refer to
airfrorn the booster and oil lines by cycling airto the the installation manual for the governor) .
booster from a remote source without cranking the
engine . Add oil to the governor as needed . When all oil and air connections are secure, purge
airfrom the boosterand oil lines by cycling airto the
When there is no more air in the booster and oil I ines, booster from a remote source without cranking the
set the initial opening of the fuel racks by adjusting engine . Add more oil to the governor as needed .
the stroke of the booster piston . Turn the booster
limit screw counterclockwise to increase starting When there is no moreairinthe boosterand oil lines,
fuel, and clockwise to decrease it . This screw limits limit the volume of oil going to the governor by
the intakestroke of the boosterand the volume of oil adjusting the two oil volume adjusting screws . The
supplied to the governor in one stroke of the booster positions of these screws determine the maximum
servomotor . volume of oil supplied by the booster. This, in turn,
determines the maximum travel of the fuel racks .
Turn thescrews clockwise to reducethe travel of the
racks and counterclockwise to increase the travel .
INSTALLING AND ADJUSTING ATANDEM
BOOSTER - Models 8901-065 and Adjustthe needlevalves in oil outlets no . 2 and no . 3 .
0 8901-067 (Figures 1-4 and 2-3) If outlet no . 2 is used, its needle valve controls the
rate of oil flow to the speeder spring servo, which
determines how fast the speeder spring servo moves .
NOT E The needle valve in outlet no . 3 controls the rate at
which the power piston moves . Turn the needle
On PGA governors, decals indicating valve clockwise to restrict oil flow and counter-
where to connect lines from the booster clockwise to increase flow.
do not apply to tandem boosters . Refer to
Figure 2-3 when you connect a tandem NOT E
booster to a PGA governor.
Outlets no . 2 and no . 3 are connected to
Refer to the general rules at the beginning of this separate cylinders. Outlet no . 1 is con-
section . nected to both cylinders, with check valves
preventing flow between the cylinders.
Figure 2-3 shows locations of outlet and inlet ports Upequal amounts of oil flow through the
on governors with which a tandem booster can be two outlets if the oil volume adjusting
used . Figure 1-4 shows locations of adjustment screws are adjusted unequally. It is usually
screws and ports on a tandem booster . best to adjust both of these screws the
same distance and regulate the rate of oil
0 Connect % inch (10 mm) steel tubing from the sump flow through outlets no . 2 and no. 3 with
of the governor to the oil inlet on the booster ; and their respective needle valves .
from oil outlet no . 1 of the boostertothe accumulator
of the governor.
INSTALLING AND ADJUSTING A TWO-
On PGA, PGPL, and PGG governors equipped with STAGE BOOSTER - Models 8901-091 and
any shutdown feature, connect 1/4 inch (6 mm) steel 8901-093 (Figures 1-5 and 2-4 )
tubing from oil outlet no . 2 on the booster to the
speed setting servo of the governor . NOT E
On PGA, PGPIL, and PGG governors, connect 1/4inch On PGA, PGPL, and PGG governors,
(6 mm) steel tubing from oil outlet no . 3 on the decals indicating where to connect lines
booster to the power piston of the governor . from the booster do not apply to two-
stage boosters . Refer to Figure 2-4 when
Connect a line with an air-starting valve from the you connect a two-stage booster to a
starting-air supply to the air inlet on the booster . PGA, PGP4, or PGG governor.
7
VY 0 0 D W A _P_rJ
Refer to the general rules at the beginning of this When all air and oil connections are secure, purge
section . air from the booster and oil lines by cycling air from
a remote sourceto the boosterwithout cranking the
Connect 1/2 inch (1 2 mm) steel tubing from the sump engine . Add oil to the governor as needed .
of the governor to the oil inlet port on the booster,
and from oil outlet no . 1 on the boosterto the power When there is no more air in the booster and oil
piston of the governor. lines, regulate the volume of oil going to the
governor by adjusting the stroke adjusting screw . If
On PGA, PGPL, and PGG governors equipped with you are not using an EGB-200, -300, or -500
any shutdown feature, connect 5/16 inch (8 mm) actuator, adjust the shuttle piston adjusting screw
steel tubing from oil outlet no . 2 on the booster to and the needle valve in oil outlet no . 3 .
the speed setting servo of the governor .
Remember that :
Connect 5/16 inch (8 mm) steel tubing from oil
outlet no . 3 on the booster to the relay piston of the The stroke adjusting screw limits the volume of
governor . oil going to the governorthrough oil outlets no .
1 and no . 3 ; this controls the maximum amount
of fuel output during a booster-assisted start . 0
NOTE
If you use outlet no . 2, the shuttle piston
If you have an EGB-200, -300, or -500 adjusting screw limits the volume of oil going
actuator, leave oil outlet no . 3 of the to the speed setting servo through oil outlet
no . 2 .
booster plugged and loosen the plug in
outlet no. 2. Turn the shuttle piston
adjusting screw fully clockwise, thereby The needle valve limits the rate of flow of oil
through oil outlet no . 3 ; this controls the rate at
opening up the passage to outlet no. 1
which the output shaft of the governor moves .
(otherw4se, the booster servomotor
The needle valve setting also limits the stroke
remains inactive) . Tighten the plug in
of the power piston in the governor .
outlet no . 2.
Turn the adjusting screws clockwise to reduce the
volume of oil to the governor and fuel to the engine ;
Connect a line with an air-starting valve from the turn it counterclockwise to increase volume .
starting-air supply to the air inlet on the booster .
Turn the needle valves clockwise to reduce the rate
Fill the governor with oil to the correct level (referto and volume of oil flow, and counterclockwise to
the installation manual of the governor) . increase the rate and volume . I
0
8 is
00DWAP D
CONNECTTO
BOOSTE R
I NLE T
(ALTERNATE) CONNECTT O
CONNECTTO
BOOSTER BO O
OUTLET OU LET
ALTERNAT E
BOOSTER OUTLET
CONNECTIO N
CONNECTTO
BOOSTER CONNECTTO CONNECTT O
INLET
BOOSTER BOOSTE R
INLET INLET
(ALTERNATE )
UG 8 UG 4 0
CONNECTTO,
BOOSTE
T .0
R
OUTLE . 2
CONNECTTO
_]~~ _ CONNECTTO BOOSTE R
BOOSTER OUTLET NO . I
OUTLE T
(ALTERNATE)
CONNECT TO
CONNECTTO BOOSTER
BOOSTER INLE T
INLET
(ALTERNATE)
CONNECTTO
BOOSTER
CONNECTT O
OUTLET BOOSTE R
CONNECTTO OUTLET NO . I
BOOSTER (ALTERNATE)
INLET CONNECT TO
I BOOSTE R
INLET
CI
(ALTERNATE)
CONNECTIONS ARE IDEN TICAL ON DIAL & LEVER GOVERNOR S
PG
PG A
(Except 29, 58, 200 . 300 and 500 )
Figure 2-1 . Governors Used With Single-Cylinder Boosters
9
OODWAPr)
ALTERNATE CONNEC T
TO BOOSTER OUTLET NO . 2
WHEN RIGHT HAN D
OIL GAUGE IS USE D
CONNECTTO
BOOSTER OUTLET NO. 2
USE 1/8" TO 1/16" NPT F
ADAPTER
CONNECTTO
BOOSTE R
OUTLE T
CONNECTTO
BOOSTE R
OUTLET NO. I
CONNECTTO
BOOSTE SR
INLET
NOTES: T
1 . ALL CONNECTIONS ARE 1/8" NPTF
UNLESS OTHERWISE SPECIFIED is
2. CONNECTION TO BOOSTER OUTLET
CONNECTTO
NO . 1 AND TO BOOSTER INLET MAY
BOOSTE R
BE MADE AT EITHER LOCATION
INLE T
SHOWN.
PG-PL EGB 10 Ek 1 3
CONNECT BOOSTE R
OUTLET IN TO P
OF COOLER f4m
NOTE:
FOR REMOTE COOLER CONNECTT O
BOOSTER OUTLET BOOSTER
MAY BE CONNECTED
OUTLETNO. 2 jv
INTO COOLER A S
DESCRIBED OR INTO
A TEE FITTIN G
AT GOVERNOR OI L
OUTLET TO COOLER .
0
65) CONNECTTO
BOOSTER
OUTLET NO, I
CONNECT d
BOOSTER
INLET
CONNECTT .
BOOSTER -
INLET
EGB 35 Eli 50 EG8 10 solenoid speedseffin g
Figure 2-2 . Governors Used With Single-Cylinder Booster s
10 4b
OODWAP D
CONNECT TO
CONNECTTO I I BOOSTE R
BO / OUTLET NO. 2
OUTLET NO. 3
(ALTERNATE )
PGA 29 & 5 8
CONNECTTO
BOOSTE R
OUTLET NO . I
CONNECT TO
BOOSTER
CONNECT INLE T
TO BOOSTER (ALTERNATE)
INLE T
CONNECT TO
BOOSTER CONNECT TO
INLET BOOSTER
(ALTERNATE ) OUTLET NO. I
CONNECTTO
BOOSTER
INLET
PG-TM 58
Figure 2-3 . Governors Used With Tandem Boosters
11
WOODWA-P-D
CONNECTTO
OOSTER
8
OUTLET NO. 2
CONNECTTO
BOOSTER
OUTLET NO. I
CONNECTTO
BOOSTER
INLET
PGA-200 & 300
EGB-200,300 & 50 0
CONNECTTO CONNECT TO BOOSTER

BOOSTER OUTLET NO . 3
OUTLET NO. 2 (OPPOSITE SIDE )
CONNECTTO
BOOSTE R
OUTLET NO. I
t
f
CONNECTTO
BOOSTER
INLET
PGA 50 0
Figure2-4 . Governors Used With Two-Stage Boosters
12 a
SECTION 3
PRINCIPLES OF OPERATIO N
PRESSURE OIL
HOW SINGLE-CYLINDER AND TANDEM TO GOVERNOR
0 OR 2 OUTLETS
BOOSTERS OPERAT E AS PER FIG . 9 )
FIRST PHASE OF SINGLE-CYLINDER AND

TANDEM BOOSTER OPERATIO N
Refer to Figure 3-1 (Figure 3-1 represents a single-

cylinder booster ; a tandem booster has two pistons
and three oil outlets, but its principle of operation is
the same . )
When compressed air enters the booster, the piston (s)

move(s) up, forcing oil through the outlets to the
0 governor's pressurized oil system . The governor's
power piston moves to increase fuel .
A check valve in the oil inlet prevents oil from flowing

from the booster back to the sump in the governor .
Figure 3-1 . Single Booster, Phase 1
SECOND PHASE OF SINGLE- CYLINDER AND

TANDEM BOOSTER OPERATIO N
Refer to Figure 3-2 (Figure 3-2 represents a single-

cylinder booster ; a tandem booster has two pistons
and three oil outlets, but its principle of operation is
the same . )
0
When starting air is removed, the booster is vented
to atmosphere through the starting-air valve (cus-
tomersupplied) in the booster's air line . Spring force
returns the booster's piston(s) to its (their) original
position(s) . Oil stops flowing out of the booster .
Reduced pressure in the booster causes sump oil to
flow back into the booster . The booster is ready to
start again .
Check valves in the oil outlets prevent oil from

flowing backthrough the oil outlets intothe booster .
Figure 3-2 . Single Booster, Phase 2
13
A~~
0
HOW A TWO-STAGE BOOSTER

-OPERATE S
FIRST PHASE OF TWO-STAGE BOOSTER
OPERATION .
Refer to Figure 3-3.
When compressed air enters the booster, the main

piston moves to the right, forcing oil to the shuttle
piston cavity and moving the shuttle piston up . The
shuttle piston forces oil through oil outlet no . 2 and I
blocks oil outlets no . 1 and no . 3 .
The shuttle piston adjusting screw limits the stroke

of the shuttle piston, which limits the amount of oil
supplied through oil outlet no . 2 . Figure 3-3 . Two-Stage Booster, Phase 1
SECOND PHASE OF TWO-STAGE BOOSTER 0
OPERATIO N
Refer to Figure 3-4 .
When the shuttle piston reaches the end of its stroke,

it uncovers the passages to outlets no . 1 and no . 3 ; oil
flow through outlet no . 2 ceases . Oil remaining in the
booster flows through outlets no . 1 and no . 3 to the
relay and power pistons in the governor, moving
them to increase fuel .
The needle valve in outlet no . 3 limits the amount of

oil that goes through this outlet and its rate of flow . $"P OIL FROM
GOVERhOR
I This, in turn, limits the stroke of the power piston in
the governorand the rate at which fuel is supplied to 9003T OUTLET 0 2
ISPEVIIETTWO OR MT~N)
the engine . .TI..,

GOOST OUTLET .
fL.K PO-
BOOST OUTLET #3
The stroke adjusting screw limits the stroke of the (SMALL POWER PISTON )
main boosterpiston, which limitsthetotal amountof

oil supplied to the governor by the booster.
16
Check valves prevent oil from flowing from the
t booster into the governor's sump . Figure 3-4 . Two-Stage Booster, Phase 2
THIRD PHASE OF TWO-STAGE BOOSTER

OPERATIO N
Refer to Figure 3-5 .
Theairsideof the main piston is vented to atmosphere

through the starting-air valve . Spring forces return
the main booster piston and shuttle piston to their
original positions . Reduced pressure in the booster
causes sump oil to flow back into the booster .
Check valves prevent oil from flowing into the

booster f rom the oil outlet lines . Figure 3-5 . Two-Stage Booster, Phase 3
14 0
OODWAPr)
SECTION 4
REPLACEMENT PARTS
ORDERING REPLACEMENT PARTS 3. The part reference number in the parts list, and
the description of the part or part'name .
When you order replacement parts, include the Figures 4-1, 4-2, and 4-3 and their associated
following information : parts lists illustrate and name all the replaceable
parts of the various booster servomotors . The
1. The booster servomotor part number shown on numbers assigned are used as reference
the nameplate . numbers and are not specific Woodward part
numbers . Woodward Governor Company will
2 . The manual number printed on the cover of the determine the exact part number for your
manual (this is Manual 36684) . particular booster .
PARTS LIST FOR FIGURE 4-1
Part No . Name No . Req' d Part no . Name No . Req' d
36684- 6 0-ring 1
36684- 7 Glyd Ring 1 36684-36 5/1 6--24 Screw 4
36684-15 5/1 6"-24 Nut 4 36684-37 Flat washer 8
36684-16 O-Ring 1 or 2 36684-38 5/16" Shakeproof washer 4
36684-18 1/8"-27 Steel plug 2 36684-39 1/4" Threadseal 1
36684-19 1/8"-27 Plastic plug 2 36684-40 Flat washer 1
36684-23 Glyd Ring 1 or 2 36684-41 1/4"-28 Nut 1
36684-24 O-Ring 1 or 2 36684-42 1/4"-28 Adjusting screw 1
36684-25 Check valve assembly 3 36684-43 Nameplate 1
36684-26 1/4"-1 8 Plastic plug 1 36684-44 Cylinderhead 1
36684-27 Set decals 1 36684-45 O-Ring 1
36684-31 Cylinderhead 1 36684-46 Reducing bushing 1
36684-32 Booster spring 1 36684-47 Booster spring 1
36684-33 Accumulator cylinder 1 36684-48 Accumulator cylinder 1
36684-34 Piston 1 36684-49 Piston 1
36684-35 End cap 1 36684-50 Nameplate 1
15
OODWAPD
37 3 8 Is 39 19 4 0
37 38 15 39 19 40
16
Figure 4-1 . Exploded View of Single Boosters
16 411
OODW A
Part No . Nam e No . Req'd Part No . Nam e No . Req' d
36684- 6 O-Ring 2 36684-41 1/4"-28 Nut

36684- 7 Glyd Ring 2 36684-47 Booster spring
36684-15 5/1 6"-24 Nut 6 36684-49 Pisto n
36684-18 1/8"-27 Steel plug 4 36684-51 Set decals
36684-23 Glyd Ring 2 or 4 36684-52 Needle valve
36684-24 O-Rin g 2 or 4 36684-53 O-Ring
36684-25 Check valve assembly 6 36684-54 Nameplate
36684-26 1/4"-1 8 Plastic plug 2 36684-55 1/4"-28 Adjusting screw
36684-32 Booster spring 2 36684-56 End ca p
36684-34 Pisto n 2 36684-57 Accumulator cylinder
36684-36 5/16"-24 Screw 6 36684-58 Gaske t
36664-37 Flat washe r 6 36684-59 Servo head
36684-38 5/16" Shakeproof washer 6 36684-60 Nameplate
36684-39 1/4" Threadseal 2 36684-61 Accumulator cylinder
36684-40 Flat washer 2 36684-62 Reducing bushin g
0
Figure 4-2 . Exploded View of Tandem Boosters
17
00DWARM
Part no . Nam e No . Req'd Part no . Name No . Req' d
36684- 25 Check valve assembly 4 36684- 84 Oil failure piston 1

36684- 63 Booster servo piston 1 36684- 85 Spring 1
36684- 64 Sea l 1 36684- 86 .864 ID O-ring 1
36684- 65 Block vee seal 2 36684- 87 Booster servo plug 1
36684- 66 Back up ring 1 36684- 88 Int . retaining ring 1
36684- 67 Seal retaine r 1 26684- 89 Needle valve 1
36684- 68 .500 Springlock washer 9 36684- 90 .301 ID O-ring 1
36684- 69 .500-13 Cap scre w 1 36684- 91 Stop screw 1
36684- 70 2 :1 Ratio spring 1 36684- 92 .31 2 UNF Steel plug 1
36684- 71 Reducing bushing 1 36684- 93 .562 UNF Steel plug 1
36684- 72 Booster servo sleeve 1 36684- 94 .486 ID O-ring 3
36684- 73 Booster servo end cap 1 36684- 95 Breather filter cap 1
36684- 74 4 .234 ID O-rin g 1 36684- 96 .239 ID O-fing 2
36684- 75 .500 Thread seal 1 36684- 97 Threaded rod 4
36684- 76 .500 Flat washer 1 36684- 98 .500-20 Hex nut 80
36684- 77 .500-13 Hex nut 1 36684- 99 Nameplate 1
36684- 78 .500-13 Set screw 1 36683-100 Decal 1
36684- 79 3 .484 ID O-ring 1 36684-101 7/16 UNF Plastic plug 1
36684- 80 Servo head assembly 1 36684-102 3/4 UNF Plastic plug 1
36684- 81 Steel bal l 1 36684-103 9/16 UNF Plastic plug 2
36684- 82 Ball check spring 1 36684-104 .351 ID O-ring 1
36684- 83 Int . retaining ring 1 36684-105 .438 UNF Steel plug 1
t
f
18 a
76 1 0 99 2 74 73 76 68 98 5 101 76 77 78
93 89 94 90 91 98 68 76 90 92 96 97
71 70 66 65 63 64 67 68 159
P/N 8901-091 (2:11 RATIO)

and
P/N 8901-093 (3:1 RATIO)
103 95 105104 102 25 80 79 84 85 86 87 88 8 3
Figure 4-3 . Exploded View of Two-Stage Boosters

v
r"f!
4b
i
cv)
4b c> OODWAPT)
0
BULLETIN 03014H
UG32 & UG40 GOVERNOR S
DIAL CONTROL
LEVER CONTRO L
WOODWARD GOVERNOR COMPAN Y

ENGINE & TURBINE CONTROLS DIVISION
FT . COLLINS, COLORADO, U .S .A .
MAIN OFFICE : ROCKFORD, ILLINOIS, U .S .A .
BRANCHES & SUBSIDIARIES :
HOOFDDORP, THE NETHERLANDS o SLOUGH, BUCKS ., ENGLAND - TOKYO, JAPAN 03014H
_E
to
TABLE OF CONTENTS
Section I
GENERAL Page
Description 1
Dial Type Controls 1
Lever .Type Controls . 2.
Auxiliary Equipment 2
Installation 2
Oil Specifications 3
Outline Drawing (Dial Type) 4
Outline Drawing (Lever Type) 5
Section 11
OPERATION
Principle of Operation 6
0
Cross-sectional View 8
Starting Prime Mover 8
Compensating Adjustments 8
SECTION II I
MAINTENANCE
General 10
Lubrication 10
Inspection and Test 10
SECTION I V
DISASSEMBLY 12
SECTION V
INTERNAL ADJUSTMENT and REPAIR 15
ASSEMBLY
SECTION VI
21 0
PARTS LIST and EXPLODED DRAWINGS 25
0
Section I
GENERA L
SYNCHRONIZING
MOTOR ~
nail), they are identical except for dimensional differ-
ences in the accumulator cylinders and accumulator
pistons (Figure 30, piece numbers 66 and 67) . The
UG40 governor offers a greater work capacity than
the UG32 model .
As with any governor, it is recommended that the
prime mover be equipped with a separate overspeed
device to prevent runaway in the event of an), failure
which may render the governor inoperative .
DIAL TYPE CONTROL S
1 . The Synchronizer, or speed adjusting control,

is used to change the governor speed setting
when running alone or to change the load
when the prime mover has been paralleled
with other units . The synchronizer indicator
located directly below the synchronizer merely
COMPENSATING I/ F1141- SERRATED DRIVE SHAFT indicates the number of revolutions of the
NEEDLE VALVE PLU G
synchronizer knob .
Figure 1 . Dial Type Governo r
OIL FILLER CUP
DESCRIPTION TOP COVE R

OIL GAUGE
The UG40 hydraulic governor is used on large diesel, SPEED CONTROL
SHAFT
gas, or dual fuel engines or steam turbines driving
alternators, d-c generators, pumps, compressors, or
marine propellers. It is available in dial or lever types
with either a keyed or serrated drive shaft (Figures
I and 2) . It is normally isochronous ; i .e., it will
maintain a constant engine or turbine speed for all
load changes within the capacity of the engine or tur-
bine except momentarily at the time the load change
occurs. However, speed droop is available-a standard
item on dial governors, a special auxiliary on lever
governors-to automatically divide and balance load
between units driving the same shaft or paralleled
in an electrical system .
Stalling work capacit) of the UG40 governor is 40

foot pounds ; its useful work output over the full
COMPENSATIN G
available output shaft rotation of 38' is 31 foot OIL DRAIN PLUG --NEEDLE VALVE PLU G
pounds .
The UG40 governor is identical in external size and

appearance to the discontinued model UG32 ; inter- Figure 2 . Lever Type Governo r
I
I
-K
2 . The Synchronizing Motor : Most UG4o dial 4. The load limit control mechanically and
type governors are furnished with a motor hydraulically limits the load that can be put
mounted on a special cover to provide remote on the engine by restricting the angular ter-
speed control . Its use enables the switchboard minal shaft rotation of the governor, and con-
operator to match the frequency of an alter- sequently, the maximum quantity of fuel
supplied to the prime mover . The control
nator with that of other units, or a system,
may also be used for shutting down the en-
before synchronizing and to change load dis-
gine by turning it to zero .
tribution after synchronizing .
CAUTION : Do not manually move the prime
The motor used is of the split field, series mover linkage to increase fuel without first
wound, reversible type . It should be wired turning load- limit-knob to 10.-
as shown on page 30. A slip'coupling is pro-
vided between the motor shaft and the syn- LEVER TYPE CONTROL S
chronizer adjusting gear to allow the operat .or
Control shaft : Speed adjustment on UG40
to adjust speed by turning the synchronizer
control knob on the governor. The friction lever type governors is accomplished by a
coupling also prevents motor damage when control shaft which connects to a remote speed
speed setting stops are. reached . For adjust- adjustment linkage . A gear segment mounted
ment of the coupling see Section V . on this control shaft adjusts speeder spring
tension . Low and high speed stops mounted 0
3 . Speed droop is incorporated in the governor on the control shaft limit maximum and mini-
through a linkage which varies the compres- murn speed setting .
sion of the speeder (speed adjusting) spring
as the terminal shaft rotates during fuel cor- 2 . Speed droop mechanism - a special, internally
rection. Increased fuel reduces spring com- adjusted auxiliary on lever type governors -
pression, reduces the governor speed settin g automatically divides and balances load be-
accordingly, and the unit will gradually reduce tween units driving the same shaft, or paral-
its speed as load is applied. This relation- leled in an electrical system . As in the dial
ship between load and speed acts as a resis- type governor, droop is incorporated through
tance to load changes when the unit is inter- a linkage which varies the compression of the
connected withother units either mechanically speeder (speed adjusting) spring as the term-
or electrically. Bulletin 25031, Part III gives inal shaft rotates. Increased fuel reduces spring
a detailed discussion of parallel operation . compression, reduces the governor speed set-
As droop is reduced toward zero, the unit ting accordingly, and causes the unit to
becomes able to change load without chang- gradually reduce its speed as load is applied .
ing speed . As a general rule, units running When the governor is set at "zero droop",
alone should be set on zero droop, intercon- there is no change in speeder spring com-
nected units should be run at the lowest droop pression as the terminal shaft rotates and the
setting that will give satisfactory load division . governor controls as on isochronous unit .
For example, A .C . generating units tied in
with other units should have droop set suffi-
There are no calibration marks on the droop
components of lever type governors . Thus,
41)
ciently high (30 to 50 or more on the dial) care must be taken when adjusting to zero
to prevent interchange of load between units . droop not to go beyond the zero droop point
If one unit in the plant, or system, has enough and thus encounter "negative" droop . Negative
capacity, its governor may be set at zero droop droop causes an increase in speed as load
and it will regulate the frequency of the
increases .
entire system . This unit will then take all the
load changes within the limits of its capacity AUXILIARY EQUIPMEN T
and will control frequency if its capacity is Both the lever and dial type governors can be fur-
not exceeded . nished with a shutdown device operated either
The system frequency is adjusted by operating electrically, hydraulically, or pneumatically . A
the synchronizer of the governor having zero low lubricating oil pressure shutdown device can
droop . The distribution of load between units be furnished on dial type units ; a solenoid actuated
is accomplished by operating the synchronizers load limit device is available for the lever type
of the governors having speed droop . governors .
For more detailed instructions on speed droop
settings, see Bulletin 01502 on Plant Operating INSTALLATION
Problems . When the governor is installed on the prime mover,
2 410
7
L0101 BITIA E
0
particular care should be exercised to see that it is by a lever or special tool in order to obtain no
mounted squarely and that the drive connection to fuel (zero load) position .
the prime mover is aligned properly . A gasket
should be placed between the base of the governor The linkage from the governor terminal shaft to
and the mounting pad on the prime mover . If the the fuel control system should be properly aligned
governor is equipped with a serrated drive shaft and free from lost motion or excessive friction . it
(as in figure I ), it should slip into the internal is often desirable to install a light spring acting to
serrations of the drive freely enough to drop into decrease fuel to compensate for lost motion due to
place of its own weight . wear. Avoid exceeding the working capacity of the
governor by using too strong a spring . A spring
CAUTION : Do not drop or rest the governor on connected between linkage pins will take out lost
its drive shaft, or drive a gear or coupling on or motion without adding its load to governor work
off the shaft . required . For specific information on fuel linkage
installation, refer to the instruction manual for the
If a keyed type governor drive shaft (as in figure
2) is used, the gear placed o n this shaft must slide partii;ular prime mover being used .
on freely and then should be checked
, to insure that
it is meshing properly . There should be neither
OIL SPECIFICATION S
binding nor excessive backlash . Irregularities caused
by uneven gear teeth, shaft runout, etc ., will be
picked up by the governor, transmitted to the fuel Proper selection of the oil used in the governor is
control system, and will result in erratic governing . necessary to realize best governor performance
and longest service life . The oil should have a
Since the load limit device on the dial type governor minimum tendency to foam, retain air, form sludge,
operates both hydraulically and mechanically, the or deposit varnish . It should protect governor parts
load indicating pointer position cannot be forced from corrosion, and not be detrimental to seals or
toward the minimum setting by turning the load paint . Synthetic oils are not usually recommended .
limit control unless the governor is running (or has'
oil pressure in its accumulators) . When installing The oil selected should have a high viscosity in-
the governor, the terminal shaft must be rotated dex; the viscosity should be within the range of
100 to 200 Saybolt Universal Seconds at normal
operating temperatures . Usually, if the average'
operating tem erature of the governor oil is below
1200. , 1. 10 oil is satisfactory ; if between
1200F. and 1400F ., S .A .E. 20 oil ; froff 1400F . to
1600F ., S .A.E. 30 oil ; between 1600F. and 180'F .,
S .A .E . 40 ; and above 1800F ., S .A.E. 50 oil . The
oil in the engine may be used in the governor if it
meets these requirements .
COMPENSATING Oil contamination is the major cause of governor

ADJUSTING
POINTE R troubles . Use only new oil or filtered oil . Con-
tainers used for governor oil must be clean, and
should be rinsed with a light grade of the same oil
before being used.
Anytime the governor oil appears to be dirty or

breaking down from contaminants or excessive tem-
peratures, drain the governor while it is hot, flush
with the lightest grade of the same oil, and refill
with fresh oil .
'-p--l-
NEEDLE VALVE
or
PLU G Should a solvent be used to clean the governor, it
must be a type which does not damage oil seals or
gaskets. Solvents contaminate governor oil and
SCREWDRIVER INSERTED IN must be completely flushed out before the gover-
COMPENSATING NEEDLE VALVE
nor is filled with fresh oil . Otherwise, the oil put
in after the solvent has been removed should it-
Figure 4 . Compensating Adjustment, Dial self be *drained and replaced with fresh oil after
Type Governor one day .
3
7141 VARIABLE SPEED OIL PRESSURE GOVERNOR, SPEED RANGE
APPROXIMATELY 2 : 1
4 4 WORK CAPACITY :
UG32 GOVERNOR-32 FOOT POUNDS (444 Kg~m) IN EACH
DIRECTION THROUGH TERMINAL SHAFT ROTATION OF 391
~41
UG40 GOVERNOR-40FOOT POUNDS (555Kg-cm)IN EACH
DIRECTION THROUGH TERMINAL SHAFT ROTATION OF 38'
WEIGHT : 100 POUNDS (45Kg) APPROXIMATELY WITHOUT AUXILIARY

X 45*CKAMFER- EQUIPMENT
i1 6 I
POWER : APPROXIMATELY I/I H .P. REQUIRED AT DRIVE SHAF T
61 4 FOR CONSTANT SPEED OPERATION, NORMAL SPEED SHOULD BE

800 1000 R.R M .
NOTE : -7
TERMINAL SHAFT MAY g- 31-
EXTEND ON EITHER OR
to BOTH SIDES .
I
6 NO
~IJJFULL FUEL
Lh SERRATIONS
38.
0
-48 SAE SERRATIONS r MAXIMUM
AX
BOTH SIDES . FUEL
UEI
SYNCHRONIZI 4
m MOTOR '16 1
COMPENSATION
:0) ADJUSTMENT 12'
A
G_
(92 DIAL CONTROL WITHOU
0 NO AUXILIARLU
FUE L
il-_ ilit :!~: __o I
PRESSURE TEST PL G
(UG32-200 P.S .13
MAXIMU M
FUEL 12 (UG40-250 PS.I.) G I _,-COMPENSAT NG NEEDLE VALVE
'144
MUST BE ACCESSIBLE)
T !I
a
0 121&
- DF I W_ I F6RADIUS MAXIMUJIM
M
- - - i I I
2101
AMETER
X, UM gj
Tl 2
(D is, 4 MAXIMUM
- 3-11
0 FU L
FUL
1411 SALRATIONS
DRIVE SHAFT- 118 S.AE I
SERRATIONS
kW'--h- 45~ CHAMFER
RADIUS
1
2 1'
61 1 4 t5'
V2
§21101AMETER I I j
.6240
lXjKEYWAY t
16 -
1-18 CASTL E N U
64DIAMETER(4)
KEYED DRIVE SHAFT
OPTIONAL
DLAL CONTROL WITH
SYNCHRONIZING MOTOR 499 9
4999
VARIABLE SPEED ISOCHRONOUS OIL PRESSURE GOVERNOR
SPEED DROOP AVAILABLE ON SPECIAL ORDE R
WORK CAPACITY :
UG32 GOVERNOR-32 FOOT POUNDS (444 Kg-cm) IN EACH
DIRECTION THROUGH SHAFT ROTATION OF 38 *
UG40 GOVERNOR-40 FOOT POUNDS (555 Kg-cm)IN EACH
DIRECTION THROUGH SHAFT ROTATION OF 38-
FULL
SERRATIONS41j ~ WEIGHT : 95 POUNDS (43 Kg) WITHOUT AUXILIARY EQUIPMENT
POWER : APPROXIMATELY 1/2 H .P REQUIRED AT DRIVE SHAFT
SPEED DROOP CAM-MOVE DRIVE SHAFT SPEED RANGE : 350-1000 R.PM . FOR BEST CONTROL,
TO INCREASE DROO P KEEP MAXIMUM SPEED AS NEAR 1000 AS POSSIBLE . DRIVE IS
VERTICAL (FROM BELOW) AND MAY ROTATE EITHER DIRECTION .
-- SETTING LEVER AND TERMINAL

SHAFT LEVERS NOT NORMALLY FURNISHED,
BROACHED BLANK LEVERS AVAILABLE .
PRESSURE TEST PLU G

(UG32-200 P.S 1 .)
(UG40-250 PS .0
KEYED DRIVE SHAFT

FURNISHED IF SPECIFIE D
-48 SERRATIONS
\ 11 1
LM5
.7500 DIAMETER
F2j500
_T
-4 ~_ 1
.187 DIAMETER
DRIVE SHAFT COUPLINGS
AVAILABLE FRO M
WOODWARD GOVERNOR CO.
SERRATED DRIVE SHAFT
FURNISHED IF SPECIFIE D
Figure 6 . Outline Drawing of Lever Type Governo r
5
kl;f*i*l bi~
Section 11
OPERATIO N
PRINCIPLE OF OPERATIO N up, compressing the lower compensating spring and
The schematic diagram, figure 7, shows the essential raising the outer end of the floating lever and pilot
parts of the governor . Two accumulators are pro- valve plunger. Movement of the power piston,
terminal shaft, actuating compensating piston, re-
vided for pressure oil storage capacity ; the maximum
ceiving compensating piston and pilot valve plung-
pressure of governor oil is regulated by by-pass ports
er continues until the control port in the pilot
in the accumulator cylinders .
valve bushing is covered by the control land on the
There is always full accumulator oil pressure on plunger. As soon as the control port is covered,
the top area of the power piston (regardless of the power piston and terminal shaft are stopped
pilot valve position) which will turn the terminal at a position corresponding to the increased fuel
shaft in the direction to shut off fuel if there is no needed to run the engine at normal speed under
pressure (or low enough pressure) on the bottom increased load .
area of the power piston . The pilot valve will sup-
As the actual unit speed returns to normal, the fly-
ply this same oil pressure to the bottom area of the
weights and speeder rod return to normal position .
power piston if the valve is moved down far enough
The receiving compensating piston is returned to
to open the control port. Due to the difference
normal position by the compensating spring at the
of areas on the top and bottom of the piston, a 46
same rate as the flyweights, thus keeping the con-
greater force on the bottom will then overcome the
force on the top side and will move the power trol port covered by the control land on the pilot
piston up, turning the terminal shaft in the direc- valve plunger . Flow of oil through the compensat-
ing needle valve determines the rate at which the
tion to increase fuel .
receiving compensating piston is returned to normal .
If the pilot valve is moved up, the area under the pis- At the completion of this cycle, flyweights, speeder
ton is opened to sump, reducing the force exerted on rod, pilot valve plunger and receiving compensat-
the bottom of the piston . The force exerted by the ing piston are in normal positions ; power piston
oil pressure on the top will then be greater and and terminal shaft are stationary at a position cor-
will move the piston down, turning the terminal responding to increased fuel necessary to run the
shaft in the direction to decrease fuel . prime mover at normal speed under increased ' load .
The governor drive shaft, gear pump, pilot valve

bushing assembly and ballhead rotate together . A DECREASE OF LOAD
laminated drive shaft interconnects the gear pump Assume now that load on the prime mover is de-
and ballhead driver gear . creased and speed increases . As the speed increases,
the flyweights move out raising the speeder rod and
The spring under the pilot valve supports the the inner end of the floating lever, thus raising
weight of the pilot valve and floating lever . The the pilot valve plunger and uncovering the con-
spring above the actuating compensating piston acts trol port in the pilot valve bushing . As the con-
to eliminate lost motion in the compensating link-
age and has no effect in the normal operation of the
governor .
trol port is opened, the bottom of the power cyl-
inder is opened to sump and the oil pressure (red)
on the top of the power cylinder forces the power
0
piston down and rotates the terminal shaft in the
INCREASE OF LOA D direction to decrease fuel .
Assume the load on the prime mover is increased,
As the power piston moves down, rotating the
resulting in a decrease in speed . As speed decreases
terminal shaft, the actuating compensating piston
the flyweights move in, allowing the speeder spring
moves up and draws the receiving compensating
to lower the speeder rod and the inner end of the
piston down, compressing the upper compensating
floating lever, thus lowering the pilot valve plunger
spring and lowering the outer end of the floating
and uncovering the control port of the pilot
lever and the pilot valve plunger . Movement of
valve bushing. The opened control port admits
the power piston, -actuating compensating piston,
pressure oil (red) to the bottom of the power cylin-
receiving compensating piston and pilot valve
der (green) . Since the bottom area of the power
plunger continues until the control port in the
piston is greater than the top area, oil pressure will
pilot valve bushing is covered by the control land
move the piston up and rotate the terminal shaft
on the pilot valve plunger . As soon as the con-
in the direction to increase fuel .
trol port is covered, the power piston and terminal
As the power piston moves up rotating the terminal shaft are stopped at a position corresponding to de-
shaft, the actuating compensating piston moves creased fuel needed to run the engine at normal
down and forces the receiving compensating piston speed under decreased load .
6 40
L
I-
40
PRESSURE OIL
SUMP OIL SPEED DROO P
FULCRUM SPEED DROO P
TRAPPED OI L LEVER SPRIN G
COMPENSATING OI L
0 FUEL INCREAS E
LOAD (Fuel)
INDICATING POINTER
(Dial Type Only )
SPEED DROOP MECHANISM

FOR LEVER TYPE GOVERNO R
LOAD LIMIT ADJUSTING KNOB
(Dial Type Only) ACTUATING
LOAD LIMI T COMPENSATING PISTON
AND INDICATION RAC K
DRIVE SHAFT FROM ENGIN E
Figure 7 . Schematic Diagram of UG40 Governo r
As speed decreases to normal, the flyweights return At the completion of this cycle, the flyweights,
to normal position lowering the speeder rod to speeder rod, pilot valve plunger and receiving com-
normal position. The receiving compensating piston pensating piston are in normal positions ; the power
is returned to normal position by the compensating piston and the terminal shaft are stationary at a
spring at the same rate as the flyweights, thus keep- position corresponding to decreased fuel necessary
ing the control port in the pilot valve bushing to run the prime mover at normal speed under de-
covered by the control land on the pilot valve creased load .
plunger . Flow of oil through the compensating
needle valve determines the rate at which the re- In actual operation, the events described occur al-
ceiving compensating pistQn is returned to normal . most simultaneously, rather than step by step .
7
ky;10191
This description is based upon speed changes re- CAUTION : Be sure that the screwdriver fits 0
sulting from load changes . However, the same se- into the shallow slot of the compensating
quence of governor movements would occur if a needle valve and not into the deep slot lo-
difference between actual governor speed and gov- cated at right angles to the shallow screw-
ernor (and prime mover) speed setting is produced driver slot .
by turning the speed control shaft on the lever
type governor or the synchronizer control knob on
the dial type governor . 3 . Allow the prime mover to hunt or surge for
about one-half minute to bleed trapped air
CROSS-SECTIONAL VIEW from the governor oil passages . Loosen nut
The cross-sectional view, figure 8, shows the posi- holding the compensating adjusting pointer
tion of the governor parts with the prime mover and set the pointer at the extreme left (MIN .)
running at - normal - speed - under, steady ~ load . The position .
centrifugal force of the flyweights (due to the speed
of rotation) balances the opposing force of the 4 . Gradually close the needle valve until hunting
speeder spring with- the flyweights in the vertical just stops . Do not go beyond this position .
position . In this position, the flyweights hold the Check the amount of needle valve opening by
pilot valve plunger in its centered position, with closing the valve completely, noting the frac-
tion of a full turn required to close the valve.
the control land just covering the control port
Re-open the valve to the point at which hunt-
in the pilot valve bushing. With the control
port closed, oil pressure is balanced across the power ing stopped . Test the governing action by
manually disturbing the -prime mover speed . 0
piston and the power piston and terminal shaft are
If the governor functions properly with the
held stationary .
needle valve more than one-eighth turn open
STARTING PRIME MOVE R in a governor with but one compensating spring
When starting the prime mover, set the throttle to (see page 18) or three-eighths turn open in a
the idle or start position . If a dial type governor governor with two compensating springs (page
is being used, set the load (fuel) limit control to 19), the adjustment is satisfactory and in-
limit fuel at the speed-no-load position. This pre- structions 5,6, 7, and 8 below may be ignored .
vents the prime mover from getting excessive fuel
during the start . Experience will determing if it 5 . If hunting did not stop with the needle valve
is necessary to further limit the fuel on future at the minimum openings given in step 4,
starts
' . After the prime mover has warmed up, turn raise the compensating pointer two divisions
the load limit control to 10. Use the synchronizer on the scale and continue as follows :
control to adjust the prime mover to its normal 6 . Open the needle valve and allow the prime
speed . mover to hunt.
7 . Repeat instruction 4 .
COMPENSATING ADJUSTMENT S
8 . If necessary, repeat 5, 6, and 4 until adjust-
Although the governor may appear to be operating ment is satisfactory . The desirable needle valve
satisfactorily because the prime mover runs at con- opening is from 1/8 to 1/4 turn on governors
stant speed (without load), the governor still may with one compensating spring and from 1/2 to
not be adjusted correctly. High overspeeds and
underspeeds or slow return to normal speed after
3/4 turn on governors with two compensat-
ing springs .
40
load changes may result from incorrect compensa-
tion adjustments . NOTE : It is desirable to have as little com-
pensation as possible . Closing the needle valve
Make th~ following adjustments to be certain that
further than necessary will make the prime
the governor will give optimum control .
mover slow to return to normal speed after
After the temperature of the prime mover and the a load change . Excessive compensating piston
oil in the governor have reached their normal op- travel caused by adjustment of the compensat-
erating values, the compensation should be adjusted ing adjusting pointer too far toward the right
without load on the prime mover as follows : (MAX.) position will cause excessive speed
1 . Loosen the nut holding the compensating ad- change after load change .
justing pointer and set the pointer at its ex- 9 . After correct adjustment is obtained, install
treme right (MAX .) position (see figure 4) . the compensating needle valve plug over the
Tighten the nut after the pointer has been set . needle valve.
2 . Remove the compensating needle valve plug 10 . Check governor operation under load . Occa-
that covers the compensating needle valve, sionally, slight readjustments of the needle
open the compensating needle valvethree or valve or compensating adjusting pointer are
more turns with a screwdriver. necessary for best operation under load .
8
0
EV T
SPEED CONTROL
SHAFT
SPRING LOADED
ACCUMULATO R
RECEIVING
COMPENSATIN G
40 P1CTr)W -
LAMINATE D
DRIVE ASSEMBLY
COMPENSATIN G
NEEDLE VALVE
Figure 8 . Sectional Cutaway of a Lever Type Governo r
9
OODWAP
Section II I
MAINTENANC E
GENERAL friction drive cover of some dial type gov-

When requesting information concerning governor ernors may fall out if not held in by a snap
operation and maintenance or ordering replacement ring, but no other parts of the governor will
parts, it is essential that the following information come out unless intentionally disassembled .
be included : 2 . Flush thoroughly with clean light grade fuel
1 . Governor serial number (shown on governor oil to remove any foreign matter .
nameplate) . 3 . Drain thoroughly and refill with clean gov- 0
2 . Bulletin number. This is Bulletin 03014 . ernor oil. Follow the above procedure when-
ever the governor is removed from the prime
3 . Part reference number, name of part, or de-
mover for any reason .
scription of part . See pages 25, 27, and 29 .
If it is not possible to shut down long enough to
It is suggested that the best mechanic available
remove the governor from the prime mover, pro-
(preferably one experienced with small parts as-
ceed as follows :
sembly) be permanently assigned to all governor
repair work. Cleanliness of tools and work space 1 . Remove the oil drain plug (figure 1 or 2)
is essential . A work bench, vise, arbor press, speed and drain the oil from the governor .
lathe, air line and containers for cleaning solvents 2 . Replace the oil drain plug and fill the gov-
should be provided if possible. The usual small ernor with clean light grade fuel oil . Open
hand tools are required, and a few special Wood- the needle valve (figure I or 2) two or three
ward Governor tools are desirable if subassemblies turns and run the engine for approximately
thirty seconds .
are to be disassenibled . Refer to Woodward Bulletin
03504 for list of special tools for overhaul of UG40 3 . Remove the oil drain plug and drain out the
fuel oil and foreign matter. Replace the oil
governors .
drain plug .
4. Refill the governor with the specified governor
oil (see Oil Specifications, Section 1) .
LUBRICATION 5 . Adjust the needle valve as described in Com- 0
The governor oil should be clean and free of foreign pensating Adjustments, Section 1, and replace
particles (see Oil Specifications, Section 1) . Under the compensating needle valve Plug.
favorable conditions, the oil may be used for ap- 6 . To insure that all fuel oil is drained, repeat
proximately six months without changing . If the (1), (4) and (5) after operating unit briefly.
governor does not operate properly, dirty oil may Whenever the governor is to be stored, it should
be the cause of the trouble . be completely filled with oil .
To change the oil :
I . Remove the governor as directed under "Re-
moval of Governor from Prime Mover", page
12 .
INSPECTION AND TEST
NOTE : Mark lever positions on the terminal
shaft and on the speed adjusting shaft of a Governor faults are usually revealed in speed varia-
lever type governor before removing the gov- tions of the prime mover, but it does not necessarily
ernor . Also keep compression on the speeder follow that all such speed variations indicate gov-
spring when inverting the lever type governor ernor faults . Therefore, when improper speed vari-
to prevent the ballhead from being dislodged . ations appear, the following procedure should be
and the gear from being disengaged . The carried out :
10
iT MDD]
Check the setting of the compensating needle valve .
It is impossible for the governor to function correct .
ly if the needle valve is closed tight . Make the
compensating adjustments in Section I if necessary .
If the speed variations are erratic but small in mag-
nitude, the fault may lie in the prime mover drive
to the governor . Excessive backlash or a tight mesh-
ing of the gears driving the governor may be the
cause . No amount of adjustment or other work
on the governor can correct this situation .
If the speed variations of the governor are large
and erratic, and not correctable by changes of ad-
justment, or if the governor fails to control at all,
it should be repaired or replaced .
As a last resort, to prove whether the prime mover
or the governor is at fault, another governor, known
to be in good condition, should be installed on
the prime mover . When this is done, see that the
test governor is the same type as the one being
0 removed . See Bulletin'03501 for more detailed
troubleshooting instructions .
Figure 9 . Dial Type; Case, Cover and

Synchronizing Moto r
I . Check the load to be sure that the speed

changes observed are not the result of load
changes beyond the capacity of the prime
mover .
2 . Check the engine operation to be sure that
all cylinders are firing properly, and that the
injectors are in good operating condition .
3 . Check the operating linkage between the gov-
ernor and the prime mover to make certain
there is no binding or lost motion .
If neither load nor prime mover irregularities are
found to be the cause of the speed variation, the ____ Z
cause may be either in the governor or in the prime Figure 70 . Lever Type Case, Cover and
mover drive to governor . Speed Adjusting Shaft
If the above checks show that internal adjustments adjusting linkage from the governor speed
or repairs of the governor are necessary, the instruc- control lever . Do not remove the lever from
tions outlined below will apply. its shaft without first marking its position .
4 . Remove the four stud nuts that hold the gov-
REMOVAL OF GOVERNOR FROM PRIME MOVER
ernor assembly to the mounting pad on the
In cases of major repairs or a complete governor prime mover and lift the governor off the
change,'the unit may be removed from the prime studs and away from the prime mover. Re-
mover as follows : move the gasket from the mounting pad .
1 . Remove the oil drain plug (figure I or 2) . NOTE : At all times, use care in handling
Drain the oil from the governor and replace and setting down the governor. Be particular-
the drain plug. ly careful to avoid striking a sharp blow to
2 . Disconnect the linkage from the terminal shaft the end, of the drive shaft . Such treatment--
(fuel control linkage) . might damage governor drive shaft, drive shaft
3 . On a lever type governor, disconnect the speed bearing and governor oil pump gears .
Section IV
DISASSEMBLY
0
TOP COVER , 2 . Remove cover (D) and gasket (E) .

DIAL OR LEVER GOVERNOR (Figures 9 and 10) : SYNCHRONIZING MOTO R
1 . Remove cover screws (A) and lock wash- DIAL GOVERNOR (Figure 9) :
ers (B) . 1 . Remove the top cover as described above.
Figure 17 . Dial Type Panel
12 40
10101 D1117~
0
2 . Remove four screws (G) and lock washers
(H) that hold mounting pad M to cov-
er (D) .
3 . Remove the motor (J) and motor seal spring
(K) .
CONTROL PANEL
DIAL GOVERNO R
1 . Turn the speed droop knob (QQ, figure 11)
to zero .
2 . Turn the synchronizer knob (KK) counter-
clockwise until it stops (Low Speed Position) .
3 . Set the load limit knob (W) at 10.
4 . Rotate the terminal shaft with a special wrench
(figure 12) or linkage lever to set load indi-
cator pointer to approximately 8.5 . When ro-
tating the terminal shaft downward, push
down on the load limit strap (YY, figure 11)
to release trapped oil .
5 . Remove the ten screws (A) that hold dial
plate (B) to the panel ; remove the dial plate . Figure 12 . Panel Removal, Dial Type Governo r
6 . Scratch mark ihe position of the load limi t
pointer disk (Z) on the side of the panel boss . 3 . Invert governor on bench (no parts will fall
This is the 8 .5 position . out) . Remove the four outside hex screws and
7. Unhook the case end of speed droop spring washers (R & S, figure 9 ; Y & Z, figure 10) .
(E) .
4 . Hold case and base together and set governor
8 . Remove cotter pin (A, figure 14) and speed upright . Lift case off base . It may be necessary
droop link pin (B) . to tap case lightly to break gasket joint loose .
9. Push speed droop adjusting lever (L, figure
11) back slightly and lift up speed droop BALLHEAD
lever (figure 12) to release speeder spring
DIAL OR LEVER GOVERNOR
tension .
1 . Remove inside cotter pin (AA, figure 15) and
10 . Remove ten panel mounting screws (C, figure
pull out pilot valve pin (1313) .
11) and lock washers (D) .
11 . Tap panel (ZZ) with a plastic hammer or
wood block to break loose from case, if neces-
sary .
12 . Lift load limit strap (YY) (also see figure
12) and pull out bottom of panel approximate-
ly one-half inch . Rotate terminal shaft toward
panel to get power lever down out of the way .
13 . Turn the synchronizer knob clockwise to high
speed position . Hold up speed droop lever
(D, figure 14) and push bottom of panel in
and top of panel out .
14 . Insert a medium size screwdriver in tipper
coils of speeder spring (figure 13), press down
on speeder spring and disengage spring from
panel .
15 . Lift load limit strap and pull panel assembly
out of case .
CAS E
DIAL OR LEVER GOVERNO R
1 . Remove cotter pin (A, figure 15) and pull
out power link pin (B) . SPEEDER SPRING
2 . Remove lock screw (W, figure 16) and pull
out the compensating link slide block M . Figure 73 . Removal of Speeder Spring from Pane l
0 13
OODWA MP I
46
0
GG
RR
Figure 74 . Ballhead and Speed Setting Assembl y
14 410
TME
2 . Lift up inner end of floating lever (CC) ; above . Clamp base inverted in vise, cut lock
push down on rod end with screwdriver. Slip wire (E), and remove the three screws (F)
lever backwards, releasing lever from rod end that hold retainer plate (1) to base (CC) .
(II) . Remove floating lever .
3 . Lift out ballhead assembly . 2 . If a serrated drive shaft is used, remove taper
pin (G), serrated drive shaft adapter (H),
CONTROLET retainer plate (1), bearing (J), oil seal (K),
DIAL OR LEVER GOVERNO R oil seal retainer (L), gasket (M), key (N),
1 . Pull up compensating link Q, figure 15) . In- and drive shaft (0) .
sert assembly pin or rod through hole .
2 . Invert assembly and remove nine hex screws and 3. If a keyed drive shaft is used, remove cotter
pin (S), castle nut (T), retainer plate (U),
washers (DD & EE, figure 17) . If clamped in
bearing (V), oil seal (W), oil seal retainer
vise, do not use unnecessary force ; clamp at (X), gasket (Y), spacer (Z), key (AA), and
thickest surfaces of the casting. drive shaft (1313) .
3 . Tap base lightly with plastic hammer and lift
off carefully. 4. If ground surface of base is not perfectly flat,
4 . Let controlet remain in this position unless has deep scratches, or is grooved from the
it is to be adjusted or repaired . pump gears, it must be resurfaced. Remove
check valves (Q), drive out dowel pins and
BASE AND DRIVE SHAFT
surface grind base to remove not more than
DIAL OR LEVER GOVERNOR (Figure 17 ) .010 inch. If it is not possible to surface grind,
1 . Remove controlet from the base as described lap smooth on a flat plate .
Section V
INTERNAL ADJUSTMENT AND REPAI R
MAXIMUM OR MINIMUM SPEED
LIMIT ADJUSTMEN T
DIAL GOVERNOR
This adjustment may be made with the prime mover
running or on a governor test stand .
1 . Remove dial plate (13), (figure 11) . Turn
synchronizer knob to run prime mover at high
maximum or low minimum speed desired, de-
pending upon which setting is being made.
Minimum setting is not always required .
2 . Remove synchronizer indicator knob (KK) .
40 3 . Pull synchronizer indicator gear (VV) out of
mesh ; turn clockwise until gear pin contacts
first reduction gear (WW) for high speed
setting stop . Turn counterclockwise until gear
pin contacts first reduction gear for low speed
stop .
LEVER GOVERNO R
This adjustment may be made on a governor test
stand, or on the prime mover while running .
1 . Remove the cover as described in Section IV .
Remove the cotter pin (H, figure 10) and pull
the stop levers (L and M) off the serrated
center portion of the shaft (N) .
2 . Start the prime mover, set the throttle to
high speed position and adjust the throttle-
to-governor linkage to bring the prime mover
to desired high speed .
3 . Slip the high speed lever (L) back onto the
Figure 15 . Controlet Assembl y
49 15
OODWA P
serrated portion of the shaft so that the contact To obtain this clearance, make the adjustment
screw (K) just touches the back of the case. in paragraph 5 above, but before replacing
Adjust the screw if necessary. the cotter pin (H, figure 10), slip the low
4 . Set the throttle to low speed . speed stop lever off the serrations and turn
it back two serrations when replacing it into
5 . Slip the low speed stop lever M back onto position. Replace the cotter pin (H) . Loosen
the serrated portion of the shaft so that the
the shutdown nuts and run them up as high
lever just touches the boss at the top of the
as possible on the shutdown rod . Turn the
case . If the gap between serrations does not control shaft past minimum speed position
allow close enough adjustment, the low speed
until there is about 1/16-in& clearance be-
stop lever may be filed at the contact point.
tween the low speed stop and the boss on the
Be careful not to get filings into governor .
case . Screw the lower shutdown nut down on
Replace . the . cotter .. pin (H) . .
the'shutdown rod until it contacts th'e"speeder
NOTE : If the governor has a shutdown rod plug and the prime mover starts to shut down.
through the speeder plug, (CC, figure 14), Run the upper shutdown nut down and lock
there must be enough clearance between the the two nuts together tight . Check action of
low speed stop lever and the governor case, throttle (and governor control shaft) for
when the throttle is at low speed setting, to setting minimum speed and shutting down the
allow the over-travel required to shut down . unit.
0 0
AA---
Figure 76. Terminal Shaft, Compensating Adjusting Pointer and Case Subassembly
16
[4191~m-j
0
SYNCHRONIZING PRIME MOVER
DIAL GOVERNO R
If governor fails to respond to the control switch
on switchboard, it may be due to any of the follow-
ing causes :
1 . Low voltage.
2 . Short in wiring .
3 . Friction drive not properly adjusted . See ad-
justment procedure below.
4 . Dial plate binding dials or disks . (See Sec-
tion VI, Control Panel, Dial Governors, sub-
paragraph 17) .
5 . Motor shaft not linking up with friction drive
cover. Loosen motor mounting screws and re-
position motor .
FRICTION COUPLING ADJUSTMENT

DIAL GOVERNOR
This coupling must be tight enough to avoid a
speed adjustment change due to vibration, and also
tight enough to enable the synchronizing motor,
if used, to turn the speed adjusting gear . Four-
and-one-half pound-inches torque will meet this re-
quirement . Do not tighten so that the speed cannot
be adjusted manually by turning the synchronizer
knob . The friction of the coupling may be in- COMPENSATINGZ COMPENSATING
NEEDLE VALVE NEEDLE VALVE PLUG
creased by removing the cover from the governor,
Q -0 Figure 18 . Removing Receiving Compensating
I Pisto n
removing the retaining ring (M, figure 11), prying

the drive cover (N) out of the coupling and turn-
ing the special nut (P) on the shaft clockwise while
holding the speed adjusting knob . If the special
nut (P) turns too freely, replace it with a new one .
V I DD"*'
t C EE-A
ZERO SPEED DROOP ADJUSTMENT
D DIAL GOVERNO R
Full 38' rotation of the governor terminal shaft
6Q~;) should cause no vertical movement of the speed ad-
it--J
K-(p UPPER
I SPRING COLLAR,,_ CLEARANCE ~LOCK NUT
J ---rm
qz:HO
Figure 17 . Base and Drive Shaft Figure 19 . Spring Collor Clearanc e
0 17
k72~~ e~
ROD EN D
DASHPOT
COVER
Figure 22 . Testing Rod End for End Pla y

PRECOMPRESSION RECEIVING ADJUSTING SHIMS
.000' to .002' COMPENSATING TO CHANG E 0
PISTON PRECOMPRESSION extension should contact the gear, and the indicator
Figure 20 . Precompression Dimensio n reading should not change when the terminal shaft
is rotated . Turn the speed droop zero adjustment
justing gear (17, figure 14) (that is, no change of screw (G, figure 11) indirection necessary to reduce
governor speed setting) if the speed droop adjusting movement of the gear .
knob is set on zero . Since perfect adjustment is CAUTION : Be certain to tighten lock nut (F)
unlikely, .002-inch movement of the gear is allow- after making this adjustment.
able . '
SINGLE SPRING AND SHIM COMPENSATING
A dial indicator should be used to measure move- SPRING ADJUSTMEN T
ment of the speed adjusting gear . The indicato r
This adjustment applies to units produced before
June, 1957 .
1 . Remove the cover, panel (dial type), case, and
ballhead as described in Section IV .
2 . Remove the compensating needle valve plug
and open the compensating needle valve four
of five turns (figure 18) .
3 . Plunge the controlet and base into solvent .
0
Move the compensating link up and down
several times to flush out oil. Blow out the
controlet and base assemblies with an air hose .
4. Remove the dashpot cover (UU` or VV, fig-
ure 15) .
5 . Unlock rod end of receiving compensating
piston from the lock nut, using the floating
lever as a wrench (figure 18) . Unscrew rod
end a few turns . Unscrew lock nut to make
clearance between lock nut and spring collar
when nut is lifted (figure 19) .
6. Measure precompression (figure 20) . With
the weight of the receiving compensating
piston supported by the tipper spring collar,
the top surface of the collar should be from
LINE OF SIGHT .000- to .002-inch above the machined face
Figure 21 . Sighting Spring Collar Flush with of the controlet . Shims are used between the
Controlet Top spring and the upper spring collar to make
18
corrections in this dimension, if necessary . Do be made with the piston in its normal ver-
not change the amount of precompression un- tical attitude to include the weight of the
less instructions given in Compensation Ad- parts. See Table I for value of "A" dimension .
justments, Installation, and Oil Specifications, The piston part number is stamped on the
Section 1, and Lubrication, Section 111, have stem and is visible through the inspection
been followed and operation is still not satis- opening .
factory . After once being set for the particular NOTE : Some of the first units produced did not
prime mover and load characteristics, the set- have the part number on the piston assembly stem
ting should not be changed . Operating trou-
so it is necessary to remove the piston and identify
bles are usually caused by some other factor .
the part by measurement of plunger width and
7. Tighten nut on piston stein until upper spring length .
collar becomes exactly flush with machined
Table I
surface . Sight over top as shown in figure 21
while making this adjustment. PISTON PLUNGER OVERALL "A"
PART NO. WIDTH LENGTH DIMENSION
8. Tighten rod end and lock to nut using float-
ing lever as a rod end wrench (figure 18) . 033127 3/8" 3-3/16" 1/16"
Do not disturb flush adjustment . 1/2"
033129 3-3/16" 3/16"
9. Replace dashpot cover.
033230 3/8" 3-1/16" 3/16"
10 . Test for lost motion by very delicately mov-
033599 5/8" 3-3/16" . 5/16 "
ing the rod end up and down with the finger
tips (figure 22) . There should be no lost mo- To remove the piston assembly, the base (figure
tion or end play . 24) must be removed from the controlet. The rod
CAUTION : When testing for lost motion, end and the lock nut (figure 23) must be removed
use no f orce . The test will be worthless if the from the piston, then the piston can be removed
compensating spring is compressed . through the bottom of the controlet.
11 . If lost motion is felt, it indicates the tipper PILOT VALVE ADJUSTMENT
spring collar is not flush with the machined DIAL OR LEVER GOVERNO R
surface as shown in figure 21 . 1 . Remove cover, panel (dial type), and case as
TWO OPPOSING SPRING COMPENSATING described in Section IV .
SPRING ADJUSTMEN T 2 . Remove pipe plug in passage to control por t
(figure 24) . Use flashlight to inspect port
opening.
This adjustment applies to units produced after
3 . Push down on speeder rod (figure 25) or shut-
June 1, 1957.
down rod (if used) . This will move flyweights
1 . Remove the cover, panel (dial type), and case to inner position . Note amount of port open-
as described in Section IV. ing .
2 . Adjust the receiving compensating piston lock 4 . Continue pushing down on speeder rod (or
nut until the upper face of the receiving com- shutdown rod) and move flyweights to outer
pensating piston is set at dimension "A" above position raising the 'Pilot valve land (figure
the lower face of the inspection opening in the 26) . Note amount of port opening .
controlet (figure 23) . This adjustment must
Figure 23 . Receiving Compensating Piston PIPE PLU G
Clearance Figure 24 . Control Port Inspectio n
19
OODWA P
5 . The amount of opening for inner and outer

positions of the flyweights should be the same
and should be correct to within .005-inch .
6. If the pilot valve land needs to be raised, turn
speeder rod nut clockwise and vice versa . Re-
check adjustment.
7 . REPLACE PIPE PLUG.
GENERAL REPAIR INSTRUCTION S
Refer to the paragraph on general maintenance in
Section III .
Most of the . repair- work consists . of cleaning and .
polishing of the governor parts . All pistons, plung-
ers, valves and rods should move freely without bind
or catching. The receiving compensating piston and
its spring collars may give trouble from this cause .
Use a speed lathe and fine hard stone to polish
the receiving compensating piston . Do not break
sharp corners of the large diameter., Do not lap
in parts if possible to free up by other means.
0
Be extremely careful when polishing the pilot valve
plunger lands ; broken corners on the land will
ruin this part. Polish the plunger with a fine hard
stone using a speed lathe and holding the stone
across lands of equal diameter . Do not break the
sharp corners of the control land . Figure 26 . Pilot Valve Adjustment, It
DIAL PANEL LEAKAG E not eliminate the leak, remove and inspect the oil
If oil is visible at the dial panel, remove the dial seals (AA, MM, and SS, figure 11) and the oil gauge
plate and tighten the panel screws . If this doe s (M through R, figure 16) and oil gauge fitting (S) .
The panel oil seals seldom leak ; do not replace
them unless necessary.
OIL SEAL S
If necessary to add a small quantity of oil to the
governor oftener than once a week, all of the oil
seals should be inspected for leakage . If there is
no external indication of a leak, the drive shaft oil
seal has been worn or damaged, allowing oil to leak
from the governor into the prime mover housing .
Repair the drive shaft oil seal as described below. 410
DRIVE SHAFT OIL SEAL AND
DRIVE SHAFT BEARINGS
1 . Disassemble the drive shaft as described in
Section IV .
2 . Discard worn oil seal and install new seal
with lip towards chamfered end of oil seal
retainer . Also install a new oil seal retainer
gasket.
3. Inspect drive bearings for wear and freeness
of rotation and the shaft for wear from oil
seal . Polish or replace Jf necessary .
4. Install the assembled oil seal and oil seal re-
tainer on the drive shaft, using special care
not to damage the oil seal lips . Reassemble
Figure 25 . Pilot Valve Adjustment, i the drive shaft as shown in figure 17 .
20
du
19T91 10171 .1 T
a
Section V1
ASSEMBL Y
GENERAL easily, turn pilot valve 180' and try again .

When assembling the governor after repair, adjust- Do not install cotter pin now .
ment, or complete overhaul, observe the following 2 . Test for free action of floating lever.
precautions to avoid damaging the components . a . Push down lightly on speeder rod .
1 . Do not press the drive shaft assembly into the b . Move one flyweight through full travel
bore of the base with an arbor press or ham- several times .
mer .
C. Press down 1/4-inch approximately on rod
2 . Avoid tightening the drive shaft retainer plate end, and move flyweights through full
screws (F, figure 17) too much. Excessive tight- travel as shown in figure 27 .
ening may bend the retainer plate . There d . Lift rod end 1/4-inch approximately and
should be V8-inch clearance between the plate move flyweight through full travel as
and the boss on the base . shown in figure 28 .
3 . Whenever the governor is moved, be careful
3. If floating lever not perfectly free under
not to drop or rest it on the drive shaft .
any of the conditions under 2, it will be neces-
4 . Check all pistons and plungers for free move- sary to try various rotative arrangements o f
ment in the bores.
5 . Replace all gaskets and lock wire .
CONTROLET AND BASE ASSEMBLY

1 . Do not shellac the seal strip (HH, figure 15)
between the base and controlet . If the old
seal strip is worn or damaged, replace it. In-
spect controlet machined surface for scratches,
nicks, dirt particles, etc. Coat the controlet
surface with oil, place the seal strip (HH)
in the groove of the controlet, using soft
grease to hold in place.
2 . Make sure the pilot valve bushing (GG),
pilot valve plunger (DD), pilot valve spring
(EE), and spring seat (FF) are in place be-
fore positioning the base on the controlet .
3 . Clamp controlet lightly in vise (inverted),
place base assembly in position and turn drive
shaft to cause lug on shaft to engage the slot
in pilot valve bushing (GG) .
4 . Place and tighten nuts . Use cylinder head
method for drawing down . Do not exert too
much force.
5 . Turn drive shaft. If not free, it must be
aligned by loosening nuts and striking at
corners of base with plastic or light babbit
hammer until shaft turns free .
BALLHEAD
1 . Place ballhead assembly in controlet . Slide
floating lever (CC) on speeder rod pin, press
down on rod end, and slip lever on rod end
pin (11, figure 15) straddling pilot valve . In-
sert pilot valve pin (1313) . If it will not enter Figure 27 . Checking Floating Lever Action, I
21
-1
positions of the speeder rod, pilot valve, rod

end, and floating lever .
a . Invert floating lever and test.
b . If unsatisfactory, turn pilot valve 180' and
test .
c . If still unsatisfactory, try turning rod end
or speeder rod 180', or invert floating lever
again .
d . Continue with combinations of positions
of the parts until free action is obtained .
1. Insert cotter pin (AA, figure 15) through pilot
valve pin (BB) and secure .
5 . Check * pilot valve adjustment and remove
temporary assembly pin if in actuating com-
pensating piston link hole .
CONTROL PANEL
DIAL GOVERNOR
1 . Reassemble the dial control panel by reversing
0
Figure 29 . Assembled Control Pane l
the disassembly sequence shown in figure 11 .

See figure 29 for positioning of control panel
cams, levers, and racks .
2. Check to see that load indicator pointer disk
(Z, figure 11) is on 8 .5 mark of panel boss .
This may have been accidentally changed at
some time during the assembly work .
3. Use special wrench or linkage lever to rotate
'
terminal shaft and move power piston down .
4. Insert panel . Push up on bottom of load limit
strap to get bottom of panel in .
5. Insert speeder spring into place while lifting
up speed droop lever (D, figure 14) .
6. Rest bottom of strap on panel opening shelf . 0
Keep bottom of panel out 1/2-inch .
7. Rotate terminal shaft to raise power piston
to highest position .
8. Match panel outline to outline of pad on sides
only .
9. While holding up the load limit strap, push
panel on gently and rotate special wrench
down very slowly a small amount until pin
in power piston goes into slot of rack, and
panel contacts pad surface . Secure with two
panel screws (C, figure 11) and lock wash-
ers (D) .
10. Rotate terminal shaft once or twice with spe-
cial wrench . If an oil film remains in con-
trolet, it will be necessary to release pressure
in power cylinder when rotating terminal
Figure 28 . Checking Floating Lever Action, It shaft lever downward by pushing down on
22
OODWA P
load limit strap . The load indicating pointer 12 . Secure panel with lock washers and screws .
must travel from 0 to 10 with the load limit 13 . Push down with speed droop lever .
pointer set at 10 . If it does not travel both 14 . Push speed droop adjusting lever back and
ways, remove panel and try again, starting turn speed droop lever down .
with step 2 . If the panel cannot easily be
removed, push down on the rack with a 15 . Install speed droop link pin (13, figure 14) .
screwdriver or pull up with a hook until load 16. Install speed droop spring (E, figure 11) .
indicator is at 8 .5 position . 17. Install dial plate . Turn knobs and rotat e
11 . Press down on top of load limit strap. Spring terminal shaft to be sure dial plate does not
load should be felt, but the strap should move bind . If binding occurs, loosen dial plate
down 3/16-inch . If not, remove panel and screws and center dial plate or ream out holes
try again, starting with step 2 . with a three corner scraper .
23
RT 9 r
3? 3C,_ 3~ 36 I
31 37
T " I- /3 8
I
42 -11~ I
65
30 k4 I
1
33 43,-"4> 39 53
44
29
Speed Droop Parts j
111'~265 50
28 -~~ I
1 +-27
~,j 52
0 26 123
<V
M-25
4-24
1
8--23
(M-2 0
22
19
0
---2 1
Lever Type
0-72
01-86
Single Spring 1 0
Style Receiving
Compensating
Piston
t
aj
104 103 .ip-270 41D

106 6~ 89
&.--90
1
Figure 30 . Dial and Lever Type Governor Controlet and Base Part s
24 410
T
L
1-19 OODWA P
V
Parts List
INFORMATION AND PARTS REPLACEMENT : When requesting additional information concerning governor
operation, or when oydering repair parts, it is very essential that the following information accompany the request .
Governor serial number (shown on nameplate) ; needed since the bulletin reference
numbers do not identify the exact part number required for any one governor.
2. Bulletin number.
3 . Part reference number, name of part, or description of part .
REF. NO . REF . NO.

NO . PART NAME REQ'D NO. PART NAME REQ' D
03014-1 Ballhead Drive Gear ----------- 1 03014-50 Speed Droop Lever ------------- 1
03014-2 5/16" Shakeproof Washer ------- 3 030141-51 Speeder Screw Pin ------------- 1
03014-3 5/16'~-24 x 3/4" Hex. Head Screw- 2 03014-52 Speed Droop Link Pin --------- 1
03014-4 Ballhead Bracket -------------- 1 03014-53 Cotter Pin -------------------- 3
03014-5 5/16'~-24 x 4" Hex Head Screw-- 1 03014-54 Cotter Pin -------------------- 7
03014-6 Ballhead and Gear Assembly ---- 1 03014-55 Power Lever Pin --------------- 2
03014-7 Flyweight Pin ----------------- 2 03014-56 Power Link ------------------- 1
03014-8 Solid Ballhead and Gear Assembly 1 03014-57 NPTF V8" Pipe Plug ----------- 4
03014-9 Spring Coupling Assembly ----- 1 03014-58 Pilot Valve Plunger ------------ 1
03014-10 Ball Bearing ------------------ 1 03014-59 Floating Lever ----------------- 1
03014-11 Flyweight Bearing ------------- 4 03014-60 Pilot Valve Pin ---------------- 1
03014-12 Flyweight --------------------- 2 03014-61 1/4" x 9/16" Straight Pin ------- 2
03014-13 Spring Ballhead ---------------- 1 03014-62 Controlet --------------------- 1
03014-14 Flyweight Pin ----------------- 2 03014-63 3/8" Shakeproof Washer -------- 1
03014-15 Cotter Pin -------------------- 4 03014-64 N"-24 x lV2" Hex . Head Ca p
03014-16 Ballhead Cover ---------------- 1 Screw ------------------------- 1
03014-17 Pin -------------------------- 2 03014-65 Accumulator Spring ------------ 2
03014-18 Speeder Rod ------------------- 1 03014-66 Accumulator Cylinder ---------- 2
03014-19 Speeder Rod Spring ----------- 1 03014-67 Accumulator Piston ------------ 2
03014-20 Thrust Bearing ---------------- 1 03014-68 Actuating Compensating Pisto n
03014-21 Shut Down Rod --------------- 1 Spring ------------------------ 1
03014-22 Cotter Pin -------------------- 2 03014-69 Actuating Compensating Piston
03014-23 Pilot Valve Plunger Nut ------- 1 Link ------------------------- 1
03014-24 Speeder Spring ---------------- 1 03014-70 Actuating Compensating Piston- 1
03014-25 Speeder Plug ---------------- 1 03014-71 Actuating Compensating Piston
03014-26 #8-32 Nut ------------------- 2 Pin --------------------------- 1
03014-27 Retaining Ring --------------- 1 03014-72 Y8'~-24 Stud ------------------ 13
03014-28 Shut Down Rod --------------- 1 03014-73 Check Valve Assembly --------- 2
03014-29 Bushing ---------------------- 1 03014-74 Base-Controlet Seal Strip ------- 1
03014-30 1/16" x 3/8" Cotter Pin --------- 2 03014-75 2/0 Taper Pin ----------------- 1
03014-31 .249" x 5,/8" Pin ---------------- 1 03014-76 Retaining Sleeve --------------- 1
03014-32 #8-32 Shut Down Nut -------- 1 03014-77 Ballhead Gear Driver Assembly- 1
03014-33 Speeder Plug ------------------ 1 03014-78 Spring Drive Laminations ------- 12
03014-34 Speed Droop Cam ------------- 1 03014-79 Pump Driven Gear Assembly---- 1
03014-35 Speed Droop Lever ------------ 1 03014-80 Pilot Valve Bushing ------------ 1
03014-36 Flat Washer ------------------- 1 03014-81 Pilot Valve Spring Seat --------- 1
03014-37 #10 Shakeproof Washer -------- 3 03014-82 Pilot Valve Spring ------------- 1
03014-38 #10-32 x 3/8" Hex Head Screw--- 1 03014-83 Dowel Pin -------------------- 4
03014-39 Cotter Pin -------------------- 2 03014-84 Base -------------------------- 1
03014-40 Speed Droop Link Pin ---------- 1 03014-85 1/8" Socket Head Pipe Plug ------- 3
03014-41 Speed Droop Link ------------- 1 03014-86 3/8'~-24 Elastic Stop Nut -------- 13
03014-42 Link Pin --------------------- 1 03014-87 Drive Shaft --------------- ----- 1
03014-43 Cotter Pin -------------------- 1 03014-88 Drive Shaft Key --------------- 1
03014-44 Flat Washer ------------------- 1 03014-89 Gasket ------------------------ 1
03014-45 Speeder Rod ------------------ 1 03014-90 Oil Seal Retainer -------------- 1
03014-46 Speeder Rod Nut -------------- 1 03014-91 Oil Seal ---------------------- 1
03014-47 Plug ------------------------- I 03014-92 #77503 N .D . Double Shield
03014-48 Speeder Gear ------------------ 1 Bearing ----------------------- 1
03014-49 Speeder Screw ----------------- I 03014-93 Retainer Plate ----------------- 1
25
184-~
183
At ,
182 181 1 185
18 0
179
161 162
53 163186 178 18
7
160 - 152
161 177,,~
T
30 " j 188
98
7!
159 157 1
153 14
152 158 -1 1 rl " 165 176
'~154
/ 166--a 17A
155 156 167 175
169 1168
,
167 190 ~-189
150 170-,tb, 191
151
O~-
0 1,4 9 - 171
0 IA8 175
u~147 172 194
174
0 141 146 244---~~q 193
IA5 -j
n lAO 2A3 192
245
IAA r 246 L 7
IA3 235--T 1231 -"-l 95
1,42
132 179 1!, i I
-139 A
136 ,
'137 196
Ob , I- t,,22 201 '%P-57
~242
- 242- 10 197 aa
133 -138 198
lll~v- 202 237 19 1 9
CL 135
247 204
239 240 205 202
134 1 'ek 21 200
203 .
238 -V , 1, 1 " I
235
236 2AI
Z
191 lo-215 204
2 206
23,1 230
229 216
21 8 121 4 210
230 2 221 209
231 207
233 213 8
232,~~ 223 [205920
A 211
226
231 22 7
230 229 228 212

OODWA R
Parts List
INFORMATION AND PARTS REPLACEMENT : When requesting additional information concerning governor
operation, or when ordering repair parts, it is very essential that the following information accompany the request .
Governor serial number (shown on nameplate) ; needed since the bulletin reference
numbers do not identify the exact part number required for any one governor .
2 . Bulletin number.
REF. NO . REF . NO .
NO . PART NAME REQ' D NO. PART NAME REQ' D
03014-94 Spacer ------------------------ 1 03014-137 Speed Droop Adjusting Lever ---- 1
03014-95 Y8r-18 Castle Nut ------------- 1 03014-138 Speed Droop Fulcrum ---------- 1
03014-96 1/8" x 11/2" Cotter Pin ----------- 1 03014-139 #8-32 x 1/2" Machine Screw---- 4
03014-97 1/4'~-28 x Y8" Hex . Head Screw-- 3 03014-140 Oil Sight Glass Retainer -------- 1
03014-98 .035 Dia . Lock Wire ----- As Req'd 03014-141 Oil Sight Glass Gasket --------- 2
03014-99 #0 Taper Pin ----------------- 1 03014-142 Oil Level Sight Glass ----------- 1
03014-100 Serrated Drive Shaft Adapter ---- 1 03014-143 Friction Drive Plate ------------ 1
03014-101 Drive Shaft Key --------------- 1 03014-144 Synchronizer Friction Drive Case- 1
03014-102 Drive Shaft ------------------- I 03014-145 Friction Drive Spring ---------- 1
03014-103 1/4" Socket Head Pipe Plug ------ 1 03014-146 1/V-28 Thin Elastic Stop Nut --- 1
03014-104 Compensating Needle Valve ----- 1 03014-147 Friction Spring ---------------- 1
03014-105 Flat Washer ------------------ 1 03014-148 Synchronizer Friction Driv e
03014-106 Compensating Needle Valve Plug 1 Cover Assembly ---------------- 1
03014-107 Check Valve Assembly ---------- 2 03014-149 Retaining Ring --------------- 1
03014-108 Receiving Compensating Pisto n 03014-150 Key -------------------------- I
Assembly --------------------- 1 03014-151 Top Cover (Plain) ------------ 1
03014-109 Receiving Compeiisating Piston 03014-152 1/4" Lock Washer -------------- 8
Spring ------------------------ 2 03014-153 Hex. Head Cap Screw ---------- 8
03014-110 Spring Seat ------------------- 1 03014-154 Oil Cup ---------------------- 1
03014-111 Upper Collar ------------------ 1 03014-155 Slide Block -------------------- 1
03014-112 Receiving Compensating Piston 03014-156 Compensating Adjusting Link ---- 1
Lock Nut --------------------- 1 03014-157 Compensating Lever and Link Pin 1
03014-113 Receiving Compensating Piston 03014-158 Spacer Link ------------------- 1
Nut -------------------------- 1 03014-159 Actuating Compensating Piston
03014-114 Power Piston ------------------ 1 Link Pin ---------------------- 1
0301.4-115 Power Piston to Load Limit Rack 03014-160 Power Lever ------------------ 1
Pin --------------------------- 1 03014-161 #5 Taper Pin ----------------- 2
03014-116 Flat Washer ------------------- 1 03014-162 Link Pin ---------------------- 1
03014-117 Shut Down Spring ------------- 1 03014-163 Speed Droop Link -------------- 1
03014-118 1/32" x 3/8" Cotter Pin --------- 1
40 03014-119 Dashpot Cover Subassembly -
03014-120 Shut Down Lever -------------- 1
I
03014-164 Compensating Lever ------------ 1
03014-165 Oil Sight Gage Cap ------------ 1
03014-166 Threaded Bushing ------------- 1
03014-121 Shut Down Lever Pin ---------- 1 03014-167 Gasket ------------------------ 2
03014-122 #10-32 x 1/2" Round Head Screw 2 03014-168 Sight Glass ------------------- 1
03014-123 Dashpot Cover ---------------- 1 03014-169 Oil Sight Gage Complete (Hous-
03014-124 Shim-.005" Thick -------- As Req'd ing not furnished separately) ---- 1
03014-125 Shim-.010" Thick -------- As Req'd 03014-170 Oil Gage Fitting -------------- 1
03014-126 Shim-.020" Thick -------- As Req'd 03014-171 Compensating Adjusting Fulcrum 1
03014-127 Upper Collar ------------------ 1 03014-172 Compensating Adjusting Lever-- 1
03014-128 Receiving Compensating Pisto n 03014-173 "0" Ring --------------------- 1
Spring ------------------------ 1 03014-174 Oil Seal --------------------- 2
03014-129 Lower Collar ------------------ 1 03014-175 Roller Bearing ----------------- 2
03014-130 Bushing ---------------------- 1 03014-176 Cover-Case Gasket ------------- 1
03014-131 Receiving Compensating Piston-- 1 03014-177 Top Cover (Motor) ----------- 1
03014-132 Speed Droop Lever Spring ------ 1 03014-178 Motor Mounting Plate --------- 1
03014-133 Speed Droop Lever Screw ------- 1 03014-179 #8 Shakeproof Washer --------- 6
03014-134 Speed Droop Adjusting Screw --- 1 03014-180 #8-32 x -Y8" Round Head Screw- 4
03014-135 #10-32 Machine Screw Nut----- 1 03014-181 Bodine Synchronizing Motor ---- 1
03014-136 Flat Washer ------------------ I 03014-182 Wire Marker ------------------ 1
48 27
268
153-1 154 154- 69 (9 24 8

1 51 . F-
249
I Cl ~)Q I
161
160 165 176

Z! G-1 66
c rl 61
167 250
30 16 8
164 174 175 167
16 9 263
157
159 158 257
256 1 190 264
98 265
0 15 6
155
0 171 266
CR) IN
n ~, 256
0
175 257
17
2. X c 174
tA 173 261 V 258
r~-259
251 194
252
254 195 1 3
253-*r 57
19 6
11 197
235
198 192
~551 19 9
1 260
200 -72
Parts List
INFORMATION AND - PARTS REPLACEMENT : When requesting additional information concerning governor
operation, or when ordering repair parts, it is very essential that the following information accompany the request .
1 . Governor serial number (shown on nameplate) ; needed since the bulletin reference
numbers do not identify the exact part number required for any one governor .
REF. NO . REF. NO.

NO. PART NAME REQ'D NO . PART NAME REQ' D
03014-183 Wire Marker ------------------ 1 03014-228 Synchronizer Indicator Knob ---- 1
03014-184 Wire Marker ------------------ 1 03014-229 Socket Head Setscrew ----------- 4
03014-185 Motor Seal Spring ------------- 1 03014-230 Knob ------------------------ 3
03014-186 # 10-32 x Y8" Flat Head Screw - - 4 03014-231 #610 Taper Pin --------------- 5
03014-187 I/V-28 x Ys" Hex . Head Screw-- 8 03014-232 Seal Spring ------------------- 1
03014-188 Oil Cup ---------------------- 1 03014-233 Seal Washer ------------------- 1
03014-189 Dowel Pin -------------------- 2 03014-234 Load Indicator Pointer --------- 1
03014-190 Compensating Lever Stop Pin ---- 2 03014-235 #8-32 x N" Phillips Binding
03014-191 Case -------------------------- 1 Head Screw ----------- \ -------- 12
03014-192 Terminal Shaft ---------------- 1 03014-236 Synchronizer Gear Shaft -------- 1
03014-193 3/32" x 11/4" Cotter Pin --------- 1 03014-237 Oil Seal ----------------------- 2
03014-194 Compensating Pointer Indicato r 03014-238 Needle Bearing ---------------- 2
Plate ------------------------- 1 03014-239 Friction Spring Collar ---------- 1
03014-195 #6 x 1/4" Drive Screw --------- 2 03014-240 Oil Seal ----------------------- 1
03014-196 Flat Washer ------------------- 1 03014-241 Friction Spring Pin ------------ 1
03014-197 Compensating Adjusting Pointer- 1 03014-242 Panel ------------------------- 1
03014-198 Flat Washer ------------------- 1 03014-243 Speeder Screw Guide ----------- 1
03014-199 5/16"-24 Thin Elastic Stop Nut-- 1 03014-244 Pin -------------------------- 1
03014-200 Case-Base Gasket -------------- 1 03014-245 Speed Droop Cam Assembly ----- 1
03014-201 Friction Spring Pin ------------ 1 03014-246 Panel-Case Gasket ------------- 1
03014-202 Load Limit Friction Spring ------ 2 03014-247 Synchronizer Adjusting Gea r
03014-203 Load Limit Cam Assembly ------ 1 (Horizontal) ------------------ 1
03014-204 Bushing ---------------------- 2 03014-248 Hex . Head Machine Screw ------ 8
03014-205 Load Limit Gear --------------- 1 03014-249 1/4" High Collar Lock Washer --- 8
03014-206 "0" Ring --------------------- 1 03014-250 Cover (Speed Droop) ---------- 1
03014-207 #8-32 x 1,4" Phillips Round Hea d 03014-251 Speeder Adjusting Gear Segment- 1
Screw ------------------------ 2 03014-252 I/V-28 Hex . Nut -------------- 1
03014-208 Load Limit Strap Adjusting Plate- 1 03014-253 1/4"a--28 x 11/2" Setscrew --------- 1
03014-209 Load Limit Strap and Rack Pin- 5 03014-254 High Speed Stop -------------- 1
03014-210 Load Limit Strap -------------- 1 03014-255 Low Speed Stop --------------- 1
03014-211 Flat Washer ------------------- 1 03014-256 Control Shaft Bushing ---------- 2
03014-212 Load Limit Lever -------------- 1 03014-257 Oil Seal ----------------------- 2
03014-213 Flat Washer ------------------- 1 03014-258 3/32" x I" Cotter Pin ----------- 2
03014-214 Load Limit Rack --------------- 1 03014-259 Control Shaft ------------------ 1
03014-215 Synchronizer Adjusting Shaf t 03014-260 Case -------------------------- 1
Assembly ---------------------- 1 03014-261 Nameplate -------------------- 1
03014-216 Synchronizer Shaft Pin --------- 1 03014-262 Spacer ----------------------- 1
03014-217 Needle Bearing ---------------- 2 03014-263 Gear Segment ----------------- 1
03014-218 .18Y'x .562" Pin --------------- 2 03014-264 Stop Screw (5/16"x2-1/4 "
03014-219 # 10 Split Lock Washer --------- 10 Hex Hd- Screw) ---------------- 2
03014-220 #10-32 x Y8" Phillips Filliste r 03014-265 Lock Nut (5/16"-24) ----------- 2
Head Screw ------------------- 10 03014-266 Bushing Nut ------------------ 2
03014-221 Synchronizer Indicator Shaft ---- 1 03014-267 Torsion Spring ---------------- 1
03014-222 Synchronizer Indicator Gear ----- 1 03014-268 Low Speed Stop Screw ---------- 1
03014-223 Synchronizer Stop Pin ---------- 1 03014-269 Hex Nut (5/16"-18) ------------ 1
03014-224 First Reduction Gear Shaft ------ 1 03014-270 Hex Hd . Nylock Screw
03014-225 First Reduction Gear Assembly --- 1 (3/8"-24 x 3/8") ---------------- 1 3
03014-226 Dial Plate --------------------- 1 03014-271 Copper Washer --------------- 1 3
03014-227 Synchronizer Indicator Pointer --- 1
29
0
JT; for*] cyu!] D
SYNCHRONIZING MOTOR MAINTENANCE AND PARTS LIST

INFORMATION AND PARTS REPLACEMENT : When requesting information concerning motors,
or when ordering spare parts, it is essential that this information accompany the request :
I . Serial number of the governor (the motor serial alone is not sufficient) .
2 . Voltage of the motor .
3 . Part number and name or description of part .
TO LIN E
WIRINQ DIAWM FOR SYNCHRONIZING MOTOR 0

(SWITCH NOT FURNISHED)
287
288 28 9
Part No. Name of Part No . Req'd . Part No . Name of Part No . Req'd.
279 Motor Brush 2 285 Bronze Gear 1

280 Brush Spring 2 286 End Shield, Front 1
281 Worm Shaft 1 287 Gear Housing Assembly 1
282 Bakelite Gear 1 288 Field Frame Assembly Complete 1
283 Brushholder Cap Screw 2 289 Armature Wound Complete 1
284 Brushholder 2 290 Output Shaft 1
BEARING LUBRICATION : Under normal, inter- ing greases, or their equivalents :

mittent operation, the motor bearings should be
lubricated - through the oil cup provided - every -65 degrees F .'to 32 degrees F . - use Bodine
six months with Gulfcrest A or Stanoil No. 18, or LG2 or Beacon No . 325 .
their equivalent .
32 degrees F . to 212 degrees F. - use D .A. Stuart
GEAR LUBRICATION : The speed reduction gear H .M .P . No .1 or Hodson No . 2-1000 .
housing of a new motor is filled with sufficient
lubricant to last for a one to two year period. Above 212 degrees F . or with motor mounted
When lubricating, 5lean out the old grease and re- with gear housing up - use Dow Corning No . 44 ;
fill the gear housing 3/4 full of one of the follow- put grease directly on gears .
30
BETRIEB KSZ 70/125 B
M *Aftk* M OPERATIO N
0 I
Inhaltsverzeichnis Abschnitt 3 Table of contents Section 3 Blatt Shee t
Allgemein . . . . . . . . . . .. . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . 2
Inbetriebsetzen . . . . . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . . . 3 -5
Umsteuern . . . . . . . . . . . . . . . . . . ... . . . Reversing . . . . . . . . . . . . . . . . . . . . . 6
Abstellen . . . . . . . . . . . . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . 7
Außerbetriebsetzen . . . . . . . . . . . . . . . Taking out of operation . . . . . . . . . 7
Überwachung Betriebswerte . . . . . . . . Monitoring service data . . . . . . . . . 8
Kraftstoff . . . . . . . . . . . fuel . . . . . . . . .. .. . .. 9
Schmieröl . . . . . . . . . . . luboil . . . . .
Kuhlwasser . . . . . . . . . . cooling water .. . *******'
. . . . .. 9 9
Anlaßluft . . . . . . . . . . . starting air . . . . . . . . . 10
0
Ladeluft . . . . . . . . . . . . charging air . . . . . . . . 10
Verbrennung . . . . . . . . . combustion . . . . . . . . . . 10
Leistungsbestimmung . . output . . . . . . . . . . . . . . 10+ 1 8
Motoreneinlauf . . . . . . . . . . . . . . . . . . Break-in . . . . . . . . . . . . . . . . . . . . . . 21
Beurteilung und Behandlung von Evaluation and care of lubricating oi l

Schmierölen wöhrend des Betriebe s in Diesel engines . . . . . . . . . . . . . . 24
Sepcrieren von Schmierölen . . . . . . . . Separating of lubricating oil . . . . . 25
Kondenswasser in der Ladeluftleitun g Condensating water in air receiver 26
Konservierung von Dieselmotoren . . . Conservation of Diesel engines . . . 29

Betriebsstörungen Operating difficultie s
Fehlersuchtafel . . . . . . . . . . . . . . . . Trouble shooting . . . . . . . . . . . 35 -37
Ausfall eines Zylinders . . . . . . . . . Failure of one cylinder . . . . . 38, 39+43
0 Störung an Bedienungseinrichtung Difficulties on manoeuvring stand 39
Notumsteuern . . . . . . . . . . . . . . . . . Emergency reversing . . . . . . . . 40
Ausfall von Abgasturboladern und Exhaust turbocharger an d
Vorgeblösen . . . . . . . . . . . . . . . . . . blower out of service . . . . . . . 41
Verhalten bei BLACK OUT . . . . . . Directions for BLACK OUT . . .42
M.A . N . -Abgasturbolader M .A . N . exhaust turbocharg e
Inbetriebsetzen . . . . . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . . 51
AuBerbetriebsetzen . . . . . . . . . . . . . . . Laying up . . . . . . . . . . . . . . . . . . . 51
Betriebsstbrungen . . . . . . . . . . . . . . . . Operating difficulties . . . . . . . . . 52+53
04
D36 5612 D+E 3'. 1 -2
0
0
OPERATI ON
M *Ak* P4 General
KSZ
2
KEZ
0
General
The Diese .1 engine may only be started and shut down by the responsible operators, who must
be trained for this purpose and must be familiar with the plant . A basic requirement is a
general knowledge of Diesel engine control .
If the engine has not been provided with an automatic monitoring system it is necessary to
start a log book in which all essential data and work concerning the engine (operating hours,
fuel consumption, periods between oil changes, indicator diagrams, mainterance and over-
haul work etc .,) are to be entered . If there is a change off staff, the new staff must be able
to efficiently operate and service the engine on the basis of this log book as well as the
operating instructions . The log book also serves as a means of locating irregularities or
failures .
The temperature in the engine-room should not drop below + 50C . If the temperature drops
below this figure, after alT, the cooling water spaces must be drained, unless the cooling
0 water contains an anti-freezing agent . If these spaces are not drained it is possible that
freezing causes cracks in the material . If the engine is to be shut down for a longer period,
the cooling spaces must always be drained .
During engine operation and while maintenance or overhaul work is being carried out on the
engine, the accident prevention rules and regulations must be observed . It is advisible to
display the rules and regulations in the engine-room and to continually draw attention to
hazards . Particular precaution is necessary if the engine is running and the 6asings are re-
moved .
H.
Owing to the use of fuel 6d luboil, there is the danger of fire in the engine-room . It is
imperative to ensure that fuel and oil pipes do not lead past uninsulated, hot engine
components (exhaust pipe, exhaust gas turbocharger) . After overhaul work on the exhaust
pipe all insulating materials and casings are to be carefully re-fitted . All fuel and oil pipes
must be checked for tightness at regular intervals . Leakages at pipes and tanks as well as
leakage oil accumulations are to be eliminated immediately . The fire-fighting equipment
must be checked at regular intervals .
0
If a fire breaks out in the engine-room the fuel and oil inlets are to be shut off immediately
(close valves, shut down delivery pumps, stop engine) and an attempt is to be made to ex-
tinguish the fire by means of the hand-operated fire extinguishers . If this attempt is un-
successful or the engine-room is no longer accessible all openings must be closed so as to
cut off the supply of air and to smother the fire . A pre-requisite for this is that al I openings
are sealed (doors, skylights, fans and vents shut down, funnel) . Since the fuel requires a
large amount of oxygen for burning shutting off the flow of air to the fire is one of the most
effective fire-fighting methods . A carbon dioxide fire-fighting system must not be put into
operation until there is no doubt whatsoever that no one has been left behind in the engine-
room .
Note The first minutes after the outbreak of a fire are decisive and it is therefore necessary
to stay calm and to careful I y consider the action to be to6n .
iZ:ID36 5610 E 3 .2-1

0
0
OPERATION KSZ - B
Starting
0 3
Preparations prior to Engine Start Up
Before starting the engineafter repairs or after a long period of idleness, the following
work is to be carried out (operai on s that have been carried out in the course of repairs
can be excepted) ;
I . Fue l
Dra ;ri water from sett Iing and day tanks and ref i I I tie m .
Empty filters and clean elements .
Set all stop cocks to operating position .
For heavy oil operation : To start on Diesel oil : set three-way valve to allow Diesel oil i
to How from the day tank to the mixing tank .
Switch on fuel supply pump .
0
Vent injection pumps, fuel injectors, pipes and filters, check system for tightness .
Check zero setting of pump rocks of all injection pumps and check control linkage
for binding or sticking .
Switch off fuel supply pump .
For heavy oil operation : Switch on and check heating equipment for storage, settling,
day and mixing tanks, for heated pipes and for end-preheater .
2 . Cooling Water
Drain sludge from cooling water tank and cooler .
Fill up cooling water, add corrosion inhibitor (see section 1 and 4) . I
Switch on cooling water pumps (cylinder, piston and injector cooling) .
Vent cooling water spaces and check all connections for tightness .
Check cooling water pressure and ' water level in expansion tanks .
Check expansion tanks for separated corrosion inhibiting oil (cylinder and piston cooling
water) or separated fuel oil (fuel injectors) .
Switch off cooling water pumps .
0 Switch on air-supply pump for piston cooling, check and switch it off again .
3 . Lubricating Oi l
Pump lubricating oil out of bedplate and of service tank and clean oil spaces (do not
forget thrust bearing and exhaust turbocharger .
Clean oil filter, oil separator and oil cooler .
Refill with fresh lubricating oil (for quality requirements see section 1) or separate
existing charge .
Fill pumps of cylinder lubricators with lubricating oil and operate pumps by handcrank
until all cylinder liners are supplied with oil .
The longest of the oil delivery pipes must be loosened for this ~urpose at the respective
cylinder liner until oi I flows out at the loosened connection after which it is to be re-
tightened .
Al I bearing points that are not connected to the force-feed lubrication system are to be
serviced by hand (starting valves, fuel control linkage, injection pump drive) .
Fuel drive gear casings of speed transmitter and stroke counter with lubricating oil up to
the overflow .
0%
N
Ui D36 5610 E 3 .3-2 I p .t .o .
Set all cocks to operating position and switch on lubricating oil pump(s) for bearing
lubrication . 40
Check bearings and spray no=les (see lubricating oil system in section 2) whether all
bearing points are supplied with lubricating oil .
Check pipe connections for leakage .
Check lubricating oil pressure in crankgear (M .A. N . exhaust turbocharger) and oil level
in thrust bearing .
Open relief valves and indicator valves and turn crankgear through a few revolutions
by means of the turning gear .
Efficacy of lubrication of pistons and piston rings can be checked through the inspection
hole in the cylinders at the control sid e
Disengage turning gear.
4 . Starting Air
Drain condensate from pressure air tank, check pressure and refill if necessary .
Switch on air compressor and check delivery .
Check stop valves and mainstarting valve for free movement .
Check tightness of starting valves in cylinder covers .
Blow out cylinders with pressure air (starting without fuel), close indicator valves and Is
turn engine slowly with compressed air to test engine starting system .
Reversible engines : Carry out several test manoeuvres; while checking performance of
reversing gear .
5 . Charge-Ai r
Set selector switch in cubicle of Booster blower to AUTOMATIC .
Check whether slides in silencers of turbochargers are in their extreme end position on
the turbocharger side .
6 . Short Test Run, if possible (in the case of marine engines, notify bridge before starting)
Worm up engine (cooling water for cylinders and pistons 50 0 C, for fuel injectors 405~,
-lubricating oil 400 Q .
Set stop cocks to operating position, switch on fuel, lubricating oil and cooling water
pumps . Switch on Booster blower control by .'means of switch in engine, control stand,
Wait until pilot lamp BOOSTER BLOWER IN OPERATION illuminates, the n
start engine (see sheet 3 .5) . Run engine for about 10 minutes at low speed .
Read indicating instruments during operation . Check if all fuel injectors operate correctly . 0
When engine runs satisfactory, load should be applied cw* the engine shut down .
Engine is ready to start .
Starting after short Service Interruptio n

.
Check temperature of cooling 'water for cylinders and pistons (500CJ for fuel ihiectors (460C)
and temperature of the lubricating oil (460C) and raise temperatures if they have dropped
below the values defined .
Set all shut-off devices to operating position including those for pressure air .
Switch on control system for motorlsed auxiliary blowers and switch on pumps for fuel,
lubricating oil, cooling water and air pump for piston cooling system as well as the oil
pumps for the hydraulic-pneumatic positioner .
Engine is ready for starting .
0
D36 5610 E / 3 .3-2
BETRIEB
+A&* M OPERATION
KSZ - B
0 4
363551 7
D36 5610 D+E 3 .4-2

0
0
OPERATION
*AtLA* N KSZ - B
0 Starting 5
Starting Engine (see illustration sheet 3 .4)
It is recommended that the engine be started on diesel oil and not changed over to heavy fuel
oil until all components (pistons, cylinder liners etc .) have reached normal operating
temperature .
For starting the engine from the engine control stand proceed as described hereunder (for
engines provided with automatic control system see separate description "Engine control and
monitoring system" .) In the case of marine engines, advise bridge before starting the engine .
I . Set switch in cubicle of auxiliary blower control to position AUTOMATIC .

2. If auxiliary blowers are not already running in support (check if indicator lamps
AUXILIARY BLOWERS OPERATING, provided in engine control stand, are illuminated),
turn switch - to start motorised auxiliary blowers and wait until indicator lamps light up .
3. If the telegraph order coincides with the position of the camshaft with regard to the direction
of movement, move control lever from STOP to the range STARTING WITH FUEL .
0
If the telegraph order does not coincide with the operating position of the camshaft see
sheet 3 .6 (reversing with engine at standstill) .
4.When engine is running at ignition speed (approx . 20 rpm) move control lever slowly into
the range FUEL . The fuel control lever must be moved out of the range STARTING into
the range FUEL, at least temporarily if a higher pump setting should not be desired, in
order to end the starting process . The pump setting can be reduced thereafter .
After the engine has been started up, check pressure readings of all gauges in instrument board .
The pointers of the pressure gauges for lubricating oil and cooling water should indicate the
defined values . Then it is to be checked whether all cylinders fire regularly (compare exhaust I
temperatures) . A short time after start up (approx . 60 seconds) the engine can be run up to
approx . 70 - 80 % of rated load . The time period that must be allowed before the engine can
be run at full load differs greatly from plant to plant, but should not be less than 15 minutes .
Expanded idling is to be avoided . The small amounts of fuel injected into the cyli nders during
idling tends to cause misfiring and the unburnt fuel collecting in the cylinders,'the* exhaust
0 manifold and the turbine of the turbocharger Vi ll lead to increased wear and cause a sooty
exhaust .
When engine load has been increased to above half -food (scavenging pressure --,- 0.65 bar),
check whether the auxiliary blowers are switched off . (indicator lamps extinguished) .
If the engine is new or has just had a major overhaul, or if components of the running gear
have been replaced (pistons, piston rings, cylinder liners, crank .and crosshead bearings),
the engine must be allowed to run in . For respective instructions see sheet 3 .21 Engine
Break-in) .
When the engine is to be run , by load control, the hand wheel for setting,the engine speed is
to be set to rated'speed (control-air pressure for rated speed is approx . 5 bar). The goverri~r
wi I I then operate as overspeed governor . The desired fuel pump setting is then effected by
means of the control lever . The movement of the governor is then being absorbed by the over-
running device in the lever linkage .
If the engine is run by speed control, the control lever is to be set to FULL LOAD and the
hand wheel for setting the speed is to be set to thedesired speed . The governor will then main-
0 tain the preset engine speed .
D36 5610 E 3 .5-2 P .t .o .

Changing over from Diesel Oil to Heavy Oil Operatio n
0
I . Engine is running on Diesel oil, components are at service temperature .
2 . Heating equipment has been switched on, temperature of heavy oil in day tank is
held at about 609C .
3 . Heat Diesel oil and by it the fuel injection pumps to approx . 660C .
4 . When above temperatures have been reached :
Set three-way valve to heavy oil operation (see diagram in section2) . 1
4 .1 . If plant is equipped with a viscometer and the preheating temperature must be
controlled manually:
Set heating rate of end preheoter in accordance with the readings of the viscometer
so as to obtain at the injection pumps the fuel viscosity (which is a function of the
heavy oi I quality used) shown in the viscosity-temperature diagramm (see section 1) .
4.2 . If plant is equipped with automatic control of the heavy oil viscosity :
The viscosity measuring and control system was adjusted when engine was taken in
operation the first time and the setting should normally not be changed (cf separate
description for viscosity control system) . 0
5 . Keep cooling water temperature at cylinder outlet at approx . 6 8 0 C .
Heavy oil has a greater density than Diesel oil . Therefore, with the some pump setting,
the heat developed and consequently the thermal loading on the engine will be slightly .
greater though the heat value of heavy oil is lower than that of Diesel oil . Consequently,
the fuel pump setting should be reduced by a like amount when the engine speed of a
marine engine is rising slightly after the change-over to heavy oil operation .
Starting on Heavy Oi l
When it is intended to start the engine on heavy oil, the following additional preparations
will then be necessary :
I . Switch on heaters for heavy oil day tanks, heavy'oll pipes* a nd'end -preheaters .
2. Switch on fuel supply pump to heat with the hot fuel the injection pumps and those
parts of the pipe system that have no heating facilities .
3 . Heat up cooling water for cylinder-, piston- and injector cooling . 0
4 . The engine can be started as soon as the heavy oil at the injection pumps has reached
a temperature that equals a fuel viscosity of < .2 .5 E (cf Viscosity-Temperature Dia-
gram in Section 1) .
5 . When the engine is running, switch off heating facilities for lubricating oil and cooling
water, unless thermostatic'controls are provided .
6 . As to applying load and checks to be made after start-up,. sed instructions given under
Diesel oil operation .
D36 5610 E / 3.5-2

M *Aftk+ M OPERATION
KSZ - B
ersing 6
Reversin g
The engine can be reversed at standstill or during operation (at a speed of less than 30 % of .
the rated speed) . Immediately the reversing process has been ended, STARTING WITHOUT
FUEL is being effected with the control lever in the same position .
Reversin g with E n g i n e at Standstil l
I . Move control lever from STOP to position REVERSE AHEAD or REVERSE ASTERN (note
interlocking by engine telegraph) . The lever is being arrested in this position and will remain
so during the reversing process .
2 . Immediately the reversing process has ended, move control lever either back to STOP or,
if the engine is to be started, to STARTING WITH FUEL .
3 . When engine has reached ignition speed (approx . 20 rpm), move control lever from range
STARTING WITH FUEL in the direction FUEL (beyond notch starting end) . Thereafter,
the lever may be moved back to a lower pump setting, if desired .
Reversing with Way on the Ship (Normal Manoeuvre)
0 I . Set control lever to STOP, engine will slow down .
2 . When speed has dropped to approx . 30 rpm, move control lever to REVERSE ASTERN (or
REVERSE AHEAD) . The lever will latch in this position and will be blocked in the direction
Fuel during the reversing process .
3 . At the end of the reversing process and with the control lever still in the same position
STARTING WITHOUT FUEL is taking place . The engine and thus the ship's propeller
are slowed down and finally stopped by starting air admitted to the cylinders due to the
fact that the camshaft is in the ASTERN position, and will then be started'in the opposite
direction .
4 . Immediately the engine starts turning in the opposite direction, move control lever into the
-1
range STARTING WITH FUEL .
5 . When engine has reached ignition speed (approx . 20 rpm) move control lever from range
STARTING WITH FUEL in the direction FUEL (beyond notch starting end) . Thereafter
the lever can be moved back to a lower pump setting, if desired .
Reversing with Way on the Ship (crash manoeuvre)
1 . Set control lever to STOP, the engine will slow down
0 2 . When speed has dropped to approx . 35 rpm, move control lever to REVERSE ASTERN
(or REVERSE AHEAD) . The lever will be arrested in this position and remain so during
the reversing process .
3 . At the end of the reversing process, the engine will be STARTING WITHOUT FUEL
with the control lever in the same position . The engine and thus the ship's propeller will
then Lie slowed down and eventually stopped by starting air admitted to the cylinders due
to the fact that the camshaft has already been shifted to ASTERN and will then be
started in the opposite direction .
Note : As the speed at which the reversing process can be started (approx . 35 rpm) and thus
the engine slowed down with the aid of starting air at a crash manoeuvre depends
upon the hull -~esiqn, it is to be ascertained by practical tests during the yard trials .
4 . Immediately the engine starts turning in the opposite direction, move-control lever into
the range STARTING WITH FUEL and at the same time press key for START-UP WITH
INCREASED pump setting provided in the engine control stand .
5 . When engine has run up to approx . 25 rpm, move control lever from range STARTING
WITH FUEL into th,e direction FUEL (beyond notch starting end) . Then set to desired
load .
40 .G.- e n .e r a
Before entering a port after a long journey, it is recommended that several test manoeuvres
be carried out in order to detect any deficiencies in good time .
1536 W E 3 .6-2
0
0
OPERATION
M*Ak*H Shut-Down KSZ - B
7
Shutting Engine Dow n

I . Reduce load and run engine at light load .
2 . Set control lever.to STOP .
3 . If engine is to be kept at stand-by for restarting within a short time, keep pumps
running and keep cooling water and lubricating oil at service temperature . By-
pass coolers and, if necessary, switch on heating equipment. The QuXil lory .b lowers
or e automatically kept in operation .
4. If stand-by
* operation is not required, switch off fuel supply pump and c v*AAary blower
control .
5 . Keep cooling water and lubricating oil pumps running until the engine has been cooled
down to approx . 450 C .
6 . Close all stop cocks, especially those on the pressure air receivers . Take pressure gauge
readings 1
7. Open all indicator and relief valves in cylinder covers .
8 . Engage turning gear when it is intended to carry out any maintenance work or when the
ship is moored in f lowing water and the propeller may be turnedby the water ctoreqt .. .
Note : When it is intended to shut the eng'Ine down for several days, it is recommende d
that the engine, after shutting down, be turned for approx . 10 minutes by means
of the turning gear whilst operating the cylinder lubricators by hand (each pump
10-20 times) in order to prevent corrosion of pistons and cylinder liners . The
electrically driven lubricating oil pump must be switched on during this operatio n
If any deficiencies or disturbances have been'noted during operation, even if they may
appear to be insignificant, they should now be iemoved .
Changing over from Heavy Oil to Diesel Oil Operation before Shutdown .
I . Approx . 15 minutes before shutting the engine down,set three-wcy cock (cf fuel diagram in!
section 2) to Diesel oil operation .
2 .-;SWitch off heating system of end-preheater .
3 . When the heavy fuel oil in the pipe system is used up and has been replaced by Diesel oil,
the engine can be shut down . I
4 . Switch off all heating systems .
0 Note : The advantage of changing over to Diesel oi I is that the engine can again be
started at any time without the plant having to be pre-heated .
Maintenance and overhaul work is much easier if fuel pipes and injection system
are filled with Diesel oil .
Shutdown from Heavy Oil Operation
I . If the engine is to be restarted in a few minutes, just keep heating equipment and one
supply pump in operation .
2 . If the engine is equipped for start-up On heavy oil (pier-to-pier operation) the steps
for shutting the engine down are the same as for Diesel oil operation, except that the
heating systems must be shut off too .
3 . If the engine is not equipped for starting on heavy oil and it has been stopped while
running on beavy oil, proceed as follows (see diagram in section 2)-.
1 .1 . -get three-way co& (40) so that Diesel oil is being delivered to the mixing tank .
3 .2 . Set three-way cock (39) to flushing position, i .e . the fuel returned from the engine is
emptied into the heavy oil day tank .
3 .3 . Keep supply pump running until the whole system is filled with Diesel oil .'
3 .4. Switch off supply pump and re-set three-way cock (39) to operating position (fuel
flowing to mixing tank) .
D36 5610 E 3 .7-2 __ R.t.0.
Cautioni
If cock (39) is not re-set but left in this position, Diesel oil will be pumped into the
0
heavy oil day tan6 when the system is restarted .
3 .5 . The injection pipes from the pumps to the fuel injectors and the injectors themselves
cannot be flushed and the heavy oil they contain will congeal sooner or later,
depending on the oil viscosity . These parts must therefore be heated up before the
engine can be restarted . If the lost part of the fuel injection pipe cannot be heated,
it must be removed, heated up and emptied .
Crash manoeuvre, see reversing
Laying u p
Shut engine down as described .above . The following additional operations will be required :
I . Drain cooling water completely .

2 . Carry out maintenance work in accordance with Maintenance Schedule and with
the help of the work cards contained in section 4 . 40
3 . Check condition of lubricating oil and replace it, if necessary- Then prime engine by
switching on the lubricating oil pump whilst turning the engine by means of the turning
gear and operating the cylinder lubricators by hand .
4. Apply a coat of grease or a preservant to all bright parts, cf recommendations sheet 3 .29 .
5 . Turn engine at regular intervals by means of the turning gear and see that piston come s
to stand in a different position than it had assumed before . While engine is being turned,
operate cylinder lubricators by the hand crank .
6 . Close relief and indicator valves after turning to prevent formation of condensate in the
cylinders .
9
D36 5610 E 13 .7-2
OPERATIO N
M *Ak+ P4 Monitoring
KSZ - B
KSZ - C
0 8
Monitoring during Operation
Genera l
After overhauls involving the replacement of pistons, piston rings, cylinder liners, main-,
crank- or crosshead bearings, the engine must again be run in . For instructions see sheet
3 .21, Engine Break-in .
When setting the engine speed, note possible barred speed ranges (marked in red on the
tachometer) which must be passed quickly . During operation, especially after load changes,
observe cooling water temperatures (cylinders, pistons, fuel injectors) and switch Booster
blowers on or off in good time .
Unless the engine is equipped with an automatic monitoring system, it is recommended that
during operation instrument readings are taken and recorded . Irregularities and incipient
0 disturbances will thus be noted in good time and can then be removed . We have established
a sample form of "Service Records" which is available on request . The filled-in forms, which
should be filed by date, will supply pertinent information in the case of investigations . The
first essential for preparing such records is that the measuring instruments are in satisfactory
condition and give correct readings .
The work to be carried out at regular intervals will be seen in the Maintenance Schedule
(section 4) which is based on operating hours .
The engine and its auxiliaries should always be kept in clean condition as it will enable
the personnel to ascertain pipe leakages or other possible disturbances quickly .
I
The pressures and temperatures given in section 1 are guide values . The exact values applicable
to the plant are ascertained and recorded during the yard or acceptance sea trials and are
entered in this table .
see table overleaf
Co D36 5610 E 3 .8-3 p.t . 0.

Engine . . Serial No . . .
0
Operating data at full load in test report 0
Temperature C Pressure ba r
Intake air before compressor . . . . . . . . . . . . . . . . . . . . .
Charge-air before cylinder . . . . . . . . . . . . . . . . . . . . . .
0
Exhaust gas after cylinder C
1 2 3 4 5 6 7 8 9 10 11 12
before exhaust turbocharger . . . . driving end

free end 0
after exhaust turbocharger . . . . . driving end
free end
Cooling water inlet before engine . . . . . . . . . . . . . . .
outlet after cylinder . . . . . . . . . . . . . .
outlet land cooling . . . . . . . . . . . . . . o .
inlet piston cooling . . . . . . . . . . . . . . .
outlet piston cooling . . . . . . o . . . . . . .
inlet injector cooling . . . . . . . . . . . . .
outlet injector cooling . . . . . . o . o . . .
Lubricating oil inlet before engine . . . . . . . . . . . . . . . .

outlet after engine . . . . . . . . . . . . . . . .
inlet M .A .N . exhaust turbocharger driving end
free en d
Fuel inlet before engine . . . . . . . . . . . . . . .

heavy oil . . sec Redwood I/100P F Is
Position of fuel pump racks in m m
of cylinder 1 2 3 4 5 6 7 8 9 10 11 12
Engine output . . . . . o . . . . . . . o . . . . . . . o . . . . . . . . . . . . . . . . . . . kW
Engine speed . . . . . . o . . . . . . . . . o o . . . . . . o . . . . . . . . . . . . . . . o . . . . . . ]/min
Speed of exhaust turbocharger driving end . . . . . o . . . . . . . . . . . . . . . I/min
free end . . . . . . . . . . . . . . . . . o . . . . . . I/min
0
. . . ... . ... . ... .
D36 5610 E / 3 .8-3 Date
OPERATION
M+Aak*M Monitoring KSZ
0 9
Monitoring
The recommendations given hereunder are applicable to engine plants that are not equipped
with an automatic monitoring system . In automated plants the variables (pressures, temperatures,
etc .) are normally automatically monitored and recorded . But even in the case of thes e
plants, the below listed checks should be made and comparison readings taken at larger
intervals .
1 . Fue l
Check tank content of day tanks (Diesel oil and heavy oil) and refill in good time .
Drain water before drawing fuel from the next tank .
Never run day tanks dry to prevent pipes and injection system from becoming air-bound .
Water and sludge in the storage tanks should be regularly drained or sucked out, otherwise
sediments may rise - up to the level of the draw pipe .
0 Clean filters and separators regularly .
Clean conditions mus t be maintained when bunkering fuel,,and a spot test of the fuel oil
supplied is to be made every time and to be kept in the engine records . (See work
sheet in section 4) . The fuel should meet the quality requirements set forth in
section I .
In heavy oil operation, the fuel temperature must be kept sufficiently high to maintain
the specified fuel viscosity before the i9jection pumps (see Viscosity-Temperafure-
Diagram, sheet 1 .25)
Do notattempt t? mix heavy oils of differing viscosity or heavy oils with destillates in
the storage tanks to avoid disturbances during operation caused by instability of
the mixture .
Clean heavy oil by separatiDn (see sheet 1 .23) .
2 . Lubricating Oi l
Check lubricating oil level in the various tanks (engine lubrication, cylinder lubrication)
and refill as necessary .
Check lubricating oil temperatures .
0
Observe lubricating oil pressure before crankgear-and turbocharger lubrication (only
M .A . N . turbochargers) at engine control stand and adjust oil pressure ' if
necessary, to maintain it at the specified value . The oil pressure may rise above
the normal value at a cold start of the engine, but this is of no consequence as
it will drop to the preset operating pressure as ihe oi4 is worming up
Note : The engine will be automatically shut down in the event of the oil pressure
failing due to disturbances in the lubricating oil system .
Check water content of lubricating oil at the specified intervals (see maintenance schedule,
section 4) . A very simple method of ascertaining even the smallest amount of water
in the oil is the following :
Take a little oil from a point of lubrication with a dry finger and rub it onto the
lense of a lighted torch . If it contains water, a milky emulsion becomes immediately
visible .
Clean lubricating oil by separation (see sheet 3 .25) .
0
Cn
Co
16 D36 5610 E 3 .9-2 p. t .0.
Clean filters and separators regularly .
Check oil delivery at flow controls of cylinder lubricators . Measure oil consumption 0
of lubricators at larger intervals .
Use aicafine lubricating oil for cylinder fu~rication (heavy oil operation)(for quality
requirements see sheet 1 .34) .
Drain dirty-oil tank (charge-air pipe), if provided . Under unfavourable operating con-
ditions (mainly during extended part-load operation), dirty oil can get into the charge-
air pipe whence it is drained into this tank . To drain the oil, open valve in the dis-
charge pipe .
3 . Cooling Wate r
Check cooling water level in expansion tanks (cylinder -, piston- and injector cooling
systems) and top up if necessary . Check concentration of corrosion inhibitor (see
quality requirements, sheet 1 .41 and section 4) .
Check cooling water temperatures at the outlet of the cylinders . Temperatures should
be about the same for all cylinders . Should the temperature rise above the admissible
limit and if it cannot be corrected by adjusting, reduce engine load and remove the
cause . The cooling water temperature should only be lowered gradually to prevent
thermal stresses in the engine . If the engine is run at too low a temperature l
cylinder liner wear will increase and also corrosion due to the sulphur content of the
heavy oil,while the fuel consumption will increase at the same time . The valves
provided at the cooling water inlet and outlet are provided for the only purpose of
shutting off the water in the course of repairs and no attempt should be made to use
them fr)r adjusting the cooling water temperature .
Check cooling water temperatures at the outlet of the lands of the cylinders . If temperatures
of individual or of all cylinders deviate considerably from specified operating values,
cooling channels may be clogged or covered by water scale . In this case, the cooling
spaces of the respective cylinders should be cleaned as soon as possible, otherwise liner
ports are likely to become fouled up with carbon deposits .
Notes on piston coolin g

0
As may be noted from the"Quality Requirements for Cooling Water" in Section 1, an
anti-corrosion oi I must be used for piston cooling water treatment . This oil produces an
oil-in-water emulsion, which forms a protective film gn the cooling space walls and thus
prevents corrosive damage to the material if the cooling system contains air .
It is therefore necessary to check the cooling water emulsion at intervals of 250 operating
hours- , as specified on work cor2'000 .07 " Checking Cooling Water" in the maintenance
schedule (Section 4), and to add further anti-corrosion oil if the concentration is too low .
D36 561 0 E / 3 .9-2

OPERATION KSZ
M*AftL*P1ll1 Monitoring
0
10
The cooling water discharge temperature defined for injector cooling (cf section I)
should be closely maintained to control formation of carbon deposits on the fuel
injectors .
When carrying out ship manoeuvres with the engine running on heavy fuel oi l
be sure to keep the cooling water temperature for injector cooling at a high level .
Watch cooling water pressures at pressure gauges .
Check at discharge the flow of cooling water discharged from the fuel injectors, the
turbochargers and from the venting pipes of cylinder venting (if provided) .
Check piston cooling system for smooth operation by listening to the operational beat .
Loud thumping sounds are an indication of insufficient air supply to the surge tanks .
Possible causes : delivery volume of air pump is too small, a defective condensate trap,
or the non-return valve of the surge tank is closed too far or completely .
Attention! In the event of disturbances in the engine cooling system or failure of

the cooling water supply, the engine must be shut down and the cause
0
removed . For restarting see Operating Difficulties in this section .
4 . Starting Air
The pressure air receivers should be refilled immediately the engine has been started in
order to have the required pressure air available at all times .
Check whether pipes connecting the header pipe with the starting valves are growing hot
after engine start-up . A hot pipe indicates that the respective starting valve is leaking .
The valve should be repaired or replaced as soon as possible as otherwise the valv e
seat or the valve will be destroyed .
I
5 . Charge-Ai r
The charge-air coolers are provided with their own automatically controlled cooling
circuit . In the case of a high air humidity, the amount of condensate precipitated in
the charge air pipe can be considerable (cf sheet 3 .26) and is normally drained via
a float valve . Proper functioning of the float valve should then be checked .
0 The charge-air temperature should be checked with a master gouge at larger intervals .
The charge-air pressure is listed in the test records and deterioration is indicative of
the turbocharger condition .
The charge-air pressure measured before and after the charge-air cooler with a
differential pressure gauge is a yard stick for the contamination of the cooler side
and should, therefore, be checked at regular intervals . For cleaning the charge-air
cooler see work sheet in section 4 .
The switch points for switching off the motorised auxiliary blowers at rising scavenge
pressure or switching on the auxiliary blowers at dropping scavenge pressure should be
checked and compared with the values listed in the test records .
0 C)
C~
2 D36 5610 E 3 .10-2 P .t .o .
0 - Combustio n
With all cylinders developing the same output, there may be slight differences in the
exhaust temperatures between the individual cylinders, and no attempt should therefore
be made to equalize the exhaust temperatures .
The exhaust temperatures should be checked and compared with the values recorded
earlier (Acceptance Test) . In the case of greater discrepancies, the cause mus t be
determined and the fault removed .
The exhaust is to be checked for discolouration . Oil smoke makes the exhaust gases
appear white to bluish, bad combustion or overload is denoted by a dark or black
exhaust . If the engine is not overloaded, discolouration of the exhaust gas may be
caused by one or several cylinders . The faulty cylinders can be determined by taking
exhaust gas pictures (see section 4) .
The engine load should be distributed over the cylinders as evenly as practicable in
which the case the firing pressures of the cylinders and the position of the injection 0
pump racks will be the same for all cylinders .
Indicator diagrams of all cylinders should be taken at specified intervals (see Mainte-
nance Schedule in section 4) . The diagrams should be taken with a Maihak indicator
Pressure -Volume diagrams cannot be taken as an indicator linkage is not provided .
Hand-drawn diagrams can however be taken . The beginning of ignition and peak firing
pressures will be seen from the height of the compression and expansion lines which
show the load distribution over the individual cylinders . The firing pressures should be
of about the same height, deviations between the cylinders should'be negligibl e
(I - 2 %) and the stated limit should not be exceeded . High firing pressures are an
indication of either injection being too early or the injected quantity being too large,
whilst low pressures are an indication of either injection being too late or the injected
quantity being too small . Irregularities can thus be determined by comparing the diagrams
that have been taken with the diagrams established during the test run . For useful
comparison, the following operating data should be entered on each diagram :
turbine speed, charge-air pressure, exhaust temperature after each cylinder, engine
speed and, if possible, fuel consumption while diagrams were takenand the injection
pump setting . 0
Proper functioning of the fuel injectors can be checked during operation with a feeler
pin after unscrewing the ring nut . If a sharp kick is felt at- each delivery stroke of pump,
the valve operates satisfactory, if not, it is an indication of the needle sticking an d
the val ve being at fault . The faulty valve should be immediately replaced and
reconditioned to obviate damage to the injection pump and the injection pipe .
7 . Determining-the Outpu t
The engine output can be determined by measuring the torque at the propeller shaft a s
a function of the engine speed . Torque measurements, however, require special measuring
instruments .
But there is also the possibility to ascertain the engine output as a function of the
injection pump setting (cf sk'eet 3 .1 Z) .
40
D~6 5, .10-2
ld*Ak* N OUTPUT
DITERMINED FROM OPERATING DAT A M .A . N .-DIESEL
0
. = ~AY (Marine Engines ) 18
0a n ara I
The actual Fower developed and thus the condition of the engine an d the ship can be
determined from the curve iihost established during the test run and s upplied with the
engine . The fuel pump settings entered In the curve sheet for vario us engine loads
in Diesel Oil and Heavy Oil Operation are a useful basis for a later assessment o f
engine performance .
This curve sheet shouldi however, be completed whilst the ship is new by enterin g
reference figures in the pump setting scale of the diagram at various engine speeds of
the laden ship in normal weather and drift current and with minimum rudder action .
Relating operating data, i .e . charge air pressure (pQ at 450C, mean exhaust temperatur e
after cylinders(t,AnZ*) and the charger speed (nT ) should be entered with the former . Later
deviations from these figures will indicate foluhed turbine blades, fouled charge-air coolers,
marine growth, propeller damage, etc ., but also fuel injector and fuel pump wear .
If the point for engine speed as a function of pump setting is located on the left of the
theoretical propeller curve when taking the first readings under the above named conditions,
0 it is an indication of the propeller moving too slowly and with difficulty due to its design
(excessive pitch) . In these
' circumstances conditions will remain unsatisfactory .
Minor deviations in pump settings are due to differing heat values a nd densities of the fuel s
at the various bunkering stations .
Example
The diagram on the back of this sheet is an example for a four-stro k e engine . The scal e
values for a two-stroke engine are somewhat different, but the prin ciple of application is
the same .
Ratings Engine output : Ne = 4416 I<V~ (6000 bhp) = 100 %
Engine speed : n 430 rpm = 100 %
M=
Mean effective pressure : pe = 1 7 .9 bar
Given Measured engine speed : n 417 rpm 97 %

M=
Mean pump setting (heavy oil operation) 64 .5
Find Engine output and operating dat a
0
Solution
Locate the 97 % speed point along the abscissa and go up along the ! vertical line .
Locate pump setting point 64 .5 (heavy oil) in dia.qram and extend p oint down to the lowe r
left in parallel with the curves in the diagram .
From the point of intersection of the two lines go left along the hor izontal line up to th e
ordinate and read the engine output 89 % . The horizontal line also intersects the curves
for charger speed, charge-air pressures and exhaust temperature . Fr om the points of inter-
section move vertically down to the respective scales .
The following readings are obtained :
Engine output : Ne = 0 .89 x 4416 = 3 930 kW (5340 bhp )
Charger speed: 900 rpm
n TL= 14
Charge-air pressure : = 1 .85 bar
PL
Exhaust temperature after
cylinder :
tAnZ = 3480C
Cl)
D36 5600 E 3 .18-1 p .t .o .

Operating Data for Determining Engine Output (Diagram )
0
.7 114111116 Los t
_71 Loa d
'/I Lost!
01:11 i
b
i C,
. I . .
1 gu .* - -
.77 - - -: : .7A.7r. 7 7 .
.-
.4-
.
. 'Vol .
. _ _
. .7
T' 0 .0. . .. .
bu
P, %P
3/41Las t
7-0
.. . . .. . . .. ..
60
S
5 0 -2'
:LQ j , I
Ioa
! I I' 0
40 -41X Diesel6l
__Yd-rine MeW Fue l
Schw er'l0
:;Heavy Fuel Oi l
30
1 141as t
:Load
20 ----- ---- -
; I ! . ;Pro el r u Ve nI I
. .. . . !Pro ell r Cdrvei
0
, PJ l
cirrio e
0 1P . . 2p . 3) . 4P 70 80 90 100 110 nM 1%)
2~O 3(10 1 350 . 4( .)0 , . J . .1 .4 0 : . . . 50 0. . C)
37 LN) .MI;,
7t
1- .' 015 : 1 2 2 (bar) i i 364003 3
L.- A
0
Legend
Ne = Engine output [ %]
nAA = Engine speed [rpm

: Exhaust temperature after cylinder 1 0 C
t Ad
= Charge-air pressure [bar]
PL
n TL= Charger speed [rpm]
Mean effective pressure bar]
Pe = I
B = Constant spee d
C = In accordance with propeller curve
0
D36 5600 E/3 .18-1
I
. ENGINE BREAK-IN KSZ

*AtL* M
0 21
Genera 1,
Regardless of how accurately piston rings and liner bores are machined, minute deviations
from the perfect roundness and parallelism are inevitable . When furthermore the inevitable
deformation of material in the course ofassembly is taken into account, it is quite evident
that, at first, there will be no conformity of piston rings to liner walls .
The larger microscopic peaks on the surface of piston rings and cylinder liners are worn off
during the running-in process . The process will be completed when the piston rings seal
the combustion gases in the combustion chamber effectively. If full engine load is applied
before this, the hot combustion gases will pass between piston rings and liner wall and
destroy the oil film within this area . As a result, the running surfaces of rings and liners
will develop burnt spots, ring wear and formation of carbon deposits in the ring belt area
will increase, and, under extreme conditions, pistons may seize .
The length of the running-in period depends, amongst others, on the surface finish of
0 piston rings and cylinder liners, on the quality of the fuel and cylinder oils used and on
engine load and speed .
To ensure that the engine cylinders actually receive the oil type specified for the various
speed and load conditions, fill lubricators and cylinder oil tanks only so for that they will
be practically empty then the cylinder oil is to be replaced by another grade . The oil
types listed below can be mixed with each other . The cylinder lubricators should be run
wide open at the beginning .
With each engine an operating data sheet with the applicable operating values is supplied
together with the Acceptance Records . The values defined therein should be observed
during the test run at the site of erection .
2Selection of Cylinder Oils
M Operation on Heavy Oi l
During break-in the engine should, if possible, be run on heavy oil as the acidulous
combustion products tend to shortenthe break-in period .The sulphur content of the heavy
oi I shou ld, therefore, not be less than 1 .5 016 by weight .
For cylinder lubrication, use on alkaline oil, SAE 40, having a TB N of approx . 25 mg
KOH/g .
2 .2 Operation on Diesel Oil (Marine Diesel Fuel )
The following 'off-types can be used for cylinder lubrication during engine break-in,
in accordance with the break-in programme :
2.2 .1 Straight oil, SAE 30 (Straight-mineral oil or Premium oil) or a slightly alkaline
lubricating oil as is used for crankgear lubrication of crosshead two-stroke engines .
2 .2 .2 HD-oil SAE 30 or 40 as used for the central lubricating system of the auxiliary engines .
2 .2 .3 Alkaline oil SAE 40 having a TBN of approx . 25 mg KOH/g .
Alkaline lubricating oils contain reactives that improve the lubricity and load-carrying
capacity of the oil film, i .e . they contain additives that tend to retard the break-in
process . This oil type should, therefore, not be used in the beginning of the break-in
process if the engine is run on Diesel oil .
If the engine is run on heavy oil for only a short period, functional test on heavy oil,
cylinder lubrication need not be changed over to an alkaline cylinder oil .
cNerZ D36 5600 E 3 .21-1 PTO I- sheet 2

2 .2 .4 Special Break-in Oi l
Before using this oil type, the engine manufacturer must be consulted because a 0
different break-in process may be required . This oil type would replace oil described
under 2 .2 .1 and 2 .2 .2 .
3 Break-in of New Engine
3 .1 On-Boar d
Engine break-in in accordance with attached break-in programme applicable to all
crosshead two-stroke engines provided the programme does not include any speeds
falling within the critical speed ranges of the engine to which it is applied .
Engine break-in can be carried out with either a f ixed blade,VP or a zero-thrust
propeller .
During the whole length of the break-in period, the engine output should correspond
to 75-95 % of the output in accordance with the theoretical prope I ler curve .
Allotment of time for bollard trials and sea trials should be based on the propeller input .
If the output and speed defined cannot be reached in bollard trials, the latter shoul d
be shortened and the running-in period in free waters extended accordingly . But no
attempt should be made to reduce the required total break-in period .
The engine load should be reduced several times (length of period 0 .5 h, reduction in 0
speed by approx. 25 % as defined in the programme . )
Every attempt should be made to maintain the operating data defined in the operating
data sheet (firing pressure, exhaust gas temperature, charge-air pressure, etc .).
Besides the checks to be made on the crankgear, also the progress in the break-in of
the cylinder liners and piston rings is to be checked through the inspection opening
provided in the cylinder locket .
3 .2 .1 Operation on Heavy Oil
For cylinder lubrication use an alkaline oil SAE 40 (cf section 2 .1) .
3 .2.2 Operation on Diesel Oil (MDF) or Gas Oi l
For cylinder lubrication use :
- Straight lubricating oil SAE 30 (cf section 2 .2 .1 ) until engine is being run at
rated speed ,
- HD oil SAE 30 or 40 up to 75 % of rated output, then use alkaline oil (cf section
2 .2 .2 and 2 .2 .3) .
0
After break-in, change over to the cylinder lubricating oil intended for use .
4 Break-in on Site Preceded by Test Ru n
If the engine has been run in in the manufacturer's works, a follow-up break-in wil I
be necessary after final reassembly on thevorksite because of a possible deformation of
the material in the course of theerection work, 9nd the new position of the piston rings
with relation to the liner running surface .
The engine must be run for at least 12 hours as described under 3 .1 and 3 .2 before i t
is run up to rated speed and MCR . The same applies'to the selection of the cylinder oil
oil used .
5 Engine Lubrication after Handing-ove r
On handing-over of the engine, the break-in process will have been advanced so for
that the engine can be operated at full load .
Cylinder oil consumption at MCR has been set to approx . 1 .2 - 1 .4 g/kWh (0 9 - I . 0
9/PSh) . During the period of 500 total operating hours cylinder oil consumption at MCR
is to be reduced to the amount defined in the operating manual .
D36 5600 E/3 .21 -1
6 Break-in after Engine Overhau l
.
After overhauls involv ing *replacement of cylinder liners, piston crowns and/or piston
rings, marine engines should be run in as defined in the break-in programme . If circum-
stances do not permit it, the engine should be run for at least 24 hours at reduced load
and speed .
After overhauls of stationary engines, they ore to be run in as defined under 3.2.
Breaking in will also be necessary even if, for example, the piston rings of only one
piston have been changed . In fact, running-in in these circumstances requires particular
attention as the liner surface may have developed unevennesses after a long period of
operation so that conforming of piston rings to the liner wall with tight sealing round the
entire circumference will be more difficult to achieve .
Ring seating and the condition of the liner surface should therefore be checked several
times, if possible, through the inspection hole in the cylinder jacket .
Before installing new piston rings, the liner bore of the installed cylinder liner should be
closely measured and if wear and ovolity have reached the upper limit defined in the
operating manual, the liner should be replaced . When in doubt, obtain advice from any
of the engine manufacturer's service stations .
Break-in programme kiviarine engine )
En g in e s peed nM 0 :4 W~4
#tl
44
t~, I : f " ftl.'t
E:
- = = :: :-! ::-_
-
r .
=
- - 7= =. 4= __ : C I - -, -41 't -
F. - - ## -
-+'T tz :
0 . . .. . . . . . . . . . . .
= .
.. . . . .
-
.. ..
.. .
...I .
. .. .. .. .
I tt 4 1 t t t
= - =itr - 141 -
------- -----
. .... .... .
...... ... . EM Service hours h
Cylinder oil-
Break-in period Gas oil or Diesel oil (MDF) Heavy Oi I
0 - 12 h Straight oil, see under general 2 .2 .1 Alkaline oil SAE 40
12 - 18 h HD-oil
see under general 2 .2 .2 Alkaline oil SAE 40
IS - 24 h Alkaline oil SAE 40 Alkaline oil SAE 40 -
0 see under general 2 .2 .3 see under general 2 . 1
D36 5600 E 3 .21 -1 sheet 2

0
0
I
M *AQk* M EVALUATION AND CARE OF

LUBRICATING OIL DURING M .A .N .-DIESEL
0 OPERATION 24
G ener a I
Problems of oil selection vary with the engine design, the grade of fuel used and the
prevailing operating conditions (see section I ) .
Diesel engines use, almost without exception, heavy duty oils for lubrication (HD oil is
base oil improved with additives) .
Base oil is a complex compound of hydro-carbon molecules . The concentration and combi-
nation of additives added to the base oil depends upon the requirements the lubricating oil
has to meet . Additives are used to improve the resistance to aging and the corrosio n
inhibiting properties, others are employed to confer detergent and dispersant propertie s
on the oil, i .e . they enable the lubricating oil to keep residues, produced by the combustion
of the fuel and the lubricating oil, in a finely divided form in solution or in suspension ,
and they dissolve residues which have already precipitated . Additive type lubricants further-
more possess an alcaline reserve, expressed by the total base number (TBN) which neutralizes
the acidic products formed during combustion .
0
Evaluation of Used Oi l
The condition of the lubricating oil in the engine should be continually observed . The
intervals at which blotter tests on filter paper are to be made, or at which used-oil samples
are to be taken for laboratory tests are named in the maintenance schedule (it is recommended
that oil samples are sent to the oil suppliers'service stationsl-The oil sample should be taken
after the filter and, if possible, while the engine is running as this will ensure that the test
result will be representative for the whole oil charge Th the engine .
The progression of changes in the characteristics of the oil can be inferred from blotter or
spot tests . Striking changes in the appearance of blotter tests, taken between intervals of
about the some length, are an indication of irregularities, as for example insufficient
combustion, pure filtration, or the presence of fuel oil or water .
Reliable information as to whether the used oil is still suitable for further use can only be
obtained from a laboratory analysis in which the oil properties are established in accordance
with standard test procedures .
For evaluating the condition of a used oil, the following criteria are usually sufficient :
0
Lubricating oi l
additive-type I straigh t
Viscosity . . . . . . . . . . . . . . < -t- one viscosity grad e
Flash point . . . . . . . . . . . . . . o C > 155 > 155

W Water content . . . . . . . . . . . wt .percent < 0 .5 1 < 0.2
CD
preferably-cO .2(higher percentag e
Ca .
admissible for a short period )
TBN . . . . . . . . . . . . . . . . . . . mgKOH/g HD-oil :>!30%of TBN of fresh oil ,
Medium-alkaline oil > 1 8
.2 pH-value . . . . . . . . . . . . . . . .~. 5 > 5
SAN . . . . . . . . . . . . . . . . . . . mgKOH/g --0 .015 < 0 .01 5
Total contamination . . . . . . percent Depends upon aclual dispersant 0.8
(see also spot test D36 56GOE/000 .05) properties and viscosity ris e
D36 5600 E 3 .24-1 PTO + Sheet 2

The above named values are non-committal empirical values and no single one by itself
should be taken as the criterion for fixing the intervals between oil changes . When used
oil is evaluated to determine its suitability for further use, the test results of the various 0
items must be weighed with respect to each other and the gradual oil change over an
extended period of time should be known . If in doubt, consult oil suppliers . There may
also be instances where additional analyses, as for example a spectogrophic analysis, be-
come necessary .
No conclusions as to the degree of contamination can be drawn from the c o I a u r of
used additive-type lubricating oil because the dispersant-detergent properties of the oil
hold soot particles in suspension in a finely divided form (approx . 0 .5 microns) and they
cause the oil to adopt a deep black colour even if the soot concentration is very low .
The total contamination of lubricating oils can be determined by the DIN-51588 or the
ASTM-D 893 method, amongst others . Also the spot test is a suitable means to supply
respective information (see section 4) .
F u e I in the lubricating oil can be determined by measuring the flash point and the
viscosity of the used lubricating oil - after it has been cleaned - and by comparing the
measured values with the values of fresh lubricating oil . The oil charge must be changed
when the oil viscosity falls into the next lower viscosity grade,or the flash point below
1550C because of dillution by fuel oil . If a laboratory test is not feasible, the viscosity
can be roughly determined as follows : 0
Two samples of fresh oil, one of the viscosity grade above and the other below that of the
oil used in the engine, and a sample of the used oil from the engine - all having the same
temperature - are dripped on a glass or metal plate . When the plate is then tilted, the
flow velocity of thethreesamples will show whether the used oil has a higher or a lower
viscosity than it had before when it was new .
W a t e r in the Lubricating Oi l
If a laboratory test is not feasible, a drop of the used-oil is placed on a hot plate . If there
is any water in the oil, it will evaporate quickly and, in overcoming the capillary force
of the oil, it will escape with a noise (spatter test) . The water content should not exceed
0 . 2 percent . If the water content is > 0.5 percent, the oi I charge must be changed, un-
less the water content can be reduced to <0 .2 percent by careful centrifuging and/o r
by heating the oil charge for a short period of time . Water in lubricating oil promotes
corrosion of the bare metal parts of the running gear, and the formation of oil sludge
with a corresponding increase in viscosity .
0 i I C ar e 0
The engine lubricating oil is continuously cleaned in the main flow by engine-mounted
or detached filters (sieve, disc, or edge-type filters of single or duplex design) . The
filter elements are cleaned either by hand, or semi- or fully automatically . The selected
filter gouge ensures proper filtration . Depending upon the engine type, a free-let
centrifuge or a separator is provided in the by-p= for continuous operation . These devices
are capable of removing much smaller dirt particles than the filters provided in the main
flow and, if a separator is provided, operating as purificator, also the water is being
removed . The load on the main flow filter is thus partly removed, resulting in longe r
filter cleaning intervals and a better condition of the oil . Close observation of the
operating instructions of these devices is important, because optimum operation of the
separator will only be achieved with correctly adjusted throughput and temperatures,
and of the centrifuge only with sufficient oi I pressure and timely cleaning of the bowl .
A high water content in the lubricating oil is often caused by insufficient venting of the
oil tank and the crankcase . If there is no drain cock.at the lowest point of the tank for
draining the oil sludge and water settled on the tank bottom, the tank bottom must be
sucked off at regular intervals ; the effect will be about the some as with sludge removing .
0
D36 5600 E / 3 . 24-1
Air emulsion (oil has owhitish appearance) or heavy foaming on the oil surfa-ce are mostly
due to leakages on the suction side of the pump through which air is entrained by the oil .
0 This will affect the hydrodynamic pressure condition in the bearing, promote aging of the oil,
etc .'
Oi I Chang e
Fixed periods as to the life of an oil charge cannot be named, as the engine manufacturer
does usually not know the fuel and lubricating oil grades being used, nor the condition under
which the engine is running, nor whether the oil receives the proper care .
The oil should be changed when the chemical-physical characteristics of the oil charge have
changed to a degree that the lubricating, cleaning and neutralizing properties are no longer
sufficient . This can only be determined by a comprehensive analysis . Guide values are given
in the table on sheet number I and the degree of contamination of the used-oil can b e
ascertained by means of the spot test on filter paper (see D36 5600 E/000 .05) .
When changing the oil, drain oil charge while it is still at normal service temperature .
If oil system (pipes, filter, oil cooler, service tank, etc .) is contaminated by oily residues,
flush system with a low-viscosity lubricating oil before filling in the new oil charge .
0
0
D36 5600 E 3 .24-1 Sheet 2
0
0
M*JX*M SEPARATING LUBRICATING OILS M.A .N .-DIESEL
0 25
Diesel engine lubricating oils should be separated on a by-pass system while the engine is
in operation and, in the case of marine engines, also during lay days . The separator is
usually arranged to operate as a purificator, i .e . for separating two liquids (lubricating oil
and water) while discarding solids of a higher specific gravity at the same time .
Satisfactory performance of the bowl will only .be achieved if it is correctly adjusted to the
difference in densities of the fluid components . The gravity disc must be selected in
accordance with the density of the water and of the lubricating oil at separating temperature
(see instructions for separator) . In the case of disc stacks having rising channels, the
gravity disc has been correctly selected when the oil-water interface is passing through the
rising channels . Self-cleaning separators of the new generation use discs without rising
channels and the oil-water interface is moved to the perimeter of the disc or outside the
disc stack . When the correct gravity disc has been chosen and/or the oil-V .,ater interfac e
is correctly positioned, the separated oil should .be free from water and the discharged water
practically free from oil . A visual inspection to'this effect should be made at certain
0 intervals . If necessary, correct by readjusting the separator setting .
Separators with a free oil and water discharge can only be readjusted by using a different
gravity disc .
Separators with pressurized discharge by built-in single or dual pumps require a control
mechanism in order to move the oi I-water interface by changing the back-pressure in the
clean oil discharge pipe .
Only purificators that are not self-cleaning require drop-feeding of fresh water, depending
upon the contamination and water content of the used-oil, (2 - 3 drops/sec, water
temperature 20C above separating temperature) in order to maintain the water seal . The
installation of a pressure contactor on the clean-oil side is strongly recommended .
Feed-water to self-cleaning separators must be supplied at constant pressure .
I . Straight or premium lubricating oils as are used, for example, as crankcase oil in
crosshead two-stroke engines are, in general, cleaned in a separator which is designed
to operate as purificator . At a higher degree of oil contamination, due to unfavourable
service conditions, the oi I is cleaned by separation in which cose fresh water is added
0 from time to time at a rate of 2 - 5 % of the throughput and at a temperature of approx .
20C higher than the separating temperature . When this water-washing technique is
applied, it is important that the oil-water interface is correctly adjusted . If the lubrica-
ting oil is treated by intermittent addition of freshwater (freshwater temperature higher
than separating temperature of oil) - added advantage of removing acidulous combustion
products - make very certain that the clean oil discharged from the separator does not
have a higher water content than 0 .2 percent by volume .
2 . Additive-type oils (HD and alkaline lubricating oils) and fortified multi-purpose oils
are cleaned in the purifier . Again, the addition of 2 - 3 drops/sec of freshwater will
be necessary to provide for the water seal if the purificator is not of the self-cleaning
type .
0
10
c~
CN D36 5600 E 3 .25-1 p .t .o .
The separator should only be used as a clarificator for cleaning lubricating oils containin g
additives which are easily soluable in water . It is recommended that the separator supplie r
be consulted as to the bowl setting (purificator or clarificator) and the method of separatio n 0
(with or without addition of water) .
The dispersants contained in additive-type lubricating oils have highly effective sludge -
carrying properties i .e .they leepinsoluable materials produced during the combustion o f
fuel in suspension in a finely divided form . In order to remove these contaminants, th e
throughput must be reduced and the oil heated so that a separating viscosity of approx .
22 mm2~s :t cSt is obtained .
Selection of disc-type_ separators for lubricating oil (F1 1 .80327-2 001 )
Engine Two-stroke engines Four-stroke engine s
Lubricating oil Straight or premium oil Additive-type Additive-type o r

multi-purpose oi I alcaline lubricatin g
oi l
SAE viscosity 30 30 or 40
Arrangement of separato*r's Single-stage in by-pas s
I 41
Selection of separators Operating as purificator in continuous operatio n
N = Norma I
S = Self-cleaning (Clarificator only when specified by oil supplier )
Diesel oil operation N, preferably S N preferably S

Heavy oil operation N, preferably S S
Throughput in perqpn t
of rated capacity of 60 30 20
separator
Separation temperature C 75-85 80 max . 95
Separator size Separator should be capable of cleaning the oil charg e
in the system including service tan k
for diesel oil operation - At least 3 x per da y

(24 h )
At least 5 x per da y
0
for heavy oil operation At least 3 x per At least 1 .5 x per
day (24 h) day (24 h) (24 h )
I I
+
Rated capacity = maximum effective throughputyhen cleaning straight lubricating oi l
at separation viscosity-12 mm /s _n cSt provided fhat the 6il does no t
tend to form an emulsion
Note : Observe operating instructions i 3sued by the separator manufacturer before taking th e
separator in operation .
0
D36 5600 E / 3 .25-1
CONDENSATE IN CHARGE AIR PIPES
AND COMPRESSED AIR TANKS ngines i n
M8
rl00 general
0 0 46 26
Air contains water, in the finest division as water vapour . When compressing and cooling down airapartof
the water drops out . This applies both to compression and cooling down of charge air by turbochargers and
charge air coolers and to the behaviour of compressed air in air bottles . The condensate must not get into the
engine .
Under certain conditions water amounts of 1000 kg per hour may occur downstream of the charge air
cooler, i .e . in the charge air pipe . This is due to the large amount of air and the comparatively high charge air
pressures . This effect is even stronger under tropical conditions .
The amount of water in air bottles is by far smaller . It hardly exceeds 5 kg per admission .
Caution !
It is absolutely necessary that the discharge of the charge air pipe is properly functioning . Air bottles have
to be discharged after filling and prior to using the air .
The amount of water caused by compression and cooling down of air in the charge air pipe or in a
compressed air tank can be ascertained with the diagram below . The general proceeding is explained by two
examples .
0 Ambient air temperature(I bar) - oc

100 20' 300 40' 500 600 70 0,~
_W 3
HH
. .. ... . .. V: :1:: ::
.... . . .. . . . . . . .. .. . . . . .
011 0
.
. .. . . ... . . .... ....
77* .... .
.. .. .. .. .. .. .. .. .. .. .. .. .
J 14
V1
.. .. . .. . . ... . -Z : : 7
0,07 5
=4'-'4
0,05
0 I-A T
:= . : 7
01025 --H = ,
-14 t+
' r
Co
F"'o'
10
30' 40' 50* 600 70' O C
,0 Relative air
humidity Charge-air temperature after cooler -
Air temperature in tank
Diagram 1 . Nomogram to ascertain the amount of condensate in the charge air pipes and the compressed air
tanks .
D36 5600 E 3 .26-1 10 .93 Page 1 of 3

Example 1
To be ascertained : the amount of water incurred in the charge air pipe

1 . Step : Ambient air temperature . . . . . . . . . . . . . . . . . . . . 35 *C,
0
Relative air humidity . . . . . . . . . . . . . . . . . . . . . . . . 90% .
Hence the diagram shows interface 1, i .e . th e
original water content . . . . . . . . . . . . . . . . . . . . . . 0 .033 kg water/kg air.
2 . Step : Charge air temperature after cooler . . . . . . . . . . 50*C ,

Charge air pressure (over pressure) . . . . . . . . . . . 2 .6 bar.

reduced water content . . . . . . . . . . . . . . . . . . . . . . 0 .021 kg water/kg air .
3 . Step : The difference between I and 11 is the condensate amount A that drops .
A = I - I I = 0 .033 - 0 .021 = . . . . . . . . . . . . . . . . 0,01 2 kg water/kg air .
4 . Step : Multiplied with the engine output and the specific air flow rate results in the hourly incurring
wateramount QA-
Engine output P . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 .400 kW,
Specific air flow rate *) le . . . . . . . . . . . . . . . . . . . 7 .1 kg/kWh .
QA = A - P - le = 0 .012 -12 .400 - 7 .1 = 1 .055 kg Water/h - 1 twater/h . 0
Example 2
To be ascertained : the amount of water incurred in the pressure tan k
1 . Step : Ambient air temperature . . . . . . . . . . . . . . . . . . . . 35 OC,
relative air humidity . . . . . . . . . . . . . . . . . . . . . . . . 90% .
original water content . . . . . . . . . . . . . . . . . . . . . . 0,033 kg water/kg air.
2 . Step : Temperature T of the air in the tank . . . . . . . . . .. 40 "C = 313 K .

Pressure in tank (over pressure) pc. . . . . . . . . . . . . 30 bar =
absolute pressure Pabs . . . . . . . . . . . . . . . . . . . . . . 31 bar or 31 - 105 N/M2 .
reduced water content . . . . . . . . . . . . . . . . . . . . . . 0.0015 kg water/kg air .
3 .Step : The difference between I and III is the amount of condensate B that drops . 0
B = I - III = 0 .033 - 0 .0015 = 0 .0315 kg water/kg air .
4 . Step : Multiplied with the air mass m in the tank results in the water amount Q8, incurring when filling
the pressure tank .
QB = B-m .
rn is to be calculated as follows :
m = p-V
R-T
D36 5600 E 3 .26-1 10 .93 Page 2 of 3

Thereby i s
absolute pressure in tank Pabs . . . . . . . . . . . . . . . . 31 - 105 N/m2
0 volume of the pressure tank V . . . . . . . . . . . . . . . . 4000 dM3 = 4, M3,
gas constant for air R . . . . . . . . . . . . . . . . . . . . . . . 287 Nm/kg - K,
temperature T of the air in the tank ... . ... ... 400C = 313 K .
m = 31 .105 - 4 138 kg air .
287-31 3
Hence the following value is obtaine d
QB = B - m = 0 .0315 - 138 kg = 4 .35 kg water .
The specific air flow rate depends on the engine type and the engine load . For the value concerned please
see the test bed minutes . If necessary the following guide values may be used :
Four-stroke engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx . 7 .0 . . . 7 .5 kg/kWh .
Two-stroke engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx . 9 .5 kg/kWh .
D36 5600 E 3 .26-1 10 .93 Page 3 of 3

0
0
PRESERVATION OF DIESEL ENGINES Four-stroke
0 M AM M engines
29
EMW
Genera I
The most common form of corrosion of exposed bright metal surfaces is atmospheric corrosion . The form and
severity of the destructive attack depends on the prevailing climate (Continental-, marine-, tropical-, industrial
atmosphere) . Corrosion e .g . in pipes, fittings and heatexchangers, due to contact with water that remained in
the system after draining, or due to a damp atmosphere, is not readily visible and often remains undetected
until it becomes evident when damage occurs . The most common form of preservation is by applying a
protective coating to the metal surface . The applied preservative must form a dense, continuous film of good
surface adhesion, and must be able to repell water and resist aggressive media .
Even the best of preservation affords protection for a limited period of time only . Periodic checks are therefore
indispensable to ensure that re-preservation is carried out in good time .
The addition of vapour-phase corrosion inhibiting oil has proved to be useful for preservation of closed spaces .
A characteristic of these oils is that they emit continuously a small amount of gaseous inhibitors so that, in a
closed space, vapour-phase develops which serves as a preservative where necessary . Of importance is,
however, that the crankcase is completely sealed and that the preserved Diesel engine or engine components
are stored in a dry, ventilated and well temperated room .
0 Corrosion Inhibitor s
There are various types of corrosion inhibitors available to meet specific purposes and prevailing conditions .
They can be classified as follows :
1. Corrosion Inhibitor with Additiv e
The corrosion inhibitor consists of mineral oil to which an additive, for example turpentine substitute, has
been added . it can be applied to the metal surface to be protected by dipping or spraying, or with usual
brushes, and need not be heated for this purpose . The protective film forming after evaporation of the
additive can later be wiped off or washed off . if used for preservation of the inside of the'engine, the
corrosion inhibitor need not be removed before the engine is taken into operation, provided that the
preservative is soluble in lubricating oil so that it will dissolve during engine operation . These
preservatives are also suitable for the preservation of single engine components as well as for external
preservation of the whole engine .
2 . Corrosion Inhibitin g
G r e a s eProtective greases are applied with a brush or are scrubbed into the metal surface . if the grease
is soluble in oil and has only been applied as a thin layer, it need not be removed from the internal engine
parts before the engine is taken in operation, provided that the engine had been properly sealed so that
the accumulation of dust and dirt was avoided .
40 External engine parts or single components preserved with grease must, in any case, be cleaned before
use . This can easily be accomplished by washing with an oil-dissolving fluid (e .g . Diesel Fuel or cold
cleaner) . Care must, however, betaken to prevent the cleaning fluid from getting into the engine and
mixing with the lubricating oil .
3. Slushing Oil s
Slushing oils are mineral oils with corrosion inhibiting agents . They are suitable for both the preservation
of individual engine parts, and are then applied by spraying or with usual brushes, as well as for
preservation of the internal parts of the assembled engine . it is also possible to run the engine, after it has
been thoroughly cleaned, for a short period of time on slushing oil, in which case the engine oil syste m
wi I I al so be wel I preserved .
4 . Corrosion inhibiting Dipping-Compound, Vapour-Phase Corrosion

Inhibiting Oil- or Paper are other products for the preservation of single parts .
Re-Preservation of New Diesel Enqines and Spare s
Each engine, before being shipped, is preserved in our works either for normal or special protection . Special
preservation is provided when it is known that adverse climatic conditions will be encountered during
transport or at the place of destination, and when it is to be expected that the engine will be stored for an
extended period of time before it is taken in operation . When the engine is stored in a dry place, the suppliers
of the slushing oil guarantee effectiveness of the protection usually for a period of three months . When th e
D36 5600 E 3 .29-1 10-93 Page 1 of 2

engine must be stored for a longer period, re-preservation becomes necessary . The necessary operations are
described below . Re-preservation of the complete engine normally applies to four-stroke engines only .
1. Remove covers on crankcase, on gearbox of camshaft drive gear and on camshaft casing . is
2 . Remove valve protection cap and all pipe sealing plugs (Turbocharger, fuel-, lubeoil-, cooling water- and
starting air pipes) .
3. Fill fuel and lubeoil pipes, as well as nozzle cooling system with slushing oil . If a handpump is provided, fill
the lubricating oil system with slushing oil .
4 . Spray liberally with slushing oil, crankcase, all parts of the running gear, gearwheels in camshaft drive
gear, camshaft, valve drive, all pipe openings and the openings on the turbocharger . If possible, turn
engine by means of the turning gear or a barring rod and refill fuel pipe with slushing oil ; repeat several
times .
If running gear cannot be turned, fill injection pumps, pipes and injection valves with fresh slushing oil
by
actuating the shut-down levers . For this purpose, the fuel control [ever must be in the full load position .
Note Do not turn the running gear of the engine after it has been sealed airtight .
Preservation of Diesel Enqines for Lavinq-u p

If the preservation is to be effective, it is essential that all interior and exterior engine parts are thoroughly
cleaned before protectives are applied . Maintenance and repair work stipulated in the Maintenance Schedule
is to be carried out and entered in the engine records .
I. Drain completely lubricating oil and fuel oil from the engine, coolers and filters and blow out the pipes .
Clean oil pan, lubricating oil tank and fuel oil day tank thoroughly . Then fill oil pan or oil tank with 0
preserving oil of the same viscosity as used for the engine up to a level which will allow the oil pump to
draw up oil without taking in air .
Engine-mounted components having their own oil system or oil admission (Woodward governor possibly
exhaust turbocharger) may be filled with the same slushing oil . This oil can be left in the engine when the
engine is again taken in operation, provided the slushing oil meets the engine oil specifications, which is
normally the case . The slushing oils that are known to us are compatible with alleged (HD-) oils so that
the latter can be added, without apprehensions .
Instead of fuel oil, a highly fluid slushing oil of SAE grade 10 to 20 is filled into the fuel day tank so that
sufficient internal protection of the fuel carrying pipes and fuel delivering engine components is ensured .
2. Run engine for about 5 minutes on slushing oil so that all pipes, bearings and the injection system ar
e
filled with the preserving oil . Before starting the engine, fill in about 0 .5 Itr lightweight slushing oil into
the main starting air and control air pipes so as to preserve the starting system too . Before stopping the
engine, spray a small amount of highly fluid slushing oil into the main starting- and control air pipe to
ensure preservation of the starting system . Prior to engine shut down a small amount of the highly fluid
slushing oil is to be sprayed into the intake pipe .
3 . All pressure gauges must indicate zero after the plant has been shut down
. The engine must be secured
against unintentional turning of the running gear . The turning gear (if provided), should be engaged .
4 . There is no need for preserving the cooling water spaces if a corrosion inhibitor had been added to th
e 0
engine cooling water during operation . If a chemical agent had been used, the cooling water must be
changed and corrosion inhibiting oil added to obtain a concentration of about 3-5 percent . The engine is
then to be run for some time .
When it is intended to lay the engine up for an extended period of time, or there is the danger of the
temperature dropping below the freezing point, the cooling water must be completely drained from the
engine, the turbocharger and the coolers of the individual circuits . Note that the drain cocks of the layed-
up engine should be left open . Be sure to drain also the water space of the cooling water pump . Exhaust
valves with cage and injection valves are to be removed and to be discharged separately .
S . All bright external engine parts are to be coated with a preservative either by spraying or with the use of a
brush .
Note If a used engine is to be preserved but cannot be run on slushing oil for a short period of time
because the circumstances do not permit it, the engine can be preserved in accordance with the
instructions given under "Re-Preservation of New Diesel Engines and Spares" . But first the fuel-,
lubricating oil- and cooling water systems must be completely drained and the engine with all its
components thoroughly cleaned .
D36 5600 E 3 .29-1 10-93 Page 2 of 2

OPERATING DIFFICULTIES
M*AL+ M Fault Finding Chart
KSZ - B
35
0
G enera I
When meeting with difficulties on engine start-up or during engine operation, first check
whether any mistakes have been made in running the engine, or the nature of the disturbance .
No attempt should be made to restart the engine unless the cause of the disturbance ha s
been determined and eliminated .
The following compilation of disturbances, their causes and their remedies is intended a s
a help to recognize possible disturbances and their causes and correct them quickly . Without
claim to completeness, the compilation lists the most common troubles . For removing a
deficiency, observe the instructions given in the respective work cards of section 4 .
Do not try at random because it almost never meets with success .
0 In the event of disturbances occurring in the engine control system (faulty manoeuvres),
see instructions given in the manual for engine control gear .
n36 Al 0 P 3 - 3 ;-'?
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. .... . . . . . . ..
0 tnqjne does not start, is turning too slow, :X
------
I not at all, or swinging back - ------- . . . . . . . . . . . . . . . . . . . . . . .. . .

Cylinders do not fire, engine turns, leve r
2 on STARTING WITH F U R
3 Some of the cylinders. do not fir e
4 Violent firing with relief valves blowin g

Starting air not being cut off though leve r
5 has been moved out of STARTING rang e
6 Engine does not reach rdted speed or outpu t
7 Engine speed growing slower
8 Engine speed drops suddenl y
Engine is not running smoothly, or stop s

1 91
0 10 1 Engine speed risin g
.
III Charge-air pressure dropping or too low
112 Exhaust temperature rising or too hig h
:13 Sooty exhaust
.14 1 Relief valve blowin g

X ..
15 1 Engine does not reverse X%:X .::
116 Thrust bearing growing hot
17 Turbocharger surgin g
I Water-hammer in piston cooling syste m
0
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D36 5610E 3 .36-1
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Engine does not start, is turning too TmW ,
not at all, or swinging back
riders do not f*re, en?i ne turns, leve r
2 onblAKIINUMH UE ....
.. . . . ... . .... . ... . . . . . ..
3 Some of the cylinders do not fire
. . . .. . ... ... . . . . . .. . . . . . . . . . . . ...... . .. ... . .. ... .
:X
___ __Yta
_- air not being cut ott thou97Tever
5 hasrting -- -
been moved out of STARTING range
.X: X .. .... .... . . ...
6 Engine does not reach rated speed 'or output
1. .. . . . . ..... . ....... . X. . . . .
.. ....
7 Engine speed growing slower
8 Engine speed drops suddenly X.
9 Engine is not running smoothly, or stops . . . . . . . . . .. . . . .....

10 Engine speed risin g 0
II Charge-air pressure dropping or too lo w
13 Sooty exhaus t
14 Relief valve blowin g
15 Engine does not revers e
16 Thrust bearing growing ho t

17 Turbochargor surging
18 Water-hammer in piston cooling syste m
0
D36 5610 E / 3 .36-1
0 0
4 .77
0 -0 CC) 1-4 o, V, G) i) Line ~4
CA3 - . .. ... ..
0, PoOtioner or control gear (governor)
2 .20 detective
Ln . . . . .. . . . . .
. .. . . . . Injection pumps shut off by one of the
C) engine safety instrument s
M
. .. . . . . . .. . . .. . . . e automatically shut down due to
. .. . . . high cooling water temp . or low oil press . -
~4
3 .6 Speed setting on governor too low
203 .01 Fuel control lever not set to full load
X. X . ~ .6 Pump setting too high after start-up

-X
.. .. ..
........... . ... .. . :.. ............. .. .. ....... ...... Engine overloade d
. . . . .. 203 .01 Some of the cyI 6inders overloaded

Clia-rg-e-air !emperature too li-igh,-cooling
281 01
. . . . .. ..... 281 02 insufficient
..... ...... Air intake temperature higher than normal.
300 . . . Exhaust turbocharger and/or charge-air
281 .01 cooler fouled u p
X 057 .OT-Telief valve in cylinder cover leaking
057 .02
eliqf valve ir charge-air manifold
eOKing
X
X.:-X., goost lowers not running or supply air not
...... correctly switche d
blowers switched off too early on run,?ing
up a6d siart too late during slowing down
.............
X X Zharge-air pressure too low
...... . . ...
120 .01 Terrsing gear defectivp .or fuel control
in) C ro position
Pistons or bearings are running hot
IX
I supply failing
I
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N 0
_j cf Sheet or Work Card No . 0 LO
Q
0
Engine does not sta~tj_ is turning too slow,
I not at all, or swinging bac k
Cylinders do no tire, engine turns, !eve r
2 on STARTING WITH FUE L
3 Some of the cylinders do not fir e

Starting air not being cut aff though leve r
5 has been moved out of STARTING rang e
. . . . ..
6 Eng ine does not reach rated spee8 or outpu t X:
7 Engine speed growing slowe r
8 Engine speed drops suddenl y
9 Engine is not running smoothly, or stop s
10 1 Engine speed risin g 0
Charge-air pressure dropping or too low
13 Sooty exhaus t
14 Relief valve blowin g
15 1 Engine does not revers e
16 1 Thrust bearing growing ho t
17 1 Turbocharger surging .
18 1 Water-hammer in piston cooling syste m
0
D36 5610 E 3 .37-1
OPERATION
*AAL*F4 Failure of one Cylinder KSZ - B
38
0
Failure of one Cylinde r
If engine operation must be continued with one cylinder being out of operation due to a
defect in the injection system or a defective cylinder, the running gear of the inoperative
cylinder should not be removed to avoid disturbing the balance of mosses . The running gear
of the inoperative cylinder will then be trailed by the crankshaft without performing work
and the total output of the engine will be diminished approximately by the output of one
cylinder .
In the case of a marine engine with a solid propeller, the obtainable maximum speed will
be reduced in accordance with the propeller law and attention should then be paid to
critical speed ranges, existing or new ones induced by the inoperative cylinder, which
should be avoided in continuous operation . Attention should also be paid to the exhaust-gas
turbochargers which, with one cylinder being out of operation, may then be operating
within the surge range . Lubrication of the idling piston must be continued, i .e . the cylinder
lubricators must not be shut off nor the delivery volume reduced . Furthermore, it is to be
0 noted that it may no longer be possible to start the engine from every crank position,
depending on the number of cylinders in the engine and on the location of the inoperative
cylinder . In these circumstances, the engine should not be started from the bridge by remote
control (if provided) to enable corrective action to be taken immediately in the engine room
in the case of a start failure . Should the piston, cylinder lubrication, crosshead or connecting
rod be defective, requiring removal of the complete assembly, engine operation may only be
continued in an emergency within a limited speed range because the equilibrium -of masses
will then be disturbed . There are no fixed barred speed ranges for emergency 6peration under
such conditions because they depend upon the location of the inoperative cylinder and also
on the number of cylinders in the engine (cf sheet 3 .43) .
J
Caution 1 The exhaust temperatures after the cylinders must not exceed the admissible maximum
values .
Possible disturbances and their remedies are listed hereunder :
I . Injection system disturbe d
0 1 .1 . Put injection pump of respective cylinder out of operation .

1 .2 . Crankgear is trailed without performing work .
1 .3 . Keep up cylinder lubrication .
1 .4 . Keep up piston cooling .
1 .5 . Open indicator valves frequently to blow out the lubricating oil collecting in the
cylinder (otherwise danger of oil ignition) .
2 . Piston defective-
2 .1 . Put injection pump of respective cylinder out of operation .

2 .2 . Shut off cylinder lubrication .
2 .3 . Remove piston and piston rod .
2 .4 . Mask scavenge and exhaust ports with device supplied with the tools .
2 .5 . Seal opening for stuffing box in diaphragm with cover .
2 .6 . Shut off cooling and air suppl-y to defective cylinder and remove telescopic pipes .
2 .7. Seal control-air pipe to starting valve .
D36 5610 E 3 .38-2 12-t -0-

1 Reversing gea r
2 Hydraulic-pneumatic positione r
3 Control gear board - emergency control stand
4 Woodward governo r
41
5 Westinghouse positioner
6 Lever
7 Extension tub e
8 Selector switch for direction of rotation
9 Fuel control leve r
10 Scale
11 Cover
12 Sto p
13 Hexagonal nut
14 Locking pin
15 Leve r
16 hand cran k
17 Emergency starting butto n
18 Selector lever (NORMAL OPERATION - EMERGENCY OPERATION)
19 Handwheel nu t
20 Pressure gauge engine lubricating oil
21 Warning lamp (EMERGENCY OPERATION)
22 Warning lamp (TURNING GEAR ENGAGED)
23 Gauge cock s
24 Shut-off cock (air supply)
0
25 Pressure-air filte r
26 Indicating lamps (CAMSHAFT END POSITION AHEAD and
ASTERN)
27 Starting-air pressur e
28 Engine spee d
29 Mechanical indicator for camshaft end positio n
A NORMAL OPERATIO N
B EMERGENCY OPERATION
C NORMAL OPERATIO N
D PRESETTING FOR EMER3ENCY OPERATION ASTERN
E PRESETTING FOR EMERGENCY OPERATION AHEAD
F AHEA D
G ASTERN
0
OPERATION
Operating Difficulties KSZ - B
39
0
3 . Cylinder Lubrication Defective

If cylinders receive no lubricating oil, the piston will seize very soon and operation
with a defective cylinder lubricator will only be possible after removal of the respective
piston .
Proceed as described under 2 .
4 . Crosshead or Piston Rod Defective
4 .1 . Rem we cylinder cover .
4 .2 . Remove piston and piston rod .
4 .3 . Remove complete connecting rod .
4 .4 . Remove crosshead .
4 .5 . Shut off cylinder lubrication .
4 .6 . Put injection pump out of operatio n
4 .7 . Mask scavenge and exhaust ports wi ;h device supplied with tools .
4 .8 . Close opening for stuffing box in diaphragm with a cover .
4 .9 . Shut off piston cooling .
4 .10 .Seal control-air pipe to starting valve .
Caution! No attempt should be made to run the engine w-Ifith the connecting rod removed and
the crosshead supported on a bolt in the guideway .
5 . Engine Control Gear Defectiv e

In the event of disturbances in the remote control or automatic control gear, the engine
can be run with the emergency control gear mounted on the engine .
Starting with Emergency Control s I
5 .1 . Set selector lever (18) on hydraulic-pneumatic positioner (2) from NORMAL
OPERATION to EMERGENCY OPERATION . The gear position emergency operation
is indicated by the warning light (21 ) in the control gear board (3) .
5 .2 . Check warning light (22) TURNING GEAR ENGAGED and pressure gauge (20)
ENGINE OIL PRESSURE in the control gear board .
0
Caution! Do not start engine under any circumstances as long as warning lamp (22) shows!
5 .3 . Release hand wheel nut (19), set fuel control lever (9) to approx . 1/3 load and fix
lever in this position by tightening the handwheel nut .
5 .4 . Check speed setting on governor, and if necessary, reset it on positioner (53 .
5 .5 . . Press emergency starting button (1 7) . '
5 .6 . When all cylinders fire regularly, set fuel control lever (9) to desired POSitiDn or set
engine speed at Westinghouse Positioner (5) .
5 .7 . After trouble has been eliminated, reset selector lever (18) to position NORMAL OPER-
ATION and set fuel control lever (9) to max . load .
5 .8 . Reset hand wheel on p ositioner (5) (by turning in clockwiie direction) .
Load or speed setting in emergency operation providing positioner (2) is operable .
5 .9 . Release hand wheel nut (19), set fuel control lever (9) to desired load and fix it in
this position by hand wheel nut . The speed governor remains in operation and can,
if necessary, reduce the pump setting .
CK)
N
C~ D3o 5610 E 3 .39-2 p. t . 0 .
0
5 .10 . For shutting the engine down, set fuel control lever (9) to 0-positjo"n .
5 .11 . The engine speed is set by turning the handwheel on the Westinghouse positioner
(5). The speed is increased by turning the wheel in counterclockwise direction,
by turning the wheel in clockwise direction will reduce it .
5 .12 . After the fault has been eliminated, reset fuel control lever (9) to max . load
and the handwheel on the Westinghouse positioner (5) to min speed to permit
the remote control or automatic control gear to move the fuel control linkage
through the whole control range .
Note : The aforementioned two methods of engine control will also be possible
with the selector lever (18) in the position NORMAL OPERATION .
That is, the engine can be shut down by means of the fuel control lever
(9) at any time .
Load or speed control in emergency operation if positioner is defective .
In emergency operation, the engine load can be controlled by means of the

hand crank . The engine must be at standstill for applying the handcrank and 0
for changing over to emergency operation .
5 .13 . Take off cover (I I ) on righthand side of positioner .

5 .14 . Remove handcrank and locking pin fastened on the inside of the cover .
5 .15 . Apply handcrank (16) to square head of spindle on I ever (1 5) .
5 .16 . Loosen hexagonal nut (13) and back it off by approx . 100 mm, and also turn
handcrank in anticlockwise direction until stop (12) can be removed .
5 .17. Arrest lever (1 5) by inserting the lock pin (1 4) .
5 .18 . Turning the handcrank in clcckwise direction will increase the injection pump
setting, turning it in anticlockwise direction will reduce it . The actual injection
pump setting will be seen on the scale (10) .
5 .19 . To shut the engine down, turn handcrank in counterclockwise direction until
pump racks are in STOP position which is O-position on the scale (10) .
0
Attention! In emergency operation, the engine is run by load control by means of th e
hand crank . The speed governor will no longer act asoverspeed governorsince
the positioner was put out of operation when the engine was switched over to
emergency operation . This must be borne in mind when running the engine in
emergency operation .
Resetting
When changing-Imck from emergency operation to normal operation, first unlock lever (15) .
To insert stop (12), turn handcrank accordingly and fix stop (12) in its position by turning
the threaded spindle . Tighten nut (13) and secure it by means of the lockwasher . Check to
see that graduation scales for pump setting on positioner (2) and injection pumps tally in
their zero (STOP) position .
0
OPERATION
*AL*M Operating Difficulties KSZ - B
40
9
Emergency Reversin g
5 . 20. Move selector lever for direction of rotation (8) on the reversing gear (1) from
position NORMAL OPERATION to desired direction of rotation AHEAD or
ASTERN .
5 .21 .. Take extension tube (7) out of the holder, insert it into the lever (6) and push it down
to the stop . The gear will thus be mecanically released and a pneumatic valve operated
and the camshaft will be moved into the new end position . The new end position
is indicated by the lamps (26) in the control gear board (3) .
5 .22. Having eliminated the fault, reset selector lever (8) to position NORMAL OPERATION
and replace extension tube (7) in its holder .
Emergency Manoeuvres during Emergency Operatio n

0
Emergency manoeuvres can be carried out as long as the positioner (2) is operable .
5 .23. Set fuel control lever (9) to O-position .
5 .24 . When the engine speed has dropped to the value named in sheet 3 .6, reverse engine
to desired direction of rotation as described above .
5 .25 . On completion of the reversing process, see lamp (26), press emergency starting
button (17) . The engine together with the propeller will now be slowed down up
to stop by means of the pressure air admitted to the cylinders due to the fact that I
the camshaft has been shifted to ASTERN .and will then be turned in the opposite
direction .
5 .26 . Immediately the engine starts rotating in the opposite direction, set fuel control lever
(9) to max . 40 % load . When all cylinders fire regularly, the lever can be set to the
desired engine load .
0
D36 5610 E 3 .40-2

.1
0
OPERATION KSZ
Operating Difficulties KE Z
Engines with two Exhaust Turbochargers 41
0
I na p erative Exhaust Turbochargers and Auxiliar y

B I owers
In the event of a failure of turbochargers or auxiliary blowers, the engine can be ru n
by manual control at reduced load .
I One exhaust turbocharger inoperativ e
With one turbocharger out of operation, engine
operation can be continued at greater than half
the rated speed with the operative turbocharger
and the two auxiliary blowers (cf fig . I) .
Note : To avoid further damage to the inoperative
turbocharger, immediately the rotor should
Figure 2 be arrested if it is still able to move (cf
work sheet 500 . 05 M.A. N . turbocharger) .
If the gas side of the turbine and the air side of
0 the compressor are sealed with blind flange s
(4 and 5) (see section 4, worksheets 281 .03 and
289 .01 ), the engine can be run with the
operative turbocharger- and the auxiliary blower
at approx . 80% of the rated speed for an ex-
tended period of time . The rotor of the inoper-
ative turbocharger need not be arrested in these
circumstances (cf fig . 2) .
I Auxiliary blower 5 Blind flange (compressor )

2 Compressor 6 Sealing cover (auxiliary blower)
3 Turbine 7 Auxiliary air connectio n
4 Blind flange
(turbine)
2 . One auxiliary blower inoperative(cf fig . 3)
With one auxiliary blower out of operation, the engine can be run with the operative
auxiliary blower and the two turbochargers within the speed range up to speed A or ccn
be run up above speed B . Operation between speed A and B is not possible . Failure of
one auxiliary blower has no effect on the operating range above speed B up to MCR .
The following should be observed when plant is operated with one auxiliary blower only :
Operati n within the range up to speed A
I . Switch off controls of inoperative auxiliary blower .
2 . Seal air intake of inoperative auxiliary blower with sealing cover (cf work sheet 550 .30) .
3 . Set auxiliary blower selector switch to position I or 3 EMERGENCY OPERATION WITH
11 (or 1) - LOW SPEED, depending upon whi'Ch of the two blowers has become inoperative
(I and 11 are the numbers of the auxiliary blowers) .
4 . Switch on operative auxiliary blower (either automatically or by hand) .
5 . Engine can be started . Max . position of control lever according to speed A.
5r01 D36 5610 E 3 .41-3 p .t .o .

Running up from Range below Speed A to a Speed above B
I . Open both starting air receivers, if necessary refiff-f- Tir-st (30 bar) .
2 . Move control lever slowly into fuel range. p'ntil engine is no longer accelerating, then
press push button for AUXILIARY AIR- FOR EMERGENCY OPERATION . Move control 0
lever further into fuel range as engine is picking up speed .
3 . Observe speed indicator of turbocharger connected to inoperative auxiliary blower .
At a speed of approx . 3000-4000 rpm (depending on turbocharger type), set selector switch
to position 0 EMERGENCY OPERATION - HIGH SPEED and release button for AUXILIARY
AIR FOR EMERGENCY OPERATI ON .
4 . When the turbocharger connected to the operative auxiliary blower has also reached this
speed, the pump setting can be slowly reduced to the desired engine speed .
5 . When it is intended to run the engine within the speed range above speed B for an extended
period of time, take off sealing cover of inoperative auxiliary blower .
6 . In automatic operation, the operative auxiliary blower is being switched off automatically .
In manual operation, the auxiliary blower must be shut off by hand when the charge air
pressure rises above 0 .65 bar .
Note! As long as the selector switch of the motorized blower has not been set to position 2,
NORMAL OPERATION, the alarm AUXILIARY BLOWER DEAD will be .on,
signalling emergency operation .
Going back from speed range above speed B to speed range below speed A
I . Move control lever back to pump setting corresponding to speed B .
2 . Seal air intake of inoperative auxiliary blower by means of sealing cover .
3 . Set auxiliary blower selector switch to position I or 3, depending upon which of the
auxiliary blowers is inoperative, EMERGENCY OPERATION WITH 11 (or 1) - LOW SPEED .
After auxiliary blower I or 11 has run up, set control lever to pump setting corresp .to speedA .
3 . Operation ~Mth two inoperative exhaust turbochargers .
In the event of both turbochargers being inoperative,
the engine will be able to reach half the rated speed
with the operative motorized auxiliary blowers . If
the rotors of the turbochargers are still able to move,
they should be arrested (cf work sheet 500 .05 for
M .A . N . turbocharger) .
4 . Operation with two inoperative exhaust turbochargers
and one auxiliary blowe r
The engine can be run at approx . 40 % of the rated
speed with one operative auxiliary blower, with the
0
air intake of the inoperative auxiliary blower sealed
and the selector switch set to position I or 3, de-
pending on which of the auxiliary blowers is in-
operative, EMERGENCY OPERATION WITH 1 1
(or 1) - LOW SPEED . The rotors of the turbochargers
must be arrested if they are still able to spin . The
operative auxiliary blower is to be switched on
(automatically or by hand), depending on 1he method
of operation .
Caution! The admissible maximum engine output with inoperative turbochargers or aux .blowers
is dependent on the exhaust gas temperature and the smoke limit . The exhaust
temperatures after the cylinders and the speed of the operative turbochargers must
not exceed the admissible maximum values .
Note: The speeds A and B differ from plant to plant and the exact values should there-
fore be ascertained during the trial run and entered in this sheet .
Speed A . . . . . . . . . . . . . rpm (in general approx . 40 % of rated speed)
Speed B . . . . . . . . . . . . . rpm (in genera I approx . 65 % of rated speed)
D36 5610 E/3 .41-3

OPERATION M .A . N .2-stroke
M*JL*P1ll1 Operating Difficultie s DIESEL ENGINES1 42
0
Directions in the Case of a BLACKOU T

A BLACKOUT is defined as a sudden failure of the electric power s upply with the resul t
that cooling water, lubricating oil and fuel pump as well as the auxil iary blower of the main
engine become inoperative .
In the event of the blackout occurring whilst the engine is running i n the higher output range,
the cooling water, no longer being circulated, will be heated up by e ngine components sub-
jected to high thermal loads and may develop steam bubbles at such h at spots . Therefore, b e
aware of venting and discharge outlets!
In the case of marine plants, the main engine will keep turning for some time due to the drag
effect of the ship's propeller whilst the turbochargers are gradually slowing down until they
come to a stop . The running gear will normally survive without damage the slowing time of
the ship in a blackout with failing lubricating oil pressure as it is subjected to compression
pressures only . The turbochargers, running at a higher speed, are supplied with lubricating
oil either from an overhead tank (M .A . N . turbocharger) or by a lubricating oil pump built
0 into the turbocharger (BBC turbocharger) during the slowing down period .
At a blackout the engine should be immediately be stopped to keep th e operating risks a t
a minimum . Should the ship be equipped with a VP propeller, the latt er should .. if possible ,
immediately be set to zero pitch to avoid dragging of the engine by th e ship's propeller .
Au t o m a t e d P I ant s
In the case of a blackout, the engine is automatically and immediatel y stopped . If the plant
is equipped with a VP propellJ, -the latt-er is being set to zero pitch, if possible . These
operations are automatically tripped at failing lubricating oil pressur e . In a critical situation 0
where the rule "ship before engine" applies, this emergency stop can be temporarily cancelle d
under certain conditions .
When the electric power supply has been restored, pumps, auxiliary b lowers and fans can b e
put back into operation in the following sequence :
I . Lubricating oil pump and fuel supply pum p
2 . Cooling water pump and air compressor for piston co olin g
3 . Auxiliary blower s
0 4 . Engine room fans
5 . Seawater pump
Note : In no circumstances must the engine be allowed to start up automatically- after a black-
out . The locked fuel supply pumps are reset as soon as one auxiliary blower is started up .
The control lever of the automatic control gear must be set to STOP and only then
should the engine be restarted and load gradually applied in accordance with the
automatic run-up program .
Manually Control led Plant s
With manually controlled plants, the engine must be stopped immediately in the case of a
blackout in order to obviate'serious damage due to failing lubrication and thermal overloadin g
of engine components .
After the electric power supply has been restored, the procedure for st arting up the engine is
the same as in automated plants . Here again, it is important that the engine be restarted onl y
after at least one auxiliary blower is running and that engine load b e applied only gradually .
04
D36 5600 E 3 .42-2 12 . t . 0 .

0
BLACKOUT Test
On commissioning of the plant, the behaviour of the engine and the response of the shut-
down device is tested during a deliberately caused blackout . This test should only be
carried out at an engine speed below approximately 50 % or a load below approximately
15 % for safe keeping of the engine .
0
11LAM * 4&* 114
F"
OPERATION M.-A. N . -DIESEL
=~:~Y Operating Difficulties 43
0
Operation with one inoperative cyl inder(theproblemof

vibrations )
In the event of disturbances it may be necessary to put a cylinder out of operation by
interrupting the supply of fuel . And, depending on the nature of the defect, the crankgear
may be left in place or it may have to be removed . It will be of advantage, with regard to
vibrations, when the crankgear need not be removed since the mass equilibrium will then
wit be disturbed . Moreover, it is advisable to run the inoperative cylinder against the
compression pressure as it will reduce the effect of occurring disturbances .
The following measures are recommended :

I . Reduction of output and spee d
Reduce engine output in order to avoid overloading the operat ive cylinders . The exhaust
'
gas temperatures must not be allowed to exceed the maximum admissible values .
0 In the case of a fixed-pitch propeller drive, the speed should be further lowered due
to the propeller characteristics in accordance with the following formula :
Reduced speed : nX = n x z I
[1/minj
V V iZ---
Where
n full loa d
V= z 5 6 71 8 9 1 10 1 12 14 1 16 1 18
zz1
Z = number of cylinders 0,89 0,91 0,93 1 0,94 0,94 1 0,95 1 0,96 0,96 1 0,97 1 0,97
2 . Vibrational conditions
2 .1 . Torsional vibration s
Additional critical speed ranges may arise due to the fact that a cylinder has been
put out of operation by shutting off the injection pump, and these critical speeds will
require additional barred speed ranges . The barred speed ranges that may become
0 applicable under this abnormal operating condition are shown on a plate on the engine
control console .
2 .2 . Mass equilibriu m
If the running gear of the respective cylinder had to be removed, the mass equilibrium
will be seriously disturbed . Free mass forces and additionally free mass momentum
may occur . Thus, unusual vibrations in the engine and the hull may be induced . In
this case it will be necessary to establish further barred ranges arbitrarily .
Should it become necessary to put several cylinders out of operation at the same time,
advice should positively be requested from M.A.N. Augsburg . In the meantime, in an
emergency situation, the engine should not be run at a load higher than 50 % of ful I load
speed until advice has been received from MAN .Augsburg . The barred speed ranges
applicable to normal operation must nevertheless be observed . The whole propulsion system
should be continuously checked for evidence of overheating, gear noise, abnormal
vibration~, etc .
c~
0 '0
le
D36 5610 E 3 .43-1

0
0
OPERATION
M*A!L*M Operating Difficulties
KSZ
KEZ 44
0
Fire in Scavenge -Air Spac e

Fire in the scavenge-air space is quite unusual when scavenge-air spaces in the cylinder
block, the air duct and in the cooler are regularly serviced andkept in clean condition .
But if a fire occurs nevertheless, it will be signalled by the temperature contactors provided
in the system . Fire in the scavenge-air system will also be noticed by a sudden and sharp
drop of engine speed and smoke emanating from oil and water d,ain pipes .
In the case of fire proceed as follows :

1 . Set engine control lever to STOP .
2 . Switch off auxiliary blowers by hand .
3 . Close drain pipes (oil and water) from scavenge-air spaces .
4 . With engine at standstill, start fire extinguishing plant .
Note : The fire extinguishing lines lead to one or two points in the scavenge-air duct and
the cylinder block, depending of number of cylinders . Every supply pipes are
0
fitted with cut-off valves which can be separately opened in the case of fire . If
the alarm is released by the temperature sensor in the scavenge-air duct, open
the shut-off valves in the scavenge-air duct, or, in the other case, those
connecting the cylinder block .
6 . Allow area that has been on fire to cool down . When conditions, smoke and temperature,
permit it, check .if fire has been completely extinguished .
CAUTION : Carbon dioxide
(C02) in highly concentrated from causes suffocation .
The gas is colourless and inodorous, and it is heavier than air . Therefore,
care must be exercised when inspecting the place of fire . Before entering the
I
air duct, vent it thoroughly, if necessary with the help of pressure air ,
while venting the engine room thoroughly .
7 . Clean and inspect place of fire and repair any damage .
8 . Turn engine with turning gear under liberal supply of cylinder oil, especially within the
area where the fire had occurred (turn cylinder lubricator by hand) .
9 . Switch on auxiliary blowers by hand .
10 . Open drain-pipes (oil and water) in scavenge-air spaces .
11 . Thereafter, the engine can again be started and run up .
A fire, normally, is of no consequence with respect to further engine operation . The carbon
dioxide (C02), admitted to extinguish the fire, is not aggressive and evaporates very quickly
when the engine is started .
0
D36 5610 E 3 .44-2
0
0
ABGASTURBOLADER
EXHAUST-GAS TURBOCHARGER 3
TURBOCOMPRESSEUR A GAZ WECHAPPEMEN T
SOBREALIMENTADORES 50
0 TURBOSOFFIANT1 A GAS D1 SCARIC O
BETRIEB UND BETRIEBSST(5RUNGEN
OPERATION AND OPERATING DIFFICULTIE S
FONCTIONNEMENT ET INDIDENTS DE FONCTIONNEMENT
0 SERVICIO EIRREGULARIDADES EN EL FUNCIONAMIENTO
OPERA(;AO E ANOMALIAS DURANTE A OPERA(;AO
ESERCIZIO ED AVARIE DI FUNZIONAMENT O
D36 5650 3 .50-1 04 .82

0
0
OPERATION
NA
0 Start-up, Operation, Stoppino 51
Preparations before start-u p
The turbocharger bearings must be primed immediately before start-up of the engine .
Startincr
The turbocharger, being driven by the exhaust gases of the engine, will start up
automatically as the engine is started .
Operatio n
The following readings should be regularly taken if the respective instruments are
provided :
0 1 . Turbine spee d
2 . Exhaust temperature before turbin e
3 . Charge air temperature after compresso r
4 . Lubricating oil temperature before turbocharger
5 . Exhaust pressure before turbin e
6 . Charge air pressure after compressor
7 . Lube oil pressure before turbocharge r
In addition, the following checks should be made :
S. Tightness of exhaust gas, charge-air and oil pipes

9. Sealing air ducts for free passage and sealing air
valve for free movemen t
10 . Silencer for foulin g
11 . Turbine rotor for free movement
12 . Turbocharger for smooth runnin g
Incipient rotor or bearing damage is usually indicated by erratic operation caused

Is by imbalance or rubbing of rotating parts against stationary components . Errati c
operation can often be determined at an early stage by listening for unusual
operatina noises .
Rotor speed and charge air pressure are interdependent, i .e . the rotor turns at a
certain speed at a given charge air pressure provided the air ducts of the
compressor are in clean condition . The charge
* , air pressure can thus be used to
approximate the rotor speed .
Stoppin a
After the engine has been stopped, the rotor of the turbocharger*keeps turning for
some time due to its moment of inertia . The rundown time of the rotor is indicative
of the mechanical condition of the turbocharger . When the rotor comes to a sudden
stop, it is usually due to mechanical damage of bearings, or rubbing of compressor
wheel or turbine wheel against stationary parts, or foreign matter having become
wedged between moving parts, etc .
0
D36 5640E 3 .51-1 8 .92
0
0
M*AL*N OPERATION '
Operating Difficulties
NA
52
On shutting down the engine, there are no additional measures necessary with regard to,
cooling or lubrication of the turbocharger because both systems are connected to the engine
circuits .
Measures for Lay-U p
The measures for preserving the turbocharger if it is to be laid up or stored for an extended
period of time are practically the some as for the Diesel engine (see Operating tAanual for
Diesel engine) .
Operating Diff 1 cu Itie s
Operating difficulties are usually attended and will be noticed by abnormal instrument
readings (exhaust temperature, charge-air pressure and speed), a high noise level or leaking
lubricating and cooling water pipes . If any irregularities should be noticed in a turbocharger
during start-up or operation of the engine, the cause should be determined at once an d
40 remedial action taken . Failure to attend to what may be a minor defect initially is liable to
give rise to serious consequential damage to the turbocharger and also to the engine' . If there
are-any irregularities, the engine load should be reduced or the engine shut-down, if possible,
and not restarted until after the cause of the trouble has been removed .
Avoid hif-and-miss tactics in attending to trouble which are rarely successful . The instructions
given hereunder and the fault-finding chart (cf sheet 3 .54) are intended to assist in
diagnosing the cause of irregularities experienced accurately and suggest how the problem
can be overcome quickly .
Putting Turbocharger out of Actio n
In emergencies, it may be necessary to keep the engine in operation withoka supercharging .

In this case, the turbine rotor can either be arrested or removed altogether (cf work sheet
500 .05). It is, however, - recommended that the rotor be removed if an auxiliary blowe r
is provided along with the- turbocharger ; the former can be kept in operation- ip ~Vhich case the
tubular *slide valve in the compressor must be closed (see Operating Man6al for engine) .
0 C a u t i o nI
With the turbocharger out of action, the output of the engine should be limi+ed by reducing
the injection pump setting to such an extent that the permissible exhaust -gas temperature and
the maximum speed ofthe operative turbocharger are not exceeded .
R o t o r Da m a 9 e
In the event the locating ring and the thrust ring are subjected to very high temperatures
due to insufficient lubrication or uneven wear,, these parts are liable to seize on the shaft -
so that it will not be easy to pull them off . Since these are high-quality rotating parts,, ut-
most care must be taken in removing them . After removal of these parts, the rotor should be
checked for any damage and out-of-true . Light scratch marks in the-aAal CTirection in the
seating surface of the turbine shaft that may have been produced,45y withdrawing these parts
are of no consequence .
D36 5645 E 3 .52-2 P .t .o .

In the area of the two plain bearings, the turbine shaft is fitted with bearing sleeves which
can be replaced after bearing damage . It is recommended that these bearing sleeves be
replaced in the manufacturer's works because the complete rotor with all parts must be
0
balanced after renewal of the sleeves .
Unbalance of the rotor will be noticed by uneven operation of the turbocharger and is
attended by a relatively high rate of bearing wear . The rotor should then be checked for
unbalance and it is recommended that this work be entrusted to the factory or to a sery1ce
base which we would recommend on enquiry . For this purpose, the complete turbine rotor
(with impeller and fixing parts) should be returned, since unbalance is the result of a
combination of factors and only if the complete rotor assembly is available in the factory
or the service base can coreful balancing be ensured .
Operation with one Inoperative Cylinde r
In the event of one cylinder of the engine becoming inoperative, the defect should if
possible, be removed before operation is resumed (see Operating Manual for engine)" . Should
this not be feasible and engine operation must be continued with one crankgear removed,
the following measures should'be taken :
I . Seal charge-air pipe of inoperative cylinder by means of blind flange to prevent the air
from escaping.
2 . Seal exhaust gas pip! by means of blind flange to prevent exhaust gas from escaping .
3 . Depending on prevailing conditions and engine load, further measures may be necessary
to prevent the turbocharger from surging (intermittent delivery of air) . Surging of the
compressor occurs when the air pressure in the charge-air pipe rises excessively, a
condition that will be noticed by uneven operation of the turbocharger and a hoWlJm
noise of the -compressor . In this case, -part of the air must then be bled 'to atmosOere .
But normally, it will suffice to change the engine load to restore smooth operation .
Emergency Operation with Damaged Turbine Blade s
If a fractured blade has resulted in a considerable loss of mass of the turbine rotor and the
turbocharger has to be kept in operation without it being possible to install a spare rotor,
a temporary remedy is to cut the blade diametrically opposite to it by the some amount .
This prevents unbalance becoming too great and helps to minimlize'bearing damage and we or
of the knife-edge seals . The lacing wire can be cut in the gaps obtained and its ends
0
flattened close to the adjacent blades .
This is strictly a makeshift repair to be re-

sorted to only in a real emergencr, it is no
substitute for later overhaul' . and balancing
of the rotor .
10
USIAM I
0
*,i&* IN- FAULT-FINDING CHART NA
3
53
0
E;
DE F ICIENCIES co
"I
_Ica
ca DR
C> !
4E Q 0
0 0
.W -0 0
L-
C~
4-
M
V3
M_
V) 4 03
-t
&_ Co C5 7= M
0 C3
CD a) (D
U)
a)
4
rM
Cn M
1-cc
eo
(11
W W
M
C~
.-
cc W
ca
Cl)
a) -2
OS S I B LE CA USES 73
W I-
W
ca. C3- ca. L_ ca I- CL 0 9-
C13 ME a) "
cL I- 'C ',
0 C~ i-
-W _~e_ W tv M
co I
0
'D 2 L_ eo Ja
a)
X - a :3
CC LLJ C-3 C/~ __j __j C-1) F_
Silencer fouled up 500 .1 1
0 Compressor dirty 500.14 . . . . . . . . . . . . . .

. . ....
Turbine dirty 500.0 7
Nozzle ring dirty 500 .25 ...... . ... ..
Charge-air cooler dirty . .. ... . .. ...... . ..... . .. ..... . ...... .. . .. ...
High intake air temperature
Low intake air temperatur e
Air manifold leakin g
Exhaust manifold leaking . . . . . . . . ...
. .. . ... . . . . . .
High gas backpressure after turbine ... . .... . . .. . . . . . . . . . .
. ......
Faulty fuel injection . ... .. .. . ..
bUU .1 9 ... .. .. .
Defective bearing .. ... . . .. ... .
500 .2 3
..... .
500 .1 6 X .,
Turbine wheel or impeller damaged
500 . 21 . . .. . . . .. . . . . . . .
Rotor contact 500 .21
0 . .. ... ... ... .44
Foreign matter in turbine or impeller . . . . . .. . . . . . . . . . .
. . . . . . .. .
. . .. . . ...
. . . . . .
Thrust or locating ring damaged

500 .2 0
Seals damaged, leaky connection s
Lubricating oil filter fouled u p
Excessive pressure in oil discharge or crankcas e
Scavenge andjor exhaust ports of engin e
fouled up X_
Lock-air ineffectiv e
Oil pressure gauge defectiv e
High oil inlet temperatur e
D36 5645 E 3 .53-1

0
0
FERNSEDIENUNG
AUTOMATIKBETRIEB
M *Aftk* M REMOTE CONTROL KS Z
AUTOMATIC OPERATION 70
0
Für Anlagen mit Fernbedienungseinrichtung oder Automatikbetrieb wird eine

eigene Beschreibung "Bedienungseinrichtung und Überwachung" mitgeliefert .
If the plant is designed for remote control or automatic operation, see separate
description "Engine controls and Monitoring system "
0 %0
D 36 5610 D+E 3 .70-2

0
0
WARTUNG
KSZ 70/125 B
M+Afk+M MAINTENANC E
I
Inhaltsverzeichnis Abschnitt 4 Tabl e a f con t en ts section 4 Blatt Sheet [-
Allgemein . . . . . . . . . . * . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wartungsplan (Beschreibung) . . . . . . . . . . Maintenance schedule (description) . . 3
Arbeitskarten (Beschreibung) . . . . . . . . . . . Work cards (description) . . . . . . . . . . . 4
Ersatzteilbestellung fur Werkzeug e Ordering replacement tools . . . . . . . . . 5
Zusammenstellung der Wartungsarbeiten List of maintenance work . . . . . . . . . . 6-9
.
Wartungsplan . . . . . . . . . . . . . . . . . . . . . . . Maintenance schedule . . . . . . . . . . . . . . U-
Arbeitskarten siehe eigenes Verzeichnis . Work cards see separat I ist . . . . . . . . . . 000 .01
M .A . No -Abgcsturbo lader M .A .N . exhaust turbocharge r

0 Wartungsplan & 9 . . . . . . o . .0 . . . . . . . . 0 0 . Maintenance schedule . . . . . . . . . 51 -54
Wartungsarbeiten . . . . . . . . . . . . . . . . . . . Maintenance works . . . . 55
Kontrolle der Einzelteile . . . . . . . . . . . . Inspection of parts . . . . . . . . . . . . . . . . . 56 +57

Arbeitskarten, Kurzhinweise . . . . . . . . . . Work cards, i ntroduction, . . . . . . . . . . . 58+ 59
Arbeitskcrten siehe eigenes Verzeichnis . Work cards see ' separat list . . . . . . .. . . . 500 .01
0- D36 5612 D+E 4 .1-2

0
0
*AAL* M MAINTENANCE
General
KSZ
KEZ
2
0
General
Planned maintenance is conducive to reliable engine operation, it helps reduce down times
and lowers the operating costs of the engin-e plant . The maintenance operations listed in the
Maintenance Schedule should therefore be carried out at the specified intervals and with
great care . Regular maintenance work will help the operating personnel in recognizing incipi-
ent disturbances, and evaluation of the maintenance work performed will indicate the need
for overhauls in good time . Overhauls can thus be programmed and carried out during sched-
uled service interruptions .
The Maintenance Schedule lists the various maintenance operations and the intervals at which
they are to be carried out . The necessary work is described in detail on the work card
. The
work cards are supplied in sealed plastics covers and are to serve as a guide at the work site .
The extent and the time at which maintenance work has been carried out should be entered in
the Engine Log as evidence that it has been duly carried out . Moreover, a corresponding
entry should be made if engine components have been replaced or repaired . Spares taken from
stock should be replaced as soon as possible, so that spare parts will always be available when
needed, since transport (and customs clearance) may delay the receipt of spare parts ordered .
Before starting out on any maintenance and overhaul work ., all pipes must be made pressureless
and a check to this effect is to be rri~_de
-by reading the pressure gouges or by loosening the
screw connections cautiously . And no attempt should be made to work on the running gear or
any other moving parts without first opening the relief valves in the cylinder covers and en-
gaging the turning gear . Upon completion of any work in the crankcase, check condition of
nuts and 'heir locking devices within this range . When breaking pipe connections, seal open
ends core ;ully if they are to be reused, in particular fuel
lubricating oil and air pipes . New
pipes must be checked for cleanness and, if necessary, flushed
' before installation . Great care
must be used to prevent foreign matter from entering the pipes . When it is intended to lay the
engine up or to shut it down for an extended period of time, the individual components must be
sufficiently preserved . When repainting the engine, make sure that no point can get into the
link joints of the fuel control linkage .
Necessary repairs, no matter how small, should be carried out immed ;-+-f I ause even m nor
0
deficienciis that are not removed are liable to result in consequential damage . Moreover, ex-
perience has shown that, when several different jobs need be taken care of, they are not carried
out with the necessary care, and therefore it is recommended that even minor deficiencies be
removed at once .
As cleaning solvent for the engine and its components, use either Diesel fuel or a special
cleanser . Otto fuel or TN
Trilene must not be used in closed rooms because of the risk of fire
and explosion it involves . For drying engine components, use pressure air or towels, cotton waste
is not recommended .
Upon completion of repair and overhaul work, inspect crankcase for tools, towels or other
foreign matter that may have been left b Teh ;i-n-d . Also, make sure that all parts and components
that have been worked on are correctly secured . Check settings and clearances of new or re-
installed parts and enter measurements in Engine Log .
0 ~.0
D36 5610 E . 4 .2-2
P .t .o .
The lubricating oil filters should be cleaned and the lubricating oil circulated through the
system for several hours so that any foreign matter and dirt which may have entered the 40
separated lines are positively removed . Thereafter, the filters (including the automatic ones)
should be cleaned again . If the lubricating oil charge has not been removed, the oil should
be separated as long as possible .
is
0
D36 5610 E / 4 .2-2
*AA* P4 MA I NTE NANCE :
KSZ
Maintenance Schedule KEZ 3
Maintenance Schedul e
1 . The maintenance schedule is a summary of the required maintenance work and covers a
period of 48 090 operating hou~s -Thereafter,
. a tGough inspection of the main engine
components will be necessary, and especially of the components of the running gear
which should then be checked for wear and replaced as necessary . The maintenance
schedule is then to be restarted at the beginning .
It is recommended that such extensive repairs be carried out in one of our service points .
Write to M .A . N . Augsburg for the register "Diesel Service Worldwide", print No .
D36 5154 E .
2 . The maintenance schedule has been established on the basis of experience gained from
plants operated under average conditions . The named operating hours, therefore, are
guide values . Fixed periods cannot be given because they are dependent on prevailing
operating conditions which vary greatly . Hence, prevailing operating conditions may
permit greater or require shorter intervals between maintenance operations and therefore,
0 in these cases it will be necessary to fix the length of the intervals in accordance with
prevailing operating conditions . For instance, if, on cleaning filters, the amount of
foreign particles retained by the filter is rather great, which often occurs with new or
overhauled engines, the intervals between cleaning should be shortened .
Favourable operating conditions are considered :

Constant load (small load fluctuations) within the range of 50 to 90 percent of full load
the use of recommended lubricating oil and fuel grades, timely oil change, close adher-,
ence to recommended lubricating oil and cooling water temperatures and good separation
of the heavy oil .
Unfavourable operating conditions are considered :

Extended operation at peak or at light loads, long idling, frequent extreme load changes,
operation at too low cooling water and lubricating oil temperatures, unsuitable fuel oil.
and insufficient separation of the heavy oil .
3 . When planning maintenance work, note that the space of time listed in the first column
0
of the block of columns "Total Service Hours" is to be understood as intervals, i .e . the
respective work is to be carried out at the end of each such period (e .g . after every 500
hours, an d again after 1 000, 1500 hours etc) . The other columns define absolute service
hours . The table "Compilation of Maintenance Work According to Service Hours" lists
I
under the column "Item No ." all operations to be performed after given operating hours,
and the pertinent work cards . The table thus affords a general view of the necessary pre-
paratory work and the applicable work sheets with the description of the operations .
4 . The first few sheets of the Maintenance Schedule (sheet 4 .11 etc .) comprise one-time
operations to be carried out on new or overhauled engines . These operations are also
included in the Compilation of Maintenance Work where they are listed under the same
item number .
5 . If a special Preventive Maintenance Schedule (see overleaf) has been established for the
specific engine, the stated time intervals may not be the same as those given in this
general Maintenance Schedule . In this case, the time periods specified in the Preventive
Maintenance Schedule shall be applicable as it has been established on the basis of the
0 prevailing operating conditions of the plant .
OZ D36 5610 E 4 .3 -2
p .t .0.
M .A . N . Maintenance Schedul e 0
The trend towards reduction of lay days and ships' complements requires rationalization of
engine maintenance operations and has lead to the development of a computerized mainte-
nance system which relieves the ship's personnel of drafting maintenance schedules and
monitoring engine variables . This system, which is called the COMPEX System, is based on
a maintenance schedule tailor-made for a given engine and relevant operating conditions .
This schedule is stored in a'computer and supplies the engine operator with recommendations
for planning maintenance operations due . The report of the execution of the work is fed back
to the computer and considered in the next printout .
Then there is also the possibility of opting for a Maintenance Contract, in which case the
maintenance work will be carried out by M .A .N . personnel .
For further information please write to the Augsburg Works of M .A .N .
is
40
0
D36 5610 E / 4 .3-2
MAINTENANCE
*A4!L* M KSZ
Work Sheets KEZ 4
0
Work Sheet s
The work sheets of this section describe the operations to be carried out to execute the work
specified in the Maintenance Schedule . The sheets are arranged by engine components/Cs-
semblies in the same way as the spare parts catalogue to facilitate looking up of spare parts .
The first three digits of the number on the work sheet connote the assembly, the last two in-
dicate the sheet number .
Example :
021 . 02
T- --r_ sheet number (sheet 2)
assembly (main bearing )
The tools listed on each sheet are numbered in the some way . Generally applicable tools
0 (e .g . clamping devices) and standard tools use a number below 010 instead of the assembly
number . The tool number indicates the assembly for which it is used and serves at the some
time as order number that is to be quoted when ordering replacement parts .
The enclosed space at the lower rim of each sheet can be used for entering tl~e work time
(man hours) required to carry out the operations described in the sheet .Once ascertained,
the data will be useful in planning recurrent maintenance work . Fixed man hours have not
been given because the time that will be required depends upon various circumstances (e .g .
ready availability of tools requited, accessibility at work site, availibility of lifting gear
and skill and training of the personnel assigned) . The time required for a given job will there-
fore differ slightly from plant to plant .
A second set of work sheets, as are included in this section, is supplied in sealed plastics
covers together with a portfolio . The sheets are thus resistant against water and oil and shall
serve as an aid directly on the site of work . Upon completion of maintenance work, the
sheets should be put back in the portfolio, correctly filed, so that they are readily available
at-all times .
0
0
CD
Co
c; D36 5610 E 4 .4-2
0
0
MAINTENANC E
M*AL+M Ordering replacement tools
KSZ
KEZ
5
0
Ordering replacement tool s
The necessary tools are specified on the individual work cards and are listed under assembly
490 . When re-ordering basic, supplementary or engine tools, not only the designation but
also the 6-digit tool number, which also serves as the order number, is to be stated . The
first three digits indicate the assembly for which the tool is to be used and thus facilitates
correlation .
To avoid back checks and discrepancies, the following particulars must be stated on an
order :
Example of an order-
1 . Address . . . . . . . . . . . . . . . M.A . N . -Maschinenfabri k Augsburg -NUrnberg AkJ
tiengeselischaft,DS90OAugsburg 1, Stadtbachstr .r, I
Telephone : (0821) 322 1
Telex : 05- 375 1
0 .Cable address : MANWERK AUGSBURG
Rail address : Augsburg-Ring, AnschluB 22
Xxxxxx
2 . Engine type . . . . . . . . . . . .
3 . Works no . . . .. ... . . .. . XXXXXX
4 . Order No . = Tool No. . . . XXX .X-XX

5 . Designation . . . . . . . . . . . . XXXXXXX
6 . Quantity . . . . . . . . . . . . . . xx
7 . Consignees address . . . . . XXXXXXXXXXXXX
Engine type
f
KSZ / Assembl y
&I *,AL* 14 . REMOVING CYLINDER COVER .
C. .. 1-1 05 5 .01
0
Quont't
TOOLS REQUIRED Too] No . Desig ntlario n
Tensioning device, compl . . . . . . 055 .382 Tool number
Cylinder cover support . . . . . . . . 055 .37 3
Order numbe r
I
LEGEN D
1 Cylinder cover
(DO9 .302)
D09 .411
D09 .4189
009
.41
Note : Engine components are only to be re-ordered by

0 1 reference to the separat e
CD
Spare Parts C-atalogue .
CD
cS I D36 5610 E 4 .5-2

0
0
ZUSAMMEN STEL LUNG DER WARTUNGS-
IN,*,1&* 14 ARBEITEN NACH BET RIEBSSTUN DEN
KSZ
4
LIST OF MAINTENANCE WORK
0 6
ACCORDING TO SERVICE HOURS
Betriebsstunden , Wartungsarbeit Pos . Nr . Arbeitskarte-Nr .
Service hours Maintenance work Item No . Work c6rd No .
nach Bedarf 112 129 133 135 000 .01 000 .02 000 .06 000.08
as required 142 1 56 157 159 000 .10 000 .15 000 .16 000.1 7
164 166 167 000 .18 000 .19 000 .20 000 .25
009 .02 021 .02 021 .03 021 .04
026.01 026 .03 030.03 039 .05
030.06 03) .01 040.02 040.04
040.07 040 .08 040 .10 040.1 1
050.02 050 .03 050 .04 050.06
050.07 050 .08 055 .03 103 .01
125 .xx 200 .05 200 .06 200 .07
203 .01 281 .01 281 .02 302 .02
0
alle 2 40 41 56 000.05 000 .06 000 .07 000 .08
24
every 76 82 84 92 000 .15 000 .16 000 .17 000 .1 8
108 1 14 116 125 000 .35 035 .01 055 .01 055 .02
128 1 30 131 132 125 .xx 140 .01 140 .02 161 .01
137 1 38 146 147 162 .01 281 .03 289 .01 302 .01
148 1 49 165 302 .02 442 .01
alle 117 1 39 150

250
every
alle 500 110 1 24 126 127 281 .03

every 162
alle 140
1000
every
c1le 7 15 42 48 015 .02 015 .03 015 .04 . 020.01

every 1500 52 64 77 83 040.01 040 .03 050 .01 1360.06
85 93 . .. 100 100 .01 203 .01 162 .01 1203 .01
101 1 02 136 43 221 .01 221 .02 221 .03 221 .04
nach 3000 4 16 23 24 000 .10 013 .01 020 .01 026 .01
after 65 70 73 026 .03 120 .01 125 .40 200.01
74 97 103 119 200 .02 200 .03 200 .04 303 M
141 153 158 160
0
(D
CO
c; D 36 561 0 D+E 4 .&-2
0
0
ZUSAMMENSTELLUNG DERWARTUNGS-
ARBEITEN NACH BETRIEBSSTUNDEN
M*A&* p4 LIST OF MAINTENANCE WORK
KSZ
ACCORDING TO SERVICE HOUR S 7
Betriebsstunden Wcrtungsarbeit Pos . Nr. Arbeitskarte-Nr .

Service hours Maintenance work Item No . Work card No .
nach 6000 1 3 4 5 000 .10 010 .01 013 .01 020 .01
after 16 17 18 19 021 .01 021 .02 021 .03 026 .01
20 23 24 25 026 .03 030 .01 030 .02 030.04
30 31 33 34 030 .05 030 .06 031 .01 055 .03
36 37 43 57 120 .01 125 .40 160 .01 200.01
63 65 66 70 200 .02 200 .03 200 .04 281 .03
73 74 75 78 302.01. 303 .01 -409.01 490.06
79 80 86 90
97 103 104 11 1
116. 119 134 141
143 151 152 153
158 160 161 163
0 168 170
nach 9 000 wie 3 000

after
nach 1200 0 1 3 4 5 000 .10 010 .01 013 .01 020 .0 1

after 8 9 16 17 021,01 021 .02 021 .03 026 .0 1
IS 19 20 23 026 .03 030 .01 030 .02 030.04
24 25 26 27 030.05 030 .06 031 .01 040.05
30 31 33 34 040 .06 040 .07 055 .03 057 .0 1
36 37 43 44 100 .01 100 .02 120 .01 125 .40
45 49 50 51 160 .01 200 .01 200 .02 200 .03
53 54 57 58 200 .04 281 .03 303 .01 302 .0 1
61 62 63 65 409 .01 490 .06
66 67 68 70
73 74 75 78
0 79 80 86 90
94 95 97 98
103 105 109 11 1
113 115 116 11 9
134 141 .143 151
152 153 758 160
161 , 163 168 170
nach 15000 wie 3 000

after
nach 18000
wie 6 000
after -
nach 21 000 wie 3 000

after
0
CD
C9
4=0 D36 5610 D+E 4 .7-2
0
0
ZUSAMMENSTELLUNG DER WARTUNGS -
ARBEITEN NACH BET RIEBSSTUNDEN KSZ
*A&* PA LIST OF MAINTENANCE WOR K
0 ACCORDING TO SERVICE HOURS 8
Betriebsstunden Wartungsarbeit Fos. Nr . Arbeitskerte-Nr .
1 3 4 5 000.10 010 .01 013 .01 017 .01

nach 24000
after 8 9 10 11 019 .01 020 .01 021 .01 021 .102
12 16 17 18 021 .03 026 .01 026 .03 027 .01
19 20 21 22 030 .01 030 .02 030 .04 030 .05
23 24 25 26 030 .06 031 .01 040 .05 040 .06
27 29 30 31 040.07 055 .03 057 .01 100 .0 1
32 33 34 35 100.02 120 .01 125 .40 160 .0 1
36 37 43 44 200.01 200 .02 200 .03 200 .04
45 46 49 50 281 .03 302 .01 303 .01 409 .01
51 53 54 55 490.06
57 58 61 62
63 65 66 67
68 69 70 71
0 73 74 75 78
79 80 86 87
90 91 94 95
97 98 103 105
109 111 113 11 5
118 119 120 134
141 143 151 152
153 158 160 16 1
163 168 17 0
nach
27000 wie 3 000
after
nach
30 . 000 wie 6 000
after
nach 33000 wie 3 000

after
nach
36000 wie 12 000
after
nach
39000 wie 3 000
after
nach
a fter 42000 wie 6 000
nach 45000 wie 3 000

afte r
0 C>
Co
D36 5610 D+E 4 .8-2
0
0
ZUSAMMENSTELLUNG DERWARTUNGS-
ARBEITEN NACH BETRIEBSSTUNDE N
LIST OF MAINTENANCE WORK KS Z
0 ACCORDING TO SERVICE HOURS 9
Betriebsstunden Wortungsarbeit Pos, Nr . Arbeitskarte-Nr .
1 3 4 5 000 .10 010.01 017 .01 019 .01

nach 48000
after 6 8 9 10 020 .01 021 .01 021 .02 021 .03
11 12 16 17 026 .01 . 026 .03 027 .01 030 .01
18 19 20 21 030 .02 030 .04 030 .05 030.06
22 23 24 25 031 .01 040 .05 040 .06 040 .07
26 27 29 30 055.03 057 .01 100 .01 100.02
31 32 33 34 120 .01 125 .40 160 .01 200.01
35 36 37 43 200 .02 200 .03 200 .04 281 .03
44 45 46 47 302 .01 303 .01 409 .01 490.06
49 50 51 53
54 55 57 58
61 62 63 65
66 67 68 69
0 70 71 72 73
74 75 78 79
80 86 87 90
91 94 95 97
98 99 103 105
109 111 113 115
118 119 121 134
141 143 151 152
153 158 160 161
163 168 170
D36 5610 D+E 4.9-2

0
0
0 9 .0 0
11 .80
4
WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ
KEZ 11
FOR NEUEN ODER OBERHOLTEN MOTOR WITH NEW ENGINE OR AFTER OVERHAU L
Die angegebenen Wartungsarbeiten auf Blatt 4 . 11 bis 4 .15 The maintenance work described in sheet 4 . 11 to 4 .15 need be
sind nur einmal bei neuern oder uberholtern Motor auszufuhren . carried out only once on the new engine and once after overhaul .
Pos Arbeits- Motorteil Gesamtbetriebsstunden -Total service hours

Nr
. karte Wartungsarbeit Wntenance work C) C) 0 (D C)
Iterr'Work U') V) 0 C) C1
No,~card Part of engine CN tn C) C)
M 10
1 010.01 rundament und Inspektion : Schraubenspannung mit Inspection : Check bolt preload with
Grundplatte hydraulischer Vorrichtung (Stichproben), hydraulic tool (random test), and chocks
roundation and Pa8stUcke und Stopper auf festen Sitz and stops for tightness by sounding . . . ..
bedplate durch Abklopfen .
3 Motorverbindungs- Inspektion : Schraubenverbindungen auf Inspection : Check bolts for tightnes s

elemente festen Sitz durch kklopf6rE,(z .B . Be- by sounding (e .g . fixing bolts, exhaus t ...
Engine connect- festigungsschrauben, Abgasleitung, ...
manifold, charge-air manifold etc) .
ing elements Ladeluftleitung etci )
4 013-01 Zuganker Inspektion aller AbstUtzungen Check brace screws

Tiero d
6 Nachspannen aller Anker Retighten all tierods

.X*
15 Triebwerk Sichtinspektion aller Zylinder Visual inspection of all cylinders X-X

Running gear
D36 5610 D+E 4 .11-2

0
0
6 .84
4
"1;Pf *AQS,* WARTUNGSPLAN MAINTENANCE SCHEDULE KS Z
I KEZ '12
Pos . Arbeits- Wtorteil Gesanntbetriebsstunden - Total service hours
Nr . karte Wartungsarbeit Maintenance work
C) C, CD
C) C)
C) C)
Iterr Part of engine Work to to C14 LO C) C>
No card Cl) 10
1
16 000 .10 Kurbelwelle Inspektion : Wangenatmung Inspection : Measure crankweb defl ection s
020 .01 Crankshaft
17 Inspektion : Ve rdre hung smark ie rung an Inspection, Alignment of match-marks indi-

eingeschrumpften Wellenzapfen cating kelative position of shrunk-fitted
journals to web s
19 021 .01 Kurbelwellenlager Inspektion : Lagerspiel In3pection : Bearing clearance
Main bearin g
'30 030-05 Treibstangenlager Inspektion : Lagerspiel Inspection : Bearing clearance

Connecting ro d
bearing
33 030-05 Kreuzkopflager Inspektion : Lagerspiel Inspection : Bearing clearance

Crosshead bearing
49 040 .01 Kolben Aus- und Einbau I Kolbe6 Reinigung, Removi and rein3tall one piston, clean,
Aufmessung Kolbenringe und Nute n ...
040 .03 Piston measure rings and groove s
040-05
040 .06
Uberprofung Kolbenstellung nach Wieder- Check alignment of pi3ton after reinstalla- . . ..
51
einbau tio n
53 050 .06 Zylinderbuchse Aufmessung 1 Buchse Measure liner wear, 1 cylinder liner
Cylinder line r
D36 5610 D+E 4 .12-2

0
0
4.77
4
WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ-B
KSZ- C 13
Pas ' Arbeits- Motorteil Gesamtbetriebsstunden - Total service hour
s
Nr
. karte Wortungsarbeit Maintenance wor k
Item Work C> to
C) 5
C)6C)C50
Part of engine Ln
No . card C14 W) C> (D
Cl) 10
54 302.01 Zylinderschmierung Inspektion der Schmieranstiche be! lns~ect lubricating fittings of on e

Cylinder lubricatior 1 Zylinder cylinder
57 055-01 Zylinderkopf Nachspannen aller Zylinderkopfschraube n Retighten all cylinder cover bolts
055-02 Cylinder head und Verbindungsschrauben zwischen Ober- and bolts connecting the upper with
und Unterteil the lower part X,
58 Ab- und Anbau 1 Kopf (belm Abbau Ermitt- Remove and reinstall one cylinder cove r
lung Mitternlusedruck, falls Druck um (determine bolt loosening pressure
mehr als 10% vom Sollwert abgefallen, if it is more than 10% below nominal
alle Zylinderkopfschrauben nachspannen), value, retighten all cylinder cover
Inspektion Brennraum, KUhlrgume und Ver- bolts), inspect combustion space,
bindungsflZchen, ggf . Reinigung cooling spaces and mating surfaces ,
clean if necessary
66 100 .01 Steuerungsantrieb Inspektion : Zahnroder und Zahnspiele Inspection : Gearwheels and gear back-
100 .02 Camshaft drive lash X
70 120 .01 Umsteuervorrichtung Inspektion : Ulstand in (knsteuerbehZIter n ....
Inspection : Oil level in reversin g
Reversing gear runktionsinspektion)Sichtinspektion Um- ....
tanks, functional test, visual in-
steuerungsteile spection .of moving part s
?3 125.40 Hydraulisches Stell- Reinigung Saugfilter Clean suction filter

ger3 t
Hydraulic positionei
74 Reinigung reinfilter
Clean fine filter X.
D36 5610 D+E 4 .13-2

0
0
12 .76
*A&* WARTUNGSPLAN . MAINTENANCE SCHEDULE 4

KSZ-B
KSZ- C 14
Pas Arbeits-, Motorteil Gesamtbetriebsstunden - Total service hour s
Nr karte Wartungsarbeit Maintenance wor k
Item Work Part of engine C) C> CO C) 0
LO LO C) C~ 0
No . card CN Ul CD 00
C') 'a
75 Ulwechsel Change oi l
77 125-xx Bedienungsein .- Funktionsinspektion Make functional test

richtung
M-anoeuvring
epuipment
82 Sicherhelts- und Funktionsinspektion : SchaltgerNte und Functional test : switch gear and shut-
Notabstelleinrich- Abstelleinrichtung down device s ....
tungen
Safety and shut-
down device
85 140 .01 Woodward- Regler Inspektion : RegelgestUnge und Regierver- Inspection

: Check fuel control linkag e
203 .01 Woodward governor halten im Betrieb and governor behaviour during operatio n ....
86 d1wechsel Woodwardregler/Boostermotor Change oil Woodward governor/Booster X.

(Reinigung, Entfiftung, Hersteller- motor (clean, vent, observe manufac-
Yorschrift beachten) turer's recommendations)
100 Einspritzpumpen- Sichtinspektion : Nocken, .Antriebsrollen, Visual inspection : cams, drive rollers,
antrieb rahrungskolben, Schmierung fUhrungskolben tappet, lqbrication of tappet and ca m
Injection pump und Nockenlaufbahn tracks ....
drive
D36 5610 D+E 4 .14-2

0
0
10 .80
WARTUNGSIPLAN MAINTENANCE SCHEDULE KSZ-B 4

KSZ- C 15
1
Pos
. Arbeits- Motorteil Gesamtbetriebsstunden - Total service hours
Nr
. karte Wartungsarbeit Maintenance work
I terr Work C) C) C) C) C)
Part of engine C) C) C3
No . card W) MC) 10
C>
101 203 .01 RegelgestUnge

Inspektion : Regelgestgnge auf Lelcht- .. .
Inspection : Fuel control linkage fo r
Control linkage g3ngigkeit free movement
134 Kraftstoffilter Reinigung Cleanin g

Fuel filter (Herstellervorschrift beachten) (observe manufacturer's recommendation
141 Schmierun g Inspektion : Schmier6lablauf von Kreuzkopf-, Inspection : discharge of lubricating ....
Lubrication lreibstangen~- und Kurbelwellenlagern(sowie oil from crosshead-, crank- and main .. .
Drucklager) bearings Gs well as from thrust
bearing)
150 000 .07 KUhlwasser Profen : Konzentration Korrosionsschutzdl Check : concentration of corrosion xx.
Cooling water (Motor-, Kolben,- und DUsenkreislauf) inhibiting oil (engine-, piston-
. and injector cooling systems )
153 Elektrische Kabel Inspektion : Lose Verbindungen und Scheuer- Inspection : For loose connections .. .
::::
Electic wires stellen and chafed spot s
160 Schmierul-Betriebs- Reinigung C1 ean

filter (Herstellervorschrift beachten) (observe manufacturer's recommen-
Luboil line filter . . ... .. ... . . .. .. . . .. . .
dations) . . ... . . . .. . . .. .. . . .. . .
161 - Schmierfl-Indika- Reinigung Clea n
torfilter (Herstellervorschrift beachten) (observe manufacturer's recommen- X.X
Luboll indicator dations )
Jilter
X .X .
D36 5610 D+E 4 .15-2

9
0
0 0
11 .80
4
WARTUNGSPLAN MAINTENANCE SCHEDULE KS Z
KEZ 16
Die Betriebsstundenongaben des Wartungsplanes sind Mittelwerte, The service hours given in the maintenance schedule are average values .
die sich je nach den vorhandenen Betriebsverhaltnissen verltingern Prevailing service conditions may permit longer or require shorter inter-
oder verkurzen kt5nnen . vals .
3os . Arbeits- Motortei Gesamtbetriebsstunden - Total service h urs

I
'4r . karte
Wartungsarbeit Maintenance work c) C> C) 0 C3 C3 8 0 C> C> 0 0
C) C) 0 C) C> C> C3 C) 0 C) C) C) C> CO
tem Work C) C) C) C) C) Q C> C) C) C) C) C) C> CDP C> (D
Part of engine Cn 'o o, C%4 to CO "It rN, C) Cl) 10 0, CN to 00
',4o . card CN CN CN (1) (1) Cl) Cn 1- 'IT
0 C:) C'
1 010 .01 Fundament und Inspektion : Schraubenspannung mit Inspection : Check bolt preload wit h X.X.
Grundplatte hydraulischer Spannvorrichtung hydraulic tool (sample test)jchocks
Foundation and (Stichproben), PaBstocke und Stopper and stops for tightness by sounding
bedplate auf festen Sitz durch Abklopfen ent- at specified intervals, after ever y
sprechend Intervallangabe und nach-jeder long voyage and bad weather periods,
lungeren Reise sowle Schlechtwetter- after average or touching groun d ... ... .. . .
periode, Kollision und Grundbe-
rUhrung des Schiffes . ... ....
X.X
.. . ... .. ...
2 Zylinderblock Inspektion : Leckwasserablauf der Check: Leak water discharge from ... X
. .... .. . . . . . . . . . . -X
X. .X . . . . . . . :. . . . . . .
Cylinder block Zylinderbuchsen' cylinder liner X. XX
XX X
X
. . .
. . . . . . .
X-Y
3 Morverbindungs- Inspektion : Schraubenverbindungen auf Check : Screwed connections for . . . .

. . . . . . . .
elemente festen Sitz durch Abklopfen (z .B . Be- tightness (e .g. fixing screws :X
Engine connecting festigungsschrauben Abgasleltung, Lade- exhaust manifold,~ charge-air pipe , ....
elements luftleitung etc .) etc) . . .. . . .
X.
4 013-01 Zuganker Inspektion aller AbstUtzungen Check all brace screws X-V
X.
X
Tierod X
.X: X
LD36 5610 D_±E 4 .16 -2 :: X: : :: : :: ::: :: . :::.: :: : ::: : :X .-
0
0
11 .80
4
*A&* WARTUNGSPLAN MAINTENANCE SCHEDULE KS Z
KEZ 17
I
:,as . Arbeits- Motorteil Gesarntbetriebsstunden Total service hours
'-4r . karte --
Wartungsarbeit Maintenance work a COC~
Q 0 C) C) C) C) C)
C) C) 00 C>C)
0 C) 0 C)a
ternWork 0 C) 0 C)C14 C)in C)CO
C) -00 C3 C) C) C) C) C> C) C)
Part of engine V C-) -0 5, -:r K 25- Cl) 10 01 C14 to CC)
'slo . card C14 C4 M Cl) Cl) Cl)
C> C:, C> ' :' C" C:, I
5 Inspektion : Vorspannung be! einem Zuc~- Check : bolt preload of one pair of . .. . . .. . .. . .-:-X.:
...
ankerpaa , beginnend zw1schen Zylinder I ... .. .. ... . .. . .. .
tierods, starting between cylinder X
X:
und Zylinder 2, falls Mutternlbsedruck No 1 and cylinder No 2, if bolt . XX.
.... -XX-
... ...
um mehr als 101 vom Sollwert abgefallen, loosening pressure is more than XX
alle Anker nachspannen 10 % below nominal value, retighten X. . .
.... .... . ... ....
all tierod s
6 Nachspannen aller Anker Retiqhten all tierods
.. . . . . . . . . . .... ... . . . . . X-X -:-X .. .... . . ....

7 015-02 Kolbenstangen- Inspektion : Leckdlablauf' Check : Leak oil discharge . ... .... ... ..... . .. . . .. . .
. . . . . . . . . . . . .. .X-: .
015-03 Stopfbuchse .... .. . .. . .... ... .. .... . .. . ... ... ....
. ... .. . .... . .. . . . . . . . . . . . . . . . . . . . . . . X.
015-04 Piston rod . . . . . . . . . . . . . . . . . . . . . ... . .. . ....... X.. ....... .. . ... . ... . . . . . . . . . . . . . . .
stuffing box .. ..XX
.. . . .... . . .... ... ... ... . .. ..... . . . .... ... .. .... . . .... . . .X X. ..
. .... .. X
-XX.. : . . . .. . .. .. ..X .. .. . .. . . . . . . -X
. . .....
8 Aus- und linbau aller Stopfbuchsen, Remove and reinstall all stuffin g
2erlegen, :reinigen, Inspektion der boxes, disassemble, clean, inspect
Dichiringe seal ring s
9 Inspektion : MaBhaltigkeit und Ober- Check : Dimensions and surfac e . ...

fl9chenbeschaffenheit aller Kolben- conditions of all piston rod s ....
stangen
10 017-01 Drucklager Ablassen UlfUllung, Reinigung Geh9use, Brain oil charge, clean casing,
Thrust bearing Plessen, Lager- und Axialspiele . measure radial and axial bearing
clearances .
D36 5610 D+E 4 .17-2

0
0
11 .80
M *AM* 14 WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ 4

KEZ
1 18
:'as Gesarntbetriebsstunden - Total service hours--
. Arbeits- Motorteil
+. arte C
p
C) p C3
C3 C) 8 C)C)C) 08 C)
C) ~ C) C)
C) C)CD CO 0
C)CDC) 4:3 C) (DC) C) C> CD C)
Wartungsarbeit Maintenance work 0
tern Work C) C) C) C1 C) Q C) C) C)
Part of engine Q C-) -0 25' C'4 to CO 4 K 6 C-) '0 o' C'4 to 00
'4o . card C C14 C14 Cl) (1) M M
C' ... . 1c, I .. .. . C:> .. ..
Falls erforderlich Aus- und Einbau
If necessary, remove and reinstall thrust
Scfiubstocke, Inspektion, pads, inspec t
12 019 .01 ExzenterabstUtzung Aus- und Einbau Exzenterbolzen reinigen, Remove andrainstall eccenter bolts,
(falls vorhanden) schmieren und neueinstellen der Dgmpfung clean, lubricate and readjust damping
Eccenter bracing setting
.... .. .. . .. . .
(if provided)
.... .. .. .....
13
. .... .... . .... . .. . ... .... .. . . . . . . XX

15 020 .01 Triebwerk Sichtinspektion aller Zylinder Visually inspect all cylinders . X. . . . .. . ... . . . . . . ... ....... ... .. .. .. .. . ...... ... ........... . ... ......... .. .... ..... .. . . .. . .
: .150( . . . . . . . . . . . .. . ... . ... . ... .. ... ...... .... ... . .... .
Running gear ..... ........ . ... ... ...
. .... .... .... ... .. .... ... .. ...
.... .... .... .. . . . . . . . . . . . . . . . . . . . . . . .:.X.
16 020 .01 Kurbelwelle Inspektion : Verdrehungsmarkierung 'an Inspection : Check shrunk on journals for ... .... .... .... .. X X .
000 .10 Crankshaft eingeschrumpften Wellenzapfen twisting at match marks . . . . .. . ... . . . .. . . . . .. . . .. .. . ... . . . .. . . . . . . .
. .. . . .. . .. . . . . .. . ..
X. ..X~ . .
. .. ... .. .. .. . .. .. .. ..X....X
. . . X. ... . . .
.. ... .. .. .. .. .... ... ... ........

17 Inspektion : Wangenatmung entsprechend Check : Crankweb deflections at specifie d
Intervallangabe und nach jeder Kollision intervals and after average or touchin g
und Grundberohrung des Schiffes ground :: ::: :: : .*"
D36 5610 D+E 4 .18-2

0
0
11 .80
4
KEZ 19
I
)as . Arbeits- Motorteil Gesamtbetriebsstunden - Total service hours__
+ . karte C3 C)C) C) C) C)
0 8C)C)C30 C) C)
C) 0
Wartungsarbeit Maintenance work a
?- C) C) C)
C) C) C)C1 C)C)
C30 C) C) C) 0 C3 C) 0 0
C) C)C) CO
tenn Work 0) C") 10 01, CN CC) - 'It N C) (n 10 a" C14 U-) CO LO
. cord Part of engine C14 (14 C14 Cl) Cl) Cl) IT NT
'4o C:, C:, (:3 C' 0 ::,
.. .
.... .. .. ....
.. .
.... ....
18 Kupplungsschrauben, Inspektion : Festen Sitz aller Schrauben Check : Ughtness of all bolts by ::: :*.: . ... ... . ...
. . . . .... .... ....
(Kurbelwelle) durch Abklopfen sounding ::: : ::: :::: ::: X "
Bolts in drive X.: X. . . .
.. .. .... . ...
flange (crankshaft) ... .. . . . . .. . . .. . . . .
. .. . ... . .. . . .. . ... .. ...
19 021 .01 Kurbelwellenlager Inspektion : Lagerspiel Check: bearing clearance . . ... . . . . . .. . . ... . . . . .... ...
021 .02 Main bearing .... . .. . . . ..
021-03
.... .... . ...
20 Inspektion : Schraubenverbindungen auf Check : Screwed connections for X.
festen Sitz durch Abklopfen tightness by sounding .... . ... . ...
21 Inspektion : Absenkung der *Ilenzapfen .. ..

Check : Sagging of journal with
mit MeOvorrichtung measuring tool
X.
X.:
22 Aus- und Einbau I Lager (beim Ausbau, Remove and reinstall 1 bearing
Ermittlung Mutternlosedruck) (determine bolt loosening pressure
Inspektion ggf . Ausbau , sowle Kontrolle when removing )
welterer Lager inspect and, if necessary, remove
and inspect additdonal bearings
. . . . .. . . . . . . . . . . . . ... . . .... ... .. ..... .... .... .. .... . . ... ... . .... ... .X. ..... . . ::. : :: :::: :::: : :::: :*
23 026 .01 Tdrngetriebe Inspektion : b1stand entsprechend Intervall- Check : oil level at specified inter- .. .. . . . . .. . .. ... .... ... .... . .. . . . . . . . . . ...
. ... .. X .,
. . . . .. . .....
....
026 .03 Turning gear angabe und vor jedem Gebrauc h vals and every time before use
. . . . . . . . . . . . . . . . . . . . ... . ... . . ... . .. ... ... . . . . . . . . . .. . ....
. . . .. . . . ... . ... .. . .. . . . . .. . . . .. . . .... .. ... ... . . . . . . . .... . . ... ....
.
X * . X
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
D36 5610 D+E 4 .19-2 1 1 1 1 1 1 1 1

0
0
11 .80
4
*A&* WARTUNGSPLAN MAINTENANCE SCHEDULE KS Z
KEZ 20
as . Arbeits- Gesamtbetriebsstunden - Total service hours

. karte Motorteil
r C) 8 0C)0C)
(:) a 8
Wartungsarbeit Maintenance work C) C) 8 0 80
E3 Cc)0
'E3 C>8
C) 01 0 C> C) 0 C) C) C) 0 C> CD C) C) 0 C)
tern Work
':~' C'
Cl) 10 0, C14 ul CO I 'IT r*11 Q Cl) 10 0~ C%4 to CO
Part of engine C14 -It
~slo . card C C"
. . . . . .. ... . . . ... .... . . . . . . .. .. .... .. .. .. .. .. .. . . . . . . . . .. . .. . . . . . .. . . .. .
... . ......
24 Uberprufung Ulverschmutzung . Schmieren Check oil for contamination. .. .......
. . . .... .. . . . ..... .. ... . . ... . ... . . .. . . . . . .. . . .. . . . . . . .. . . ..
von Ritzel, Schaltrad und Spindel LubrGte pinion, turning wheel and . . . .. .. .. .. .. .. . .. .. ..
. .... ..... x . . . . . .. . . . .. . . .
spi ndl e .. .. .... .. . . . . . . .. . . .. .... ... . . . .. . . . . .. . . . .. . . . .. . . . .. . . ..
25 Vega-Test E4btor Megger-test electric motor X. : X" X.
X..
26 Ulwechsel entsprechend Intervall- Change oil at specified interval s
angabe bzw . bei Ulstandzeit grHer but not later than every 24 month s ....
24 Monate,
... .... .. . .
27 Inspektion: Wz1ager 1-Motor ggf . Inspection Rolling contact

Austausch bearings of electric motor, replace
if necessary
28
29 027 .01 Drehschwingungs- Inspektion : HOlsenfedern ....

In3pection : Sleeve springs
d5mpfer (falls vor-
handen)
Torsion vibration
damper(if provided )
D36 5610 D+E 4 .20-2 -L J

0
0
11 .80
4
M *Ak* 14 WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ
KEZ 21
)as . Arbeits- Motorteil Gesarntbetriebsstunden - Total service hours
karte a0 800 a0 C) C) C) C)
Wartungsarbeit Maintenance work 0
C> 0 0 CD CD 0C3 C~QC)
CDP C> 8C>
8C3 CE3
C) C)
0
CDC)
C) C)C>
C)
0
C> 0
tern Work 0) Cl) 10 0'. 04 Zn 00 ~~ "t r" CC) cv) %a 01 C14 Ul) cc
. card Part of engine
'4o CN C14 2 (1) M "I -It
.. . . .. . . ... . .. .... .. ..
...
X. .
30 030 .01 Trelbstangenlager Inspektion : Lagerspiel Check : bearing clearanc e . . . .
030 .02 Connecting rod .. ..

030-05 bearing
. . . . . . . . . .
31 Inspektion : Schraubenverbindungen auf Check : screwed connections for tightness X . :. .
festen Sitz durch Abklopfen by sounding : .. . . XX

X.: X
XX
32 Aus- und Einbau I Lager (belm Ausbau Remove and reinstall 1 bearing (determine
Ermittlung Mutterl6sedruck) bolt loosening pressure when removing) .
Inspektion ggf .Ausbaus sowie Inspect and, if indicated, remove and
Kontrolle weiterer Lager inspect additional bearing s
33 030 .01 Kreuzkopflager Inspektion : Lagerspiel Check : bearing clearance .... . .. . .. .. .. .. ....
030-04 Crosshead bearing X
030-05
34 o3o .o6 Inspektion : Schriubenverbindungen auf Check : Screwed connections for tightness X X.
X: .. . . ... .... .. ..
festen Sitz durch Abklopfen by sounding ...
X,
-X XX
35 Aus-- und Einbau I_L~Ler (beim Ausbau Remove and reinstall one bearin q . .. .
Ermittlung 14utternlUsedruck) Inspektion (determine bolt loosening pressur e
ggf . Ausbau, sowie Kontrolle welterer when removing) inspect and, ff indicated
Lager remove and check additional bearing s
D36 5610 D+E 4 .21-2

LL
0
0
000817 . . . . . . . . . . . . . . . . . . .. . . . . . . . .
- - ------ -- -
%.'T C'4
CN 00091F
0 ooozv
.... . .. ..
0
,v 1 0006C
0009C . .. ... ....
.... ..
N N CD OOOCC
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o 0000C . .. . . . . . . . .
. . . . . . . . . . . . .. . .
0
oooz z
c o0on X.
X . . . . . . . . . .... . .. . . . . . . .
-0
C ooot z
. . ..
. . . . . . . . . . . . . . .. . .
0008 t
Lij .Z: 0009 1 . . . . . . . . . . . . . . . . ... .
OOOZ
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.
. . . . . . . . . . . .
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co~w -W 0
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L) - C~
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t4
< 0) C,
C, .0 m
r_ .0 C~
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4- ~4 .0
a)
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r-n
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4) L" 04
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LI
I i -) 4) -N,
0 6- -0 9
'o '~ 9 9 10
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0 C:) 5::
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0
0
0 0 0 1 0
6.84
M*A4M*1M WARTUNGSPLAN MAINTENANCE SCHEDULE KS Z

KEZ 23
:)as . Arbeits- Motortei Gescmtbetriebsstunden - Total service hours
I
~,Ir . karte
Wartungsarbeit Maintenance work 0 C> 0 C) 0 C) 8 0 0 C8) 8 0 0 C) C
C) C> C) (D C) C> C) CD C) C) C) C) ( D
tern Work ~ C) C) C) C) C3 C) 0 C3 C) C) C) 0 C) C3 C) C3CO
Part of engine (D Cl) 10 0% C14 U) CC) - -4- r, C) c) 10 01 04 to
\1o .lcard C14 C14 (N Cl) Cl) Cl) Cl) 'IT "It
:) C:,
43 Instandsetzung : Automatische Entw3sserung Recondition : automatic condensate ..... . .... ... .. . . . . . . .. . . . . . . .
der BelUftungsleitung (Schwimmerableiter) drain of air supply pipe (float .. ..... .. .. .. ... .. .. .
X ... .. . . . . . . . . . . . . . . ... .
switch, discharge) :: . :*- : .- . . . . .. . . . . . .
44 Aus- und Eiabau Stopfbuchsen . Remove and reinstall stuffin g

Inspektion-Stopfbuchsen und Posaunenrohre boxes . . ...
Inspect stuffing boxes and teles-
45 Inspektion : RUckschlagventil an Windkesseln copic pipe s
Inspection ' : non-return valve on
surge tank s
46 Inspektion : Steuerventil zur BelUftungspump e . ...
Inspection : control valve o f
air supply pump
47 Instandsetzung : BelUftungspumpe Recondition : air supply pump ...
. . . . .. . .... ... .... . .. .... . . . ... .

48 040 .01 Kolben Inspektion : Kolbefiringe und Schmierzustand Inspection : ::*- X. X.: -X : X
: piston rings and 15M ~::::X
040-03 Piston durch Schauloch .. ... .. .. . .. ......
lubrication through inspection
hol e .....
. . . 3 : . .. . . .. .... . . .. ... . . . . . . . . . . . . . . . . . . ... .. .
... ........ ... . ... . ... . . .. .. . . . . . . . . . . . .. . . . .... .. .... .. . . ... . .. .. ... . .. ... . ...
. . . ...
X. . .
49 040-05 Aus- und Einbau aller Kolben, Reinigung und Remove and reinstall all pistons,
... .
WA clean, Inspektion,
inspect, Aufmessen Kolbenringemeasure
und Nute n piston . . ... . . . ... . ... . . . ... . .
. .. .
040-07 .... ... ..
rings and grooves . . ... . . . .. . ... . . ....
50 Erneuerung oberster Kolbenring, ggf . auch Replace first pistonring from the X-X . ... .
.... .:. . . :: : . . ::: ::* . .. ..
Erneuerung restlicher Ringe :X .
top and, if necessary, also the
other ring s
51 . ..
UberprUfung Kolbenstellung nach Wieder Che~k piston alignment afte r ... . X .. . .. ..
einbau reinstallation .. . .... .. .. X-
D36 5610 D+E 4 .23 -2
X-
0
0
0 0 0 -0
6 .84
4
WARTUNG$PLAN MAINTENANCE SCHEDULE KS Z
KEZ 24
:)as . Arbeits- Motorteil Gesamtbetriebsstunden - Total service h ur

'4r . karte
C) 0 0 1 C) 0
Wartungiarbeit Maintenance work C)
C)
C) 8 C)
0 0 C)
8 8C)80C) C) C) C) C) 0 (D C)
C) (D 00 C) C) 00 C3 C) C)
tem Work Cl) 10 01 C14 L0 CO - I-
Part of engine r-, C) c) 10 0, CN W) ca
'4o .icard 04 C14 Cl) Cl) Cl) Cl) -t
. . . . .... .. . . ... ... .... . .0. .... .... . ... . ... ... .... . . ... ... ... . .... . . .. . . . . . . . . . . . . .. . .. . . .. . .. . . .
52 050 .01 Zylinderbuchse Inspektion : Lauffl9che und Schlitze . . .. . . . .. . .. . . .. . . . .. . . .. . .. ... . .... . ...
Inspection: running surface and liner . .. . .. .. .... ... .. ... .. .
050 .06 Cylinder liner durch Schauloch ports through inspection hole 500 ... . . . . . . . . . . . . .
.... .... .. .. ... .... . ... . ... .... .
53 Aufmessen aller Buchsen, Inspektion Take measurements of all liners, in- x
Lauffl9che spect running surface X,
.X . X: ...
.... . .. .
54 302 .01 Zylinderschmierung Inspektion : Schmieranstiche aller Inspection : Lubricating fittings . . .
Cylind~r lubricat- Zylinder 6f all cylinders
ion
55 Aus- und Einbau RUckschlagventile, Remove and reinstall'check filves ,

Reinigung, ggf . Austausch clean, replace if necessary . ...
. . . . . . . . . . .... .. . . .. ....
. . . . . . . . . . . . . . . . .X. .. x
56 055 .01 Zylinderkop f Sichtinspektion : Dichtheit Verbindungs Visual inspection : tightness Of -X
. . . . . . . . . . . . . ..
055 .02 Cylinder head Mchen mating surfaces . . . . . . . . . . . . . . ... .... . .. ... . . . . . . . . . . . .
57 055 .03 Nachspannen aller Verbindungsschrau- Retighten all bolts connectin g .... . ... .. .
ben zwischen Ober- und Unterteil. upper and lower part of cylinder X
cover ... . . .. .
X. ....
... ... . ...
D36561013+E 4 .24 -2 1 I.X .

0
0
0 1 0 0 0 .
6.84
4
I KEZ 25
3os . Arbeits- Motorteil Gesamtbetriebsstunden - Total service hours__
karte C:) C:' C:' C:) 0 0 8 C> C) C) 8 C) C) C> C> C1
Wartungsarbeit Maintenance work CD C) C) 0 C) C> C3 C) C) C) 0 C3 C) C3
tem Work C) C) 0 C) C) C) 0 0 C) 0 0 C) C) C) C> C )
(1) C-) '0 o' C-4 U-) co ~~ r, 6 C-) Zo 0, C4 to CO -4;r
Part of engine '4tt
Ao .1car d CN C"! (1) (1) Cl) M 't
58 Ab- und Anbau aller Kdpfe (beim Abbau Remove and reinstall all cylinder covers
Ermittlung Mutternlbsedruck be! 2 (determine nut loosening pressure of 2
Zylinderkbpfen).Inspektion Brennraum, cylinder covers when removing) . Inspe7ct X
-X
Kahlaume und VerbindungsflUcfien combustion space, cooling spaces and :: : : : : ::**'** :.* .*.*.
X X X
mating surfaces X
59
6o
61 057 .01 Sicherheitsventil Inspektion : Inspection : ...

(Zylinderkopf) Aus- und linbau aller Ventile, Reinigung Remove and reinstall all valves, clean,
Relief valve Kontrolle, Uffnungsdruck, Bohrungen im check opening pressure, clean bores i n
(cylinder head) Zylinderkopf reinigen cylinder head . ..
X
62 Sicherheitsventil Inspoktion : Leichtggngigkelt Check for free movement

Triebraum) .. . ... .. .. .
Relief valve
(crankcase)
D36 561 0 D+E 4 .25-2

0
0
10 .80
4
WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ- B
KSZ-C 26
:)as . Arbeits- Gesamtbetriebsstunden - Total service hours
karte Motorteil
C)C) C) 0 C) C)8 cc
C)3C) C) C)
3
Wartungsarbeit Maintenance work C) C) C>
C) C3 CDC)C) C) C) C) 0C)C) C) C3
tern Work C3 C) C3 C> C) C3 CDO C) C) C) C) C3
Part of engine
C" 0
CD Cl) 10 01 C%4 to CO - It 11-1 C) Cl) 10 01 04 LO CO
'4o .lcard - (N CN C14 (1) M Cn (1) 14, 'IT Itt
C
63 281-03 Sicherheitsventil
63 281 .03 (Ladeluftleitung Inspektion : LeichtgNngigkeit Check for free movement
und Zylinderblock ,
falls vorhanden)
Relief valve(sca-
venge-air manifold
and cylinde r
jacket,if provided -X
. . . . . . . . . . . .
64 100 .01 Steuerungsantrieb Sichtinspektion aller Teile Visual inspection of all parts :i50(
Camshaft drive . . .. ...... . . . .... . .. .... . . . . . . X.
. . . . . . . . . ... . . ... .. ... ...
65 Funktionsinspektion :Spritzdusen Functional test : Spray nozzles . . . . . . X
X.
66 Inspektion : Zahnrgder, Zahnspiele und Inspection : Gearwheels, gear backlash . .. . . .. . . .. .

Lagerspiele and bearing clearances
X ..
67 100-01 Nockenwellenlager Inspektion : Lagerspiel Check : Bearing clearance -X- -
100 .02 Camshaft bearin g
68 Inspektion : Schraubenverbindungen Inspection : Screwed connections for

auf festen Sitz durch Abklopfen tightness by soundin g
69 Aus- und Einbau 1 Lager Remove and reinstall one bearing

Inspektion ggf .Ausbau, sowie Inspect, if necessary remove and check
Kontrolle weiterer Lager additional bearing s
D36 5610 D+E 4 .26-2

0
0
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4
M *AAk* M WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ-B
I KSZ -C 29
3os G esamtbetri ebsstun den - Total service h_o
'4r .. karte
Arbeits- Motorteil _urs__
Wartungsarbeit Maintenance work a CC)
:) 0C)
C)00C)
C)0~
E) C> C) 0 8 0 C) C) 0
C) C) C) 0 C) 0 (D
tern Work C) 0 0 0 C) 0 0 C) C) 0 C-) C) C) C) C) C )
Part of engine (D CO 10 01 04 Ln CO - '1~r r, C) M 10 01 04 til cc
'4o .icard 04 04 CN Cl) Cl) M Cl) _t "T
,3
86 Ab- und Anbau Regler, Remove and reinstall governor, inspect ... . ... ....
Inspektion Antriebswelle, blwechsel drive shaft, change all in Woodward go-
. ... ... ....
Woodward-Regler und Booster-Servomotor' vernor and booster servo-motor (clean, X. . ....
(Reinigung, EntlUftung, Herstieller vent, cf.manufacturer's recommendations ) X
vorschrift beachten) : ::: : :: .. ..
X ... ...
87 Ab- und Anbau Regler, Grundinstand- Remove and reinstall governor, genera l
setzung Regler und Booster-Servo- overhaUl of governor and booster
motor (Herstellervorscfirift beachten) servo-motor (cf .manufacturer's rec-
ommendations)
88
89
90 160 .01 AnlaBsteuerschieber Inspektion : Leichtpndigkelt Check for free movement

Starting pilo t X . .. .
valve
91 Aus- und Einbau Steuerschieber, zer- Remove and reinstall starting pilot
legen, reinigen, valve, disassemble, clean
92 161 .01 Anla8ventil Inspektion : Dichtheit . . . . . . . .. .... .. . ... ... .. ... ... .. . . . . . . ..
Check for tightness
Qylinderkopf) . . .. .. . .. .. .... .. . ... ... . .. ...
.. . .... .. ..
Starting valve
. . . . . . . . . . . . .. . .... ... .... .
(cylinder head) ..... ...... . . .... .. . . . . . . . . . . . . . . . . . . . . . X. . .
.. ... .... ... . .. .. . . .. .... . . ....... .. ... .. ..
. ... ... ....
4 .29-2
D36 5610 D+E X. . .. . . . . . . .
. . . . .. . . . . . .
0
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WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ- B
KSZ -C 33
:)as . Arbeits- Gesamtbetriebssfunden - Total service hours
Motorteil
'4r . karte
Wartungsarbeit Maintenance work a C)C)C) C)'DC3
C)C) 0 C~
C) C38 Co
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114 289 .01 X. X

Abgasleitung Sichtinspektion : Dichtheit Flansch- Visual inspection : Tightness of flanged . . . X. . . ... . . . .
. . . . . . . . . . . . . . .. X X X . .. .
Exhaust manifold verbindungen/ .DehnstUcke connections/expansion pieces X
X .. .... .. . ... .... .. ....
115 Reinigung entsprechend Intervall- Clean at specified intervals and a s

angabe und nach Bedarf necessary
X
.. .. ... . ...
116 302 .01 Zylinderschmier- Inspektion : Ulfallung und Ulfbr- Check : Oil filling and oil delivery of
302 .02 pumpe derung aller Pumpen all pumps . . . . . . . :::.: : : :::: : :: ::::::: : . : :::::: ::: : ::: :: : :::: :::::: . ... ... . ... ....
. . :: :::: : : : : ::: ::: ::: : ::: :: : :: . .. .. ... . . . . ...... ..... ... .... . . . ... .. .... ....
Cylinder lubricator Pumpen entschlammen (alle 6000 Stunden) drain sludge of pumps (every 6000 hours`%*%** *** : : :,*, -
XX .. . ... ... .. . ... .. ... . . .. .. . . . . . . . .
-:: . . ... ....
..
. . . . . . . . . . . .. ... .... . . . . ... .. . ..........
117 Schmieren Gestinge und Hebel Lubricate lever linkage ::250
. .X X:X :X
118 Ab- und Anbau Zylinderschmierpumpen Remove and reinstall cylinder lubrica-
zerlegen und reinigen tors, disassemble and clean
. . . . . . . . . .. ... .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . . . . . . . . . . . . . .
.... .. .. .. .. ... . ... .... . .. .... .
119 303 .01 Kreuzkopfschmier- Funktionsinspektion Funbtional test ........ ........ . .. . .:: : : : : :::: ::: ::. : :: : :: :::: : . . . . . . . . . . . . . .
pumpe . . ..X . . . .
. .. .... . Y.Y
Crosshead lubri-
.... .... . . . . . . . . . . . . . . . . . . .
. .. .. .... ..... . . ... .. . . . . . . . . .. . . . .
cator .
. . . . . . .. . . X .. ... ... .... ........ .........
120 Ab- und Anbau Schmierpumpen, reinigen Remove and reinstall lubricators, clea n
Inspektion RUckschlagventil und Spiel inspect non-return valve and play in
in Gelenken link joint s
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*A&* FA WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ- B
KSZ-C 37
:$as Gesarntbetr iebsstun den - Total service hours_ _
',4r .. karte
Arbeits- Motorteil
Wartungsarbeit Maintenance work C) C)
C) C>
I C>C)1 C3 CDP C) C)8C3 C)(Z)
C3C)C)C3
C3C)C)
a C3 C) C) (D 8 8 c8)
tern Work 0 C) C) C) C) C) C) C) C> C) C) C) C) C> C) C)
No . card Part of engine
10 0, 04 LO CO V* r,' C) (1) ZO o' C-4 to CO
- CN C14 Cl) Cl) Cl) Cl) 1-11
.. .. .. .. .. .. .. . . . .. .. . .. .. .. . . ...
.... . . .. . . .. ..
. . ... .. . . . . ........ .. .. .
Inspektion : Schmierolablauf von Check : Discharge of lubricating oil fror X. . .. . . . . . . . . . .
. . . . .
.X X. . *. . .
Kreuzkopf-, Treibstangen- und Kurbel- crosshead-, crank- and main bearings(as X .: X
. . . . . . . . .. . .
wellenlagern (sowie Drucklager) well as from thrust bearing X.
X. :
142 Schmieralwechsel im Motorkreislauf Change engine oil charge if indicated nac~h Bedar f
entsprechend Schmierblonalyse, as necessary by analysis, clean as necessary
Reinigung BetriebsbeMlter service tank
143 Schmutzdlleitungen Inspektion : Ablauf und RUckschlag- Check : Discharge and non-return valves , x.
Dirty- oil Pipes ventile, falls vorhanden if provided : . .Y. :XX
:XX -X
145
..... ..
. . . . . . . . . . . . . . . . .
. ... .... . . ...
. .. . . . . . . . . . . . . .
146 000 .07 KUhlwasser Sichtinspektion : DUsenkUhlwasser auf of 24 . :

Visual inspection : Free discharge . . . . . .
000 .08 Cooling water freien Ablauf und Kraftstoffeinbruch . . .. . . .. . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . .

. . .
. . . . . . . . . . . . . . . .
cooling water from injectors and check X. :
cooling water for fuel oil leakage . .... ... ....
-X . . . . . . . . . . . . . . . . . . . . . . . . . . .
D36 5610 D+E 4 .37-2

0
0
0
11 .80
KSZ-B 4
*A&* PQ WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ- C
KEZ 38
)as . Arbeits- Motorteil Gesomtbetriebsstunden - Total service hours
',4r . karte 0 C) 0 CD C, C) 8 0 C) C) 8 C) CO C> 0 C>
Wartungsarbeit Maintenance work (D C) C3 C) C3 CD C~ C> 0 C) C) C) (D C )
tem.1card
Work Part of engine > C) C) C> CD C) C> C) C) C> C) C> C) C) C> C> C1
Q C-) -0 0, 04 Ln CO -14, r_1 C> cv) 10 01 C14 LJO 00
',1o CN CN 04 CO (1) Cl) Cl) IT 11-T 'It
.. .
. ... ... . ... .... ... .. .. .... .. .. . .... .. .. .
.. .. .. .... ....
X. :
147 Sichtinspektion : Rohrverschraubungen Visual inspection : Screwed pipe
.. . . . . . . . . . ..
%tor-, Kolben- und Dusenkreislauf) connections for tightness (engine-, . . . . . . . ...... ..... ... .. X. . . . . . . . . . . . .
X. .. .... .. .. . .. X
.. .. . .. .... .X.X.
. ...... .
auf Dichtheit piston- and injector cooling system)
..... ... .... ... ... . :*....... ... . .. .. ..... ...... ...... ..... ...... . . ... ...... .. .. .. . X
. .. . .... . . . . .. . .
X. X_
. .... . . . . ... . . . . . ... . .....
... ... . . .. . . . . ... .
. . . . . . .
.. ...... . .. . . . ..X:
. .: ..:-. . .. ...... .... ...... . ... ....
X.
. . . . . . .
. . .
. . . . . . . . . . . . . . . . . . .
148 Inspektion : Wasserstand in Ausgleichs- Check : Water level in expansion tanks ... . . . . . . . . . . . . . ..
. . . . ... . . . . . .. . .. . * . . . .. . . . . ... . . . . . .. . ..
beh3ltern (Motor-, Kolben- und Dosen- (engine-, piston- and injector cooling _X . . . . ...
kreislauf system)
.. . . . . . . . . . .. . . .... .. ...... ..... ...... . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . . .. .. . ... . . . . . . .. . ... . .. . . ... ... . ... ... . . . . . .
X.
149 Sichtinspektion : Korrosionsschutzdl- Check : Corrosion inhibiting oil emul- ::24 X

X.:
emulsion in AusgleichsbehNtern sion in expansion tanks (engine-, X.X X., X
(Motor- Kolben~- und Dosenkreislauf) piston- and injector cooling system) . . . . . . . . .. . . . . .. .. .. . .... . ...
X. :
. . . . . . X
. . . .
X.,
150 PrUfen : Konzentration Korrosionsschutzdl Check : Concentration of corrosion in-
(Motor-, Kolben,- und DUsenkreislauf) hibiting oil (engine-, piston-and X . . . . . . .
X.
(bei neuer Fallung-nach 50 Stunden) injector cooling system) (if filling .. .... . ... ..
has been renewed, after 50 hours X.
151 Wasserwechsel und Reinigung Ausgleichs- Change water and clean expansion tanks X
behNlter (Motor-, Kolben- und Dusenkreis- at specified intervals and as neces- . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

lauf) entsprechend Intervallangabe und sary (engine-, piston and injector
.... ....
. . . . . . .. . . . . . . . . . .. . . .. . . .. . .. .
. . . . .
nach Bedarf cooiing system) ........ ...... ........ ...... ...... .. ........ ...... ...... ..
X.X.
X.X.
152 Inspektion : KohlwasserrNume ggf . chemische Inspect : Cooling water spaces, clean
. . . .
. . . . .. . . .. . ... . ... . ... . . .. . ... . . .. .
Reinigung chemically if necessary . .. . . . . . . . . . . . . . . .
.X. : X.X.
D36 5610 D+E 4 .38-2

0
0
11 .80
KSZ - B 4
WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ- C
KEZ 39
I
os . rbeits- Motorteil Gesorntbetri ebsstun den - Total service hours
r . arte -
Wartungsarbeit Maintenance work a C) 0 C) 0 00 C)
C) (D00 C)8C)8C)
0 80 C)00 0 CD1
0 C> C> CDP C)
em Work L12) (1) 10 01 C14 ul 0D ~~ NT r~, C) M 10 01 C14 U-) Cco)
C> C) C) C) C) CD C) C) C) C> C) 0 0 C) 0
A P art of engine (N " M Cl)
t,C a . card
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. .. .... .. . ............ . .... . . ...
. . . . . .
. . . . . . . . . . . . . . . . . . .. .. .. .. .. .. ..: ... .... . . . . .
153 Elektrische Kabel Inspektion : Lose Verbindungen und Inspection : For loose connections and . . . . . .... .. .... ... ... . .X ... .... ... .
. . ... . . . ... ... .. .... .. ..... ... ... . .. . . . .... .. .... . .. ... . .... . . X .
Electfic wires Scheuerstellen chafed spots . .... ........ .........
. . . . . . . . . . . . . . . . . . . . ... . . . ... . . . . .. . .... . .... ....
154
155
156 WasserrOckkOhler Reinigung Clean nach,Bedar f

Jacket- water as necessar)
coole r
157 Wassertemperatur- Instandsetzung :-Abweichung vom Soll- Recondition : Check for deviations from nach Bedarf
regler wert kontrollieren , (Herstellervor- nominal values (cf.manufacturer's as necessar)
Water temperatur schrift beachten) recommendations )
regulator
Schmierblpumpe Inspektion : Uffnungsbeginn des Check : Opening pressure of relief valve ... ... . .. .. ....
158 . ... ... . ... ........ .. . ... .... .... .... .... ... ... .... ... .
Luboil pump Sicherheitsventils
.. .... ... . ... .... .... .... ... .... .... ... ..
159 Instandsetzung (nach Herstellervor- Recondition (cf .manufacturer's nach Bedar f
.39-2 schrift) recommendations) as n eces sar
I D36 5610 D+E 4 I I I . Id - - - -

0
0
11 .80
KSZ-B 4
M *AM* F1111 WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ-C
KEZ 40
)as Arbeits- Motorteil Gesamtbetriebsstu n den - Total service hours

'4r : karte 0 D,
C 8 - C) C) C1 C) C)
Wartungsarbeit Maintenance work -a C)
C> C1
C) (13)
C) C) C> ) 8C)
0C8C) c8)
C)1C>
8 1C>8 C8
0 0 C)
C> C)
C) C)
C> C 3
tern Work CO ~~ Nt r . C) Cl) 10 01 C14 a) Cl) 10 01 C14 to ul CO
. card Part of engine C CN Cl) M M M 't "IT IT
~slo
. . . . . . . . . . . . . . . X .. . . . .. .
160 Schmier6l-Betriebs- Reingung : entsprechend Intervallangabe Clean at specified intervals and when X. X**
filter und bei Uberschreitung des zultssigen admissibli pressure differential is ex- .. ... .. .
Luboil line filter Differenzdruckes (Herstellervorschrift ceeded (cf .manufacturer's recommenda- .. . .. .... .... . .. ... ....
:X X
beachten) tions) . .... . ..... ........ ...... ...... ........ .. .. .. ........ .... ...:. . :.:: :: . .:. ... . . . . . . . .. . . . . . . .. . . . . . . .. . . ..
..
X. :
. . .
. .X..N
. .
. . ...
. . . .
X.
. . . . . . . . . . . : :X
61 Schmierdl- Reinigung : Entsprechend Intervallangabe Clean at specified intervals and whe n .. . . . .. . . .. . . . .. .
Indikatorfilter und bei Uberschreltung des zul9ssigen admissible pressure differential has :::X- .
Luboll indicator Differenzdruckes (Herstellervorschrift been exceeded (cf.manufacturer's
filter beachten) recommendations ) . . .. . . . . . . ... . . .. . XOX
.... .... ... ....
.... ........ . .. . ..
. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . ... . ... .. . .. . ...
62 SchmierUlseparator Reinigung (Herstellervorschrift beachten) Clean (cf .manufacturer's recommenda- :~00- .
Luboll separator tions) . . . . . . .. . .
.. --** . ... .... X.. ..... , . . . . .. .... .... ...... . . . .... ..
.. .. .. .. .. .... . .. . ..... . .. ... .... ... ... . . . .....X. ..: .. . . . . . . . . . . . . . . . . . .
63 Schmier6lkUhler Reinigung : Wasserseitig entsprechend Inter-Clean at specified intervals and a s .... .... .-X
.. . ... . . .. . . .. . .. ... . . .... .... .....
Luboil cooler vallangabe und Oach Bedarf necessary . . ... . . . .. . .. . . . . ..
.. . ... .. . . ....
164 Schmier6l- Instandsetzung : Mi Abweichung vom Soll- Recondition : Wben oil temperature nach Bedar f
temperaturregler wert (Herstellervorschrift beachten) deviates from nominal value (cf . as necessary
Luboll temperatur manufacturer's recommendations )
regulator
165 000-35 Druckluftbeh3lter Entwisserung Drain water of condensation .. .... . .... . ...
Pressure air, . . . . . X. ..X X. ... . .. . .. . .. . .. . . . . ... . .
. -XV X
X . . . . . .. - . . . . . . . . . . . . . . . . . . . . . . . . . X . -X. . .
receiver
. ... . . . . .... ... ....... .
66 Reinigung innen nach Klassifikationsvor- Clean inside in accordance with rules nach Bedar f
schrift und Bedarf and regulations of classifications as nece ar[
societies and as necessar y
D36 5610 D+E 4 .40-2
0
0
11 ..80
KS2-B 4
WARTUNGSPLAN MAINTENANCE SCHEDULE KSZ- C
kEz 41
)as . Arbeits- Motorteil Gesarntbetriebsstunden - Total service hours
',4r . karte o C) 8 C 8 C3
Wartungsarbeit Maintenance work C) C) :) C)8 8 C) C,8I8 CDO
c8) CC3 C) C) C) C0)
tern Work (D C) C) C) C) C> C) C3 C> CD C) C) C) C) C) C)
~2 ~O I,, C>
') Cl)
. card Part of engine Cl) 10 01 C4 -'r CN 'n
'slo
CD
':' C' C) I CN (1) cv)

'0 C'
'IT
C14
1~r
-) CO
-4T
167 Instandsetzung : Ventile Recondition : Valves nach Bedar f

as nece sar ,
168 409 .01 Abgastemperatur- Kontrolle auf richtige Anzeige, Ver- Check correctness of instrument reading!, : :::: :: :*- : ::. :
:***."* . - :-*-
Uberwachung gleichsmessung comparison measurement
Exhaust temperatur ... .... .. . ... ....
X.:
mea3suring plamt
169
170 490 .06 DrehmomentschlUssel Kontrolle auf richtige Anzeige Check correctness of reading s
Torque wrench .... ..
.. . . . . ...
.. :X.:
X. X.
D36 5610 D+E 4 .41-2-

0
0
ABGASTURBOLADER
EXHAUST-GAS TURBOCHARGER 4
TURBOCOMPRESSEUR A GAZ D'ECHAPPEMEN T
TURBOSOBREALIMENTADOR DE GAS DE ESCAP E
SOBREALIMENTADORE S 50
0 TURBOSOFFIANT1 A GAS DI SCARICO
WARTUNG
0
MAINTENANC E
ENTRETIEN
ENTRETENIMIENTO
MANUTENQAO
MANUTENTION E
0
D36 5650 4.50-1 11 .87

0
0
NA
M*Ak*M MAINTENANCE
Maintenance Schedule
ZA
51
0
Maintenance Schedul e
The maintenance schedule gives a Summary of service and inspection work over an
operating period of 24 000 hours . This is the normal overhaul life and the turbo-
charger should then be completely dismantled and cleaned and the dimensions of
all parts checked . After each such general overhaul, the service routine laid
down in the maintenance schedule is started again from the beginning .
In order to ensure continued reliability of the engine and the turbocharger, the
work specified should be carried out as close to the schedule as possible . This
will help the operating crew to detect any deficiencies before serious trouble
develops and provides the inspection department with information on necessary
overhauls, thus facilitating ahead-plonning of yard repairs and service i6terruptions .
0 This maintenance schedule has been prepared on the basis of experience to reflect
average duty conditions of the engine . However, it is hardly possible to cover
the widely different conditions under which individual engines and turbochargers
may be used and, therefore, the operating periods indicated should be looked upon
as typical only .
It is essential to attend at once to what may initially appear to be insignificant

deficiencies and to determine and rectify the trouble before major damage is
caused to tFe turbocharger and engine .
If the engine is not equipped with an automatic monitoring system with a data
logger, it is important to keep a log sheet in which regular entries are made
on the turbocharger (see Section 3) since this will enable any irregularitie s
to be discovered at an early stage . This type of record is also important when
investigations are made later on in assessing any damage found .
LO D 36 5643 E 4 .51-1
0
0
0
0%
-0 0
8
p
. 0
cc 0E 1
w -2 5 w
1
No? .2, LU
LD
X
-0
-2
.3. 1
9
X.X
1
< E rl ooovz . ... .L
r, 1" ': xe
L) C 12
0 oootz
CU . . . .. . . . . . .
. . . . . . . .. ..
0 3 0008 t X..
co
LJJ Ix -0 0009 1 %%
u 'm 4,
. . . . . .. . . . . . . . . . . ...
0 ooozt 3 2 : * .:. l--xl---------%
. .* . . . .* . .* . "e
e . . . . . . . . . . X .:
0006 e . . . .. . ... v
d . . ... .. ... .. .. . ............ ... . . . . . . .H . . . . HH' k
009 O .
%..
x 000C
0 LU J JDAJ84~1 cc, 0 .,
go
r_ to
0 .21.- .41 do .
40 % -4" U) >
m .0 = gm L-
co (D 0 41 14- c 41 0 9D
u -4 -.4 rn .14 41
u co 41 IL.
co r-
t) in L- 5- E 0 V) I- Q
C> = 0 co 4= Q -0
V) 4. C C" cm .~ It- w
0 go w
L.co v
-0
-4
c
L-
c
C.
al lo
0 03
41
0
1~
.I
CL. CL i- m ~o 0
t 1-
. (a. 0 03 ox -4 (1)
w a
E 2
, 8
.0
cc
cm 5- -40c
4- ul A3 .01
caL- " co0
0 U)
0
4-
4- 1 0 41
1-- .0
4 'CLM, 41 4- V) CY) CD >1
-C 'o
- (a = &- co r-I 0 0 a L.
0 co L- W 4~ co I- co
F- co V) '0 0) U)
< i 1 0 in a ,
.r
0
.0
t,
14
-4 -F,
. .4 L.
x 0
9
0 -4
-4
,P
-4
,,
CD 4 a co 0 0 C' ,
to
- g --, . .-co -.
.0--l o 0 cm J2 Cl)
a
= 0 ~ -%. w
r_
4) cc 4, ;~ . (i U)
4) 0 -M
.5
40
.to-- ..--
to x V) CD a
E C3 a CS C3
,a- 0; 24 , t;
xv CID
E 41
E .0
m
ED 4.
4--
.2 CA 0
(D
0 W I-
cm -W co 0
) .0.- ca Gjcoo .8
c IC I-
P L. = "
23 c 0 .
CD
C"
m
L. co
0 C, :3 to -i CL
S.. 0 m (7) 9-
< L- 3. CO -4 -.4
0 U, ~ 4~ t;
0
co
co
c co , Rw
cito 1-1M
:; 4-
.0 L.
L. .0
0 V
W
-4
5=
-4
-9 S.
42
'a co
.9 c
20 4-
.2 co
%... = CL 9 C12 =
2 40 s I
cr
- i
w 0 c cn L- co = a 414
2L. 0
4. co R 'A
El
=
n t -,I tj Ac " W = 2 -&C -4 = 0, =
rv -0 K. & -8 . li =
~t < " fi- V) = 44 c 4- 'A 0 S. T -,
m 4
(D 4
< 04
I a
Zt 2
C 4) - c L.
L. 0 m cc
.6 - =
C3
-0 0 - .4
r- 0 .6.
t 0 0
Ja .0
ui
C (D
joinjoepues jo#tljd oes-41lipslonipiallolsioN 914als
%0
Cf)
Z . I: Z LR LF, R & U",F S,
0
0
4 .77
BBC-
AbgasturbOlader 4
+A&* PJ WARTUNGSPLAN MAINTENANCE SCHEDULE Exhaust turbo-
charger 53
Cos . Arbeits- Motorteil Gesarntbetriebsstunden - Total service_hours
r . karte
Wartungsarbeit Maintenance work a E3
0 8C)
(D 0
C) C) 0 00
tern Work Cl) 0, C14 W) co
Part of engine ;74 C14
o .1card
508 Inspektion : Verdichterteil und Kahlwasser- Inspect compressor side and coolin g X
roume auf Verschmutzung ggf . Rainigung water spaces for contamination and
clean if necessary X: X
509 Lageraustausch Replace bearings
exx
510 Ab- und ftau Turbolader, Lageraustausch Remove and reinstall turbocharger, re-
Inspektion aller Teile place bearings, Inspect all parts
Xe
M 550 .30 Inspektion : Rohrschieber Is Sch-alldimpfer Inspect tubular slide in silencer, +
Funktion und Lelchtgangigkeit (Schlebe r check for proper functioning and fre e -XV
bei Motorstillstand geschlossen) movement (tubular slide closed when
engine at standstill )
520 Vorgebl9se Reinigung Vorgeblise Clean auxiliary blowe r
Auxillwy blower - (Herstellervorschrift beachten) (cf .manufacturer's recommendations) 1.1-~ .... .....% *% .,.
X.
521 550-30 Schmieren Vtlzlager E-Aotor entsprechend Lubricate anti-friction bearings of el .

Intervallangabe . bzw. wenn Zeitabstand seit motor at specified Intervals, at leas t
letzter Schmierung grbBer 24 Monate after 24 months (cf.manufacturer's ~:Xe*
(Herstellervorschrift beachten) recommendations)
.%%%
D36 5610 D+-E 4 .53-11 1

0
0
.0
4.77
BBC-
Agasturbolader 4
WARTUNGSPLAN MAINTENANCE SCHEDULE Exhaust turbo- 54
1 charge r
Cos. belts- Motorteil Gesarntbetriebsstunden - Total service hours
r;Im-. arte
4
te.a Wartungsarbeit Maintenance work 0 8C)8C)8 Coll C) 8 8
10 0%C>C14 tnC) 00
ork C> o C)
Part of engine 0) Cl)
'slo . card C14
ON...
522 Austausch W31zlager Replace anti-friction bearings (cf xX-
(Herstellervorschrift beachten) manufacturer's recommendations )
+ Bei neuem oder Uberholtem Turbolader + Once after 250 operating hours with
eirmalig nach 250 Betriebsstunden new or overhauled turbocharge r
++ Bei neuem oder Uberholtem Turbolader ++ Once after 100 operating hours with
einmalig nach 100 Betriebsstunden new or overhauled turbocharger
D36 5610 D+E 4.54-11

0
0
0
1 .79
4
WARTUNGSPLAN MAINTENANCE SCHEDULE NA . 52
Die Betri ebsstundenanga ben des Wartungsplanes sind Mittelwerte, The service hours given in the maintenance schedule are average values .
die sich je nach den vorhandenen Betriebsverhdltnissen ve gern Prevailing service conditions my permit longer or require shorter inter-
oder verkurzen kt5nnen . vals . .
as . &.rbeits- Gesamtbetriebsstunden -Total service hours

r. karte . Motortei I Wartungsarbei t bbintenance work t3 C) C) C) C) C1 C) C) a
C)
(5 00C)
C3C30C>
tem Work Part of engine 0 0a C)C)C1
C>
it,
a . rard 0) Cl) 10 0- " Ln co ~; 14,
501 500-07 Turbolader Betitigung Waschvorrichtung Turbine Operate washing equipment turbine and nach Bedarf,etwa alle 250
500-08 turbocharger und Verdichter (falls vorhanden) compressor (if fitted) as necessary, about every 250
502 Inspektion : Turbolader auf anomale Inspection : turbbcharger for unusual X .. .. . .

. ... .... .. .
Gerlusche und Vibrationen noise and vibrations . . ... . . . . .
X.:
X.
3 Inspektion : Ulstand Im Reservebeh3lter Inspection : oil level In stand-by tank X.:
X.N. X.I .,
504 Inspektion ., turboledernachlaufschmierung Inspection : turbocharger rundown lubricat 4*566 . . . . . . .
. . X.
bel Motorabstellung Ion during engine shutdown
X
: :X . .
505 Inspektion : Befestigungsschrauben Inspection : fastening bolts with engin e
mit Motor und alle Gehiuseschrauben and all casing bolts for firm seating .: :.*-,-, . ..X. ...
auf fasten Sitz durch Abklopfen by knockin g . . : : ::X.* * . . . *
. *.*.*-'
' .
506 500 .11 ReInIgungo Schalldumpfer entsprechend Cleaning : silencer at Intervals specified
Intervallangabe und nach Bedarf and as require d
D36 5645 D+E 4.52-1

0
0
.1-79
*AIX* IM 4
WARTUNGSPLAN MAINTENANCE SCHEDULE NA
53
as* belts Motorteil Gesarntbetriebsstunden - Total service hour
s
cr . arte I -
t Wartungsarbeit I a C) 8
tMintenance C) C)
work C) C> C> C30 E3 8 8
I Work
tern C) C) C> C> C) C) C> C)
a . card Part of engine
4) M 10 0,
~2 ~2 ~2 -C14
XX
507 Reinigung : Sperrluftleitung und Cleaning : lock-aIr pipe and throttlin g
Drosselbuchse bush
V.V
508* 500 .12 Rainigung : Verdichtertell Cleaning : compressor equipment XX
500-14
509 500-06 Inspektion : Axiales Lagerspiel Inspection : axial bearing clearance
XXY X
510 RaInIgung : Ulfilter Cleaning : oil filter
X
511 500 .19 Aus- und Einbau Fuhrungslager Removal and fitting locating bearing
XX
X
-12 500 .06 ReInigung, Inspektion Lagerzustand Cleaning, Inspecting state of bearin g
und Spiel and clearance .. .
514 500 .10 Ab- und Anbau Turbolader, zerlegen, Removing and mounting turbocharger ,
reinigen und Inspektion aller Teile dismantling, cleaning and Inspecting
X
(Werkstattarbeit) all parts (workshop work)
. .. . ... ... :X-
515 500-11 Inspektion : Rohrschleber Im Schalld3mpfer Inspection : slide valve In silencer,
Funktion und telchtggngigkeit Schleber function and smooth movement (slide
bei Aotorstillstand geschlossen) closed when engine shut down)
D36 5645 D+E 4.53-1

0
0
-l'.79
*Ak* IM 4
WARTUNGSPLAN MAINTENANCE SCHEDULE NA
54
~os * Arbei ts Motorteil Gesamtbetriebsstunden - Total service hour
s
r . karte
Wartungsarbeit tMintenance work a 0 8C) C> C>
C> 0 18) 8 8
rtern Work I (D C) 0 C) 0 C) 0 C~
art of engine CO 10 0, C14 in CO 14,
'4o . card C,4
:::X.
520 Vorgeblose Reinigung : (Herstellervorschrift beachten) Cleaning : (observe manufacturer's :-X::
Auxiliary -blbwer, instructions)
::XX. . ..
X-XI
521 550 .30 Schmieren 1131zleger E-fttor entsprechend
Lubricate anti-friction bearing
Intervallangabe bzw . wenn Zeltabstand selt
electric motor at Intervals
letzter Schmierung graBer 24 Plonste . X-X X....
specified or if more than 24 months
(Herstellervorschrift beachten) have
passed since last lubrication . . :X .
(observe manufacturer's Instructlons'~
522 Austausch W~lzlager Exchange anti-friction bearing
(Herstellervorschrift beachten) (observe manufacturer's Instructions)
Bel neuem oder Uberholtem Turbolader If new or overhauled turbocharger

einmalig nach 250 Betriebsstunden fitted, once after 250 operating
hours
D36 5645 D+E 4.54-1 1 L I

0
0
MAINTENANC E
NA
.Maintenance Work , 55
Maintenance wor k
In order to keep the turbocharger in a safe and good operating condition, specific
inspections and checks must be carried out on specific components at specific
intervals stated in the Maintenance Schedule . For admissible tolerances on gaps and
clearances between the various components see the applicable table in Section 1 .
The individual work cards established describe in detail the sequence of operations
required to perform specific maintenance tasks .
The decision as to how the turbocharger can be dismantled in the simplest manner is
dependent upon the available space in the engine room . For carrying out maintenance
tasks and inspections, in most cases it will suffice to remove the relativ e
components of the turbocharger . Removal of the complete turbocharger will normally
only be necessary on major overhaul .
Bolts and nuts must never be forced when carboned in place because machine parts
may become destroyed and would have to be replaced, or stripped threads may have to
be recut, or broken bolts drilled out . Applying light hammer tops onto bolt head
and lubricating the thread with Diesel fuel or a highly fluid special agent (e,g .
Caramba or Omnigliss) will be helpful in making the threads of bolts and nuts
running . A liberal amount of this solvent should be applied to the threaded
connection and should be allowed to act f or a reasonable period (i/2 hour or more)
so that it will be able to penetrate into the threads . The recommendations of the
manufacturer should be observed .
Bolts, nuts and lockwashers subjected to elevated-temperatures are made of scale

resistant materials . The nuts made of this material have a small collar on the face
side and the heads of such bolts carry the respective code number to prevent
confusing them with normal bolts and nuts .
When disassembling the turbocharger make sure not to confuse these bolts with the
normal bolts, but keep them apart, if necessary . When reassembling, bolts and nuts
as well as the seating surfaces should be coated with a special lubricant t o
prevent them from carboning in place and thus facilitate later disassembly . This
applies in particular to all bolts and nuts on the turbine side . Particularly
suitable for this purpose are lubricants containing molybdenum-disulphide which is
also available in form of paste (e .g . Molykote HSC) . The threads must be thoroughly
cleaned of all foreign matter before the lubricant is applied .
All screwed connections of the turbocharger, and especially those of the silencer,
that are secured by means of locknuts, washers placed underneath or lockwasher
pairs, must be in good condition if they are to be reused, otherwise they must be
replaced by new ones . Screws and nuts which have worked loose on the compressor or
turbine side will be swept along into the turbocharger by the air or gas stream and
cause serious damage . All the securing elements on hot components are made of heat-
resistant materials . We strongly recommend to order original spare parts only .
Note In the case of major overhaul or repair of essential components, it i s

recommended that a report be made on the state of the individual assembly
groups and added to the engine log . A sample form "Check List" (sheets 1 and
2) is included .
40
D36 5640E 4 .55-2 8 .92
0
0
MAIN T ENANCE NA
Checki`ng Individual Ports
56
0
Checking Individual Part s
The check list below is intended as a guide for a thorough inspection of the turbocharger
and its component parts . Minor deficiencies can normally be repaired on the spot . But
any major damage, especially defects that affect the strudtural strength, balance and .
consequently, smooth running of rotating parts, necessitate the replacement of parts or
repair in the factory . In the case of rotor parts having to be returned to the factory,, It
is absolutely necessary for the parts to be packed In a manner preventing further damage
in transit . After turbocharger has been disassembled and the individual parts cleaned,
the following checks should be made and the condition of the parts entered in the form
"Check List" . For determining degree of wear, see table "Gaps and Clearances" in Section 1 .
1 . Turbine Roto r
Are blades damaged or blade edges heavily worn?

Are roots ofmounted wheel blades firmly secured ?
0 Are there any traces of blade contact in the cylindrically turned recess of the shroud ring?
Is the lacing wire in good condition ?
Are there any signs of the blades or the disc having had contact with the nozzle ring or the
shroud ring ?
Are there any signs of the rotor shaft having made contact?
Is the shaft running true ?
Are bearings in a satisfactory condition?
Are the labyrinth seals badly worn ?
Note Local grooving caused during operation by the knife-edges of the labyrinth rings
and the locating ring in the bores of the seal covers is intentional in order to enhance
the sealing effect . If such grooving is found to exist on inspecting the parts for wear,
this does not mean that replacement is necessary . Since labyrinth seals depend for
their effect on close radial clearances, it is important whenever replacing the bearings
that the seal covers are renewed at the same time .
2 . Impelle r
0
Are there any fissures in the vanes or are they badly worn?
Are there any signs of the impeller having made contact?
Is the fit of the impeller and the taper sleeve satisfactory?
Are the seating surfaces bright ?
3 . Bearing s
Are the bores of the bearings .unevenly worn ?
Note: Diagonally opposite wear on both bearings is indicative of rotor imbalance .
Is the endwise clearance of the rotor and the play of bearings excessively large?
Are the bearing surfaces of the thrust ring and the locating ring badly worn ?
Are bearings firmly seated in the casing bore ?
0
014
C9
N D36 645 F 4 .56-1 P .t .o .
4 . Nozzle ring assembl y
Are the nozzle blades a tight f it in the supporting rings? 0

Are blades bent ?
Are there any obstructions in the nozzle ring passages ?
Are there any marks suggesting the presence of foreign matter?
Is the nozzle ring deformed ?
5 . Casings
Are casings heavily fouled by oil, dust or soot ?

Were the casings tight, especially at the joints and the connecting flanges?
Were all screws, bolts and nuts firmly tightened ?
Does the valve plate in the lock-air valve move freely (if provided) ?
Note : Free movement of the lock-air valve can also be checked during operation by
topping after removal of the valve protection . When repainting the exhaust
turbocharger, be sure that no point can get into the lock-air valve I
0
D36 5645 E /4 .56-1

MAIN T ENANCE
Cleaning 57
0
Cleaning the Cooling Water Space s
Since the cooling passages in the bearing casing are connected to the cooling circuit of
the engine, fouling and scale formation will be about the some as in the engine . There-
fore, inspection and cleaning of the engine cooling spaces should also include the turbo-
charger . For instructions on methods of removing scale deposits, see instructions given in
Operating Manual for Diesel engine .
Cleaning Si lence r
The felt lining of the silencer should be cleaned at regular intervals in order to maintain
its sound-attenuating properties . The length of the intervals depends on the condition of
the air drawn in (see work sheet 500 .1 1) .
Washing Systems for Compressor and Turbin e
Dirt deposits are not usually a problem in turbochargers, which is why washing systems
are not standard . If engines are required to operate under extreme conditions, washing
0 facilities can be provided for the compressor and the turbine as optional equipment .
C leaning Compresso r
Fouling of the air passages in the compressor will reduce the amount of air delivered . This
is indicated by a decrease in charge air pressure for a given speed and, as a result, exhaust
gas temperatures and fuel consumption will go up . The intervals at which cleaning is
required vary according to prevailing operating conditions and the relative purity of the air
drawn in . It is recommended practice to clean or wash the compressor when the charge-air
pressure for a given speed of the turbocharger and temperature of the air entering the
compressor has dropped more than 4 % .
Theie are two methods of cleaning :

I Mechanical Cleanin g
For removing the dirt layer mechanically, remove silencer and the complete compressor
casing, or only the air-intake socket . The impeller is left on the rotor during the cleaning
operation . Deposits are removed either with light Diesel fuel or any other liquid cleanser .
0 Care must be taken to keep the liquid out of the locating bearing and the charge-air pipe .
2 . Cleaning by Injection of Water into the Compressor during Operatio n

The compressor can be cleaned during operation by means of the washing system (optional)
providing contamination has not exceeded reasonable limits .
Wash i ng Proces s
When the pushbutton is depressed, compressed air is admitted through the cock into the
tank and forces the water in a fine spray into the air inlet socket . The small droplets
are carried into the compressor by the air flow and impinge at high velocity on the vanes
of the impeller, whereby the deposits are removed .
Cleaning Turbi n e
Cleaning of the turbine can be effected during operation by means of a washing system, if
provided (optional) .
0 r-
D36 5645 E 4.57-1

0
0
*AL* F111111 MAIN T ENANCE
Work Card s
NA
.58
Work Card s
The work cords supplied with the Operating Manual are consecutively numbered and
arranged in the order of operations required for complete disassembly of the turbocharger .
. The instructions given on the individual cards relate only to the job stated in the heading .
Depending on the scope of overhaul or repair work, one or several work cards may ke
required (see Reference Table) .
Each work card has the group reference of the part concerned shown in the top right corne r
which provides a cross reference to the Spare Parts Catalogue which is also compiled
.
according to equipment groups . This facilitates finding individual parts in the catalogue .
The numbering of the work cards is in such a way that all cards relating to the turbocharge r
are designated by the group code 500, taking the first three digits, whilst the ast
T__ two
digits are consecutive numbers .
Example :
500.1 2
E .Consecutive number (12th card )
Code number for turbocharger grou p
The tools listed on the work cards are all identified by the group number 596 . The tool
number alsoserves as ordering reference when replacements are required .
The work cards include guiding information on the amount of time and manpower equire d
(manhours) . The-time indicated applies only to the set of operations for the job describe d
(I . for disassembly or removal and 2 . for assembly or installation) on the card concerned .
The information given is on the understanding that the personnel employed is familiar wit h
the work involved and that all necessary tools are at hand . It is also assumed that the turbo-
charger is readily accessible and that a hoist is available for lifting off the heavy parts .
Furthermore ,, the times shown are based on a normal operating condition of a I I parts and ma y
be considerably exceeded where parts have been affected by some accidents .
0 The work cards under this section are plastic-faced and furnished in a separate folder.
These cards are thus water and oil-proof and intended for reference during the work on th e
turbocharger . On completion of any maintenance job, the work cards should be filed bac k
in the folderso as to be on hand when needed .
A table of clearances is included in section I .
D36 5645 E 4 .58-1

0
0
MAINTENANC E
M*Ak*1Q Ref ere nc--
e T a b)-Fe- NA
59
0
Reference Tabl e
The table below lists those work cards that are required for recurring work .
Maintenance Work Required work cards
Cleaning compressor during operation . . . . . . . . . . . . . . . . 500 .08

with turbocharger in place ..... 500.1 1
500 .1 3
500.14 in par t
Cleaning turbine . . . . . . . . . . 500 .07
Cleaning silencer . . . . . . . . . . 0 0 . . . . 0 . 0 . 0 . . . . . . . . . . . 0 500 .11, 500 .1 3
Checking locating bearing with turbocharger mounte d
(bearing removed) . 0 . 0 & 0 . . . . . . . . . . 0 . . . 0 0 500 .1 1
500 .1 3
0 500o'14 in part
500 .16 to 500 .1 9
500.06
Disassembling and assembling complete turbocharger . . . 500.1 0
500.1 1
500.13 to 500 .26
500.06
Putting turbocharger out of actio n

without removing rotor . . . . . 500 .05
500 .1 1
500 .14 1 n part
with rotor removed . 0 -0 . . . . . . 0 .0 500 .05
500 .1 1
500o'13 to 500.23
Gaps. and clearances . . . . . . . . . . . . . . ...... . . .. see section I
D36 5645 E 4 .59-1

0
0
0
ARBEITSKARTEN
WORK CARD S
CARTES DE TRAVAIL
TARJETAS DE TRABAJO
GAMAS DE TRABALH O
0 FOGLI DI LAVOR O
0
0
0
KSZ 70/125 . B 1 00 0
M *AAL* N
LIST OF WORK CARDS Arbeitskarte-Nr .
Work card No .
Carte travail No . 000 .0 1
Torieta troDaici No .
Work card Designation Work Card Designation

000 .02 Componentslassemblies 040 .01 Removing, maintenance and overhaul of pisto n
040 .02 Disassembling and assembling pisto n
000 .05 Dot test on filter pa Der 040 .03 Removing and installing pisto n
000 .06 SExhaust
' gas pictures ' 040.04 Pressure testing piston and piston ro d
000 .07 Checking cooling water 040.05 Installing pisto n
000 .08 Cleaning cooling water system 040 .06 Measuring piston alignmen t
000 .10 Measuring crankweb deflections 040 .07 Correcting piston alignmen t
040 .08 Releasing and preloading piston bolt s
000 .15 Replacing pipes 040 .10 Position diagram for correcting pisto n
000.16 Treating pipes positio n
000 .17 Assembling solderless screwed pipe unions 040 .11 Application of position diagra m
000 .18 Installing reinforcing sleeves, insert 050 .01 Inspection and cleaning cilinder line r
nozzles and hose connections 050 .02 Removing and installing cylinder line r
000 .19 Application of LOCTITE 050.03
000 .20 TRAFUL impregnation method 050 .04 Installing a new cylinder line r
0 000 .25
000 .23
Checking compression and firing pressures
Tensioning bolts
050 .06
050 .07
Measuring cylinder line r
Grinding cylinder cover on cylinder line r
000 .29 Bolt preloads 050 .08 Sealing cylinder space for emergency operatio n
000 .30 Bolt preloads 055 .01 Removing cylinder cove r
000 .31 Tightening torques for bolted joints 055 .02 Mounting cylinder cove r
000 .32 Hydraulic tandem tensioning device 055 .03 Disassembling and assembling cylinder cove r
000 .35 -Maintenance of air receiver 057 .01 Testing and disassembling relief valv e
009 .02 High-pressure hand pump 100.01 Checking and reconditioning timing gea r
009 .03 High-pressure pump 100.02 driv e
010 .01 Checking foundation and bedplate 103 .01 Removing and installing fuel ca m
013 .01 Checking, removing and installing tierods 120.01 Checking reversing gea r
015.01 Installing and removing diaphragm casing 125 .xx Valves of control syste m
015 .02 Checking piston rod stuffing box 140 .01 Maintenance of Woodward UG governo r
015 .03 Removing piston rod stuffing box 140 .02 Maintenance of Booster Servo moto r
015 .04 Assembling of piston rod stuffing box 1160.01 Removing and installing starting pilot valv e
017 .01 Checking and disassembling thrust bearing 161 .01 Removing and installing starting valv e
019 .01 Checking and removing eccentric bracing 162 .01 Maintenance of main starting valv e
020 .01 Checking crankshaft - 200.01 Injection pump maintenanc e
sealing oil passages 200 .02 Removing and installing injection pum p
021 .01 Measuring crankshaft alignment 200 .03 Dismantling injection pum p
021 .02 Releasing and preloading main bearing bolts 200 .04 Assembling injection pum p
021 .03 Removing and installing main bearfhgs 200 .05 Adjusting injection pum p
200 .06 Priming and disengaging injection pum p
026.01 Turning gear with electric motor 200 .07 Milling damaged delivery pipe seat s
026.03 Adjusting disc brake of electric motor 203 .01 Adjusting and maintenance of fuel contro l
027 .01 Checking torsional vibration damper linkage
221 .01 Testing injection valv e
030 .01 Releasing and preloading connecting rod bolts 221 .02 Removing and installing fuel injecto r
030 .02 Removing and installing crank bearing 221 .03 Disassembling and cleaning fuel injecto r
030 .03 Removing and installing connecting rod 221 .04 Assembling fuel injecto r
030 .04 Removing and installing crosshead bearing 281 .01 Cleaning intercooler during operatio n
030 .05 281 .02 Cleaning intercooler when remove d
Replacing bearing shells of crosshead and
crank bearings 281 .03 Maintenance of charge-air pip e
030 .06 Checking crosshead bearings 289 .01 Maintenance of exhaust manifol d
031 .01 Removing and installing crosshead pin 302.01 Maintenance of cylinder lubricato r
302 .02 Checking delivery volum e
035 .01 Removing and installing piston cooling 303 .01 Maintenance of crosshead lubricato r
stuffing box 409 .01 Adjusting exhaust temperature measuring plan t
442 .01 Water trap with float switch in pis t, on cooling
0 490 .xx
system
Tool s
036 5612 E T09_._X-xJ_ M.A.N. exhaust turbocharge r
000 .01-2
0
0
COMPONE NTS/ASSEMBLIE S KSZ-B 00 0
M+A&*Pa Arbeitskarle-IsIr .
Work card ~oI ;io.
0 Carlo tra~a
Tarieta trobajo No .
000 .02
r
~,orpon 8nLL/ASSy . Designatio n 161 500
000 General
009 Tensioning tools
010 Bedplat e
012 Engine frame
013 Tiero d
014 Cylinder jacket
01 5 Diaphragm casing
Piston rod stuffino
bo x
017 Thrust bearing 034
019 Engine bracing 040
020 Crankshaf t
021 Main bearing 281
026 Turning gear
Q27 033
Torsion vibration 040
damper )
0 Connecting rod 050
Crosshead with guide shoe 302
12 5
Guideway 014 20 0
Piston rod 015 203
Pisto n
0 11 s.1.
on coo1 035 2ni
ing
141-1
I 1f,1 9
Piston rod and pisto n _1UJ
Cylinder liner 031 120
Cylinder cove r 160
Safety valve 303
Timing gea r
Camshaft 030
Ca m
Reversing gear 012
Engine control s
Governor
Starting pilot valve 020
Starting valve 010
Main startino valv e
Fuel injection pump
Injection pump driv e
Fuel control linkage 013
Fuel injecto r
Charge-air pipe A 40 AS
Exhaust manifold
Cylinder lubricator
Crosshead lubricator
Exhaust temperature
measuring plant
490 Tool s
50 0 U .N . exhaust-gas turbocharge r
Note : The syste m adopted for numbering the

component s/assemblies is the same as that used
for the s pare parts catalogue and facilitates
looking u p of any desired spare part .
0
D36 5610 E
000 .02-3 P .t .o .
co
Four-Stroke engine s 00 0
M A64 Pd
SPOT TESTS WITH FILTER PAPER Arbeitskarte Nr.
Work card No.
0 EB&W Carte
a traail No 000 .0 5
T rjeta traba)o
Compound lubricating oi l
TOOLS REQUIRE D
1 glass rod or piece of wire
Chromatographic paper No . 2043 a/OE
cuts 50x50mrn
by Schleicher & Scholl ,
D-3354 Dassel / West German y
SEQUENCE OF OPERATION S
Dip clean glass rod or wire, which is pointed at the bottom, into lubricating
oil at service temperature .
1 Let a drop of oil adhering to the rod fall onto the filter paper and let it dry
for several hours at room temperature .
Then compare the filter paper with the samples shown on the left .
LUBRICATING OIL SPOT TES T
The spot test with the filter paper will show the degree of contamination,
0
the presence of water or fuel and the detergent-dispersive power still
existing . The state of the oil being used can thus be approximately deduced .
A spot test is no substitute for an oil analysis . Abnormal appearance of the
sample, compared with test samples from previous oil fillings which had been
in the engine for the same length of time, will indicate irregularities, e .g .
poor combustion, fuel or water leakage, insufficient attention to oil etc . The
pictures represent samples of used compound oils (HD oils) . Lubricating oils
as shown in sample 1 are slightly contaminated ; the oils shown in sample 5
have reached such an advanced state of contamination that an immediate oil
chanqe is necessary . If the appearance of the sample is similar to that of
sample 4, it is necessary to carry out a complete analysis from which the state
of the oil can be finally deduced .
Compound lubricating oils contain active substances which keep the residues
from combustion in suspension or prevent them from being deposited in the
engine (detergent-dispersive effect) . The particles of dirt are smaller than the
3 capillary tubes of the paper, which explains the distinct flow effect in the
outer range . With declining dispersive effect the dirt particles combine to
block the capillary tubes . The core of the spot turns a dark colour . Ray-shaped
formations on the rim of the spot indicate the presence of water or fuel in
0 the lubricating oil .
Not e
Spot test samples should be taken direct from the oil circuit with the engine
running at the intervals specified (see also Maintenance Schedule) and glued
into a booklet .
The same filter paper must always be used to ensure a true comparison of the
4 oil samples . The test samples shown were prepared with the chromato-
graphic paper named above .
Fuel spot test
Spot tests with the filter paper will also give some indication as to the quality
of fuel i .e . whether distillate or mixed fuel . Regarding heavy fuel oils, ap-
pearance of the spot test allows conclusions on compatibility of the mixed
components . It is recommended that spot tests also be carried out every time
new fuel is bunkered and the samples glued into a booklet .
0 364267 2
D36 5600 E 000 .05-1 2.89

0
0
M .A.N .-DIESE L 00 0
EXHAUST GAS PICTURES
Arbeitskarte-Nr.
0 M*AA:*1M Work card No.
Carte travail No . 000.06
Tarieta trabojo No.
TOOLS REWIRED
Exhaust Gase s
The colour of the exhaust gases of an engine Is Indi- 1 piece of cardboard, plywood e .g .
cative of the combustion In the cylinders and of the white paper, not to smoot h
performance of the parts involved In the gas-changing
and Injection process . At full load, the exhaust gases
should be nearly invisible . If they are not, the cylinder
causing the darkening of the exhaust should be deter-
mined . But first make sure that deterioration is not due
to a deficiency on one of the general systems, e. g .
dirt in the fuel or In thp air supply system (in the
case of the later, the back pressure after the engine
will be excessive) .
Taking of exhaust gas picture s

Having cleaned the Indicator valve or decompression sampling paper to the exhaust gases Immediately after
valve thoroughly, take a well-moistened sheet of white opening the Indicator valve in order to avoid the risk
paper, which should not be too smooth, place it on a of obtaining misleading results due to dirt spatters from
0 firm backing and hold it in front of the valve at a the Indicator valve .
distance of about 8 cm (3") and allow exhaust gases The paper will blacken more or less depending upon
to act on it for about 5 seconds . But do not expose th e the soot density of the exhaust smoke . Oil spatters,
especially when they occur with the engine running
under load, are an indication of some fault within the
cylinder. This simplified test method will suffice to deter-
mine a failing cylinder by comparison .
It Is good practice to retain exhaust gas pictures as
part of the service records to have them available for
future reference .
Example s
Figure I
The paper is only slightly blackened . Exhaust gases are

nearly free from soot . 1
Figure 2
0
The paper is more blackened with a slightly yellow under-
tone . The exhaust gas contains too much soot connoting
inferior combustion .
Figure 3
The paper is heavily blackened with yellow undertone .

Combustion is poor. All parts Involved In the Injection
process should be checked, and If there are also visible oil
spatters, the piston rings should be checked too .
+ for 1 cylinde r
3 363531 3
0 VIP
036 56GO E
000 .06-1 Arbeitszeit -Stunden Alle as required Betrietossfunden
Operating hours
Working time
Dur6ep de
- Hourt
, travoil - Heures 0"I * Every
Toules les Hevres de -arche
T iem o je trobalo - Horas Cada Horas de servicio
0
0
CHECKING COOLING WATER GENERA L 00 0
0 "Ak" Arbeitskane Nr .
Work card No
ME~ Carte travail No 000.07
Tarjeta trabalo
1. PRELIMINARY NOTE S
According to the quality requirement sheet 1 .41 and the maintenance plan the following isto be checked :
- the freshwater provided for filling resp . topping up of the engine circuit s
- the cooling water which has already been treated during later operation .
The demands on the condition of the fresh water and the mix-up ratios of the treatment agents are included
in sheet 1 .41 . They are briefly summed up as follows . For the checking intervals please see the maintenance
plan .
2. TOOLS REQUIRE D
2 .1 Tools for checking the fresh water quality .
MAN B&W-Water Test kit, containing all devices and chemicals required (to be purchased from MAN B&W or
Messrs . Mar-TecMarine, Hamburg - for supplementary notes please see the sheets 3 .11 and 3 .12) or
Durognost tablets for determination of the water hardness (Messrs . Hegl KG, Hildesheim) an d
pH-value indicator paper with colour test chart for the determination of the pH-value (Messrs . Merk AG,
is Darmstadt),asan alternative liquid pH-value indicator oran electronic measuring device an d
n/10 - nitrate of silver and 5% chromate of potassium for the determination of the chloride ion content .
Chemicals for the softening of water (Na3 P04 und Na2 COD and for the setting of the pH-value (Na N02 or
Na OH) .
Container for water sample .
2 .2 Tools for checking the concentration of the treatment agents
I When using chemical additives :
Testers in accordance wit the recommendations of the supplier .
I When using corrosion preventatives :
Emulsion tester (Messrs . Hamburger Laborbeclarf Dargatz, Hamburg),
Concentrated hydrochloric aci d
3 . CHECKING THE WATER CHARACTERISTICS
3 .1 Summary of the requirement s
Water for filling and toppin g Water in circulatio n

up
Kind of water Fresh water, free fro m Treated cooling wate r

foreign matter
Total hardness max . 10" d . Gh (Germa n
degrees of total hardness)
pH Value- 6,5-8 at 20"C 7,5-8,5 at 20' C
Chloride Ion Content max . 50 mg/ l
Table 1 . Quality requirements for cooling water (summary )
3 .2 Checking the water hardnes s

in accordance with the directions for use issued with the Durognost tablets .
Water showing higher hardness values than prescribed is to be mixed with distillate or softened water or
to be softened by adding the chemicals specified below .
40
D36 5600 E 000 .07-1 7 .93 Page 1 of 3
The water hardness is reduced by lodGh if the following quantities of chemicals are added to each 1000
litres of water :
approx . 40 g anhydrous trisodium phosphate (Na3PO4) and
0
approx . 20 g anhydrous sodium carbonate (NA2CO3)-
Note : Dissolve chemicals in water first outside the engine circuit in a separate container (to ensure that the
hardness causing salts are separated outside the engine circuit) and then slowly mix this solution into
the expansion tank with the engine running .
Chemicals to increase the hardness are, for the time being, nearly unimportant since emulsifying anti-corrosion
oils are hardly used . They were only provided for this special case to avoid foaming .
3 .3 Checking the pH-valu e
The water is to be measured with indicator paper, a liquid indicator or an electronic measuring device . The
manufacturer's instructions must be exactly followed .
The pH-value indicates the concentration of the hydrogen ions in the water and is an index of its
aggressiveness . If the pH-value is below the limit value stated, it can be corrected by adding sodium nitrite
(NaN02) or sodium hydroxide (NaOH) sodium nitrite is preferable . The quantity required will depend on the
initial pH-value .
3 .4 Checking the chloride ion conten t
Add exactly 10 CM3 n/10 silver nitrate solution (AgN03) to 350 CM3 water and hake well . Add 5 - 8 drops of a 5
potassium chromium solution (K2CrO4)- If red colouration occurs, then the chloride ion content is less than 100
mg/l . 0
If the chloride content is too high, add water with a low chloride content (distilled water or condensate) until
the solution turns red . Afterwards check once again for hardness and pH-value .
4. TESTING THE CONCENTRATION OF CORROSION PREVENTATIVES
4 .1 Summary of the requirements
Concentratio n
Chemical additive according to the table in sheet 1 .4 1

Anti-corrosion oil first, after filling 1 .5 - 2 % by volume, later durin g
stabilised operation 0 .5 - 1 % by volum e
Anti-freeze 20 % by volume at least o r
according to the lowest system temperatur e
occurrin g
Table 2 . Concentration of cooling water treatment agents

4 .2 Concentration test of chemical additive s 0
The concentration should be checked weekly resp . in accordance with the maintenance plan with the test
apparatus and chemical agents specified by the manufacturer and in accordance with the instructions issued .
A protection by chemical corrosion preventatives is only ensured if the concentration is exactly adhered to .
Higher or lower concentration will result in increased corrosion of the components which are flushed with
water .
For reasons of environment protection chemical additives are almost exclusively used nowadays . Emulsifying
anti-corrosion oils have lost importance .
4 .3 Concentration test of anti-corrosion oil s
The emulsion tester, a small container for removing the water sample and concentrated hydrochloric acid
are required for the test .
D36 5600 E 000 .07-1 7 .93 Page 2 of 3

1 . Remove water sample from a well-flushed pipe of the engine cooling
circuit. Prior to that a small amount isto be drained to clean the point
for removal . Under no circumstances whatsoever take a sample from
the expansion tank . Pour the sample over cotton wool in the emulsion
0 testerand fill tomarkA(JOOCm3 = 100MI) .
2 . Fill with concentrated hydrochloric acid up to mark B .
Warninq : Hydrochloric acid is very caustic, if any of it splashes onto
the skin, rinse it off with plenty of water immediately .
3 . Seal emulsion tester with glass stopper, invert about 10 times and
shake well (heating in a water bath will accelerate separation) .
4 . Put down emulsion tester . The hydrochloric acid separates the
emulsion, the oil being separated above mark (A) .
5 . When separated liquids are clear, read off oil content in % by volume
on scale .
6 . Thin contents of emulsion tester with plenty of water and pour away ;
clean tester with bottle brush and dry .
Note When the system is filled for the first time and after every
change of water, the concentration must be checked early in
accordance to the maintenance plan, as the oil film forming on
the walls may make the emulsion thinner .
4 .4 Checking the concentration of anti-freeze .
0 in view of the small probability that anti-freeze will be used we ask to
contact MAN B&W Augsburg Works if the occasion arises .
Fig . 1 . Emulsion tester

for checking the concen-
tration of anti-corrosion oils .
D36 5600 E 000 .07-1 7.93 Page 3 of 3

0
0
Engines genera l 00 0
CLEANING COOLING WATER SYSTEM A , k rieNr .

Wot tc a r"d N 0
0 cirt: travad No. 000.0 8
~t a trabalo
General
if the water quality is poor or in the case of inadequate water treatment, the cooling system may be
considerably contaminated even after a short period of operation . Contaminated cooling spaces and deposits
in the heat exchangers are impairing the effective cooling of components .
Impurities are settling in the form of sand or sludge, especially in areas with low flow rates . Frequentlysuch
deposits can be removed by thorough flushing . The flushing process may, under certain circumstances, be
intensified by the use of an appropriate tool, stirring up the deposits .
If a corrosion-inhi biting oil is used, a clean cooling circuit is an essential requirement ensuring stability of the
emulsion . The system must be cleaned if refilling of corrosion-inhibiting oil is frequently necessary, or, if
larger quantities of separated oil are found in the expansion tank and in case the emulsion cannot be
maintained stable .
0 Cleanin q
Within the intervals specified, the cooling system is to be inspected for contamination . Inthecaseof
advanced contamination, the system is to be cleaned immediately . This type of work should best be
performed by a specialist company which will provide the cleansers suitable for the particular type of deposit s
and materials used in the cooling system . Only if procurement of the services of a specialist firm is not
possible, the cleaning process should be performed by the engine operator .
0. i I s I u d g e , caused by lubricating oil that has leaked into the cooling system or by an excessive concen-
t ration of the corrosion-inhibitors, can be removed by flushing with freshwater with some cleaner added . In
Table 1 suitable solvents are listed in alphabetical order . Products of other manufacturers may be used,
provided their proper-ties are comparable . The manufacturer's instructions for use are strictly to be observed .
Manufacturer Product Concentration Duration of Cleaning Proces s

Temperatur e
Drew HDE - 777 4-5% 4 hirs at 50 - 60*C
0 Nalfleet Nalfleet 9 - 010 2-5% 4 hrs at 60 - 80*C
Unitor Aquabreak 1) 0,05-0,5% 4 hrs at ambient temperature
Vecom Ultrasoni c 4% 12 hrs at 50 - 60' C
Multi Cleaner
Table 1 : Cleaning aclents for removinq oil sludcl e
1) Can also be used in case of short period engine operatio n
D36 5600 E 00008-1 4 .97 Page 1 of 2

C a I c a r e o u s a n d r u s t d e p o s i t s may be caused by hard water used or excessively low concentration
of corrosion-inhibitor over a long period of time . 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,
are impairing the heat transfer to an extent thermally overloading the components to be cooled .
41
Rust in the cooling system affects the stability of the emulsion adversely, if the cooling water is treated with
anti-corrosion oil . Washed off rust can act like an abrasive (e .g . on the sealing elements of the water pumps) .
Together with the hardening constituents of the water they form iron sludge which settles predominantly in
areas of low flow rates .
In general, products used for dissolving calcareous scaling deposits are also suitable for removal of rust . in
Table 2 suitable agents are listed in alphabetical order . Products of other manufacturers may also be used if
their properties are comparable . The manufacturer's instructions for use are likewise to be strictly observed .
Prior to cleaning, it is to be checked 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 Cleaning Proces s

Temperatur e
Drew SAF - Acid 5-10% approx . 4 hrs at 60 - 700 C
Nalfleet Nalfleet 9 - 068 5% approx . 4 hrs at 60 - 75* C 41

Unitor Descalex 5-10% 4 - 6 hrs at approx . 60* C
Vecom Descalant F 3-10% approx . 4 hrs at 50 - 600 C
Table 2 : Cleaninq aqents for removal of calcareous and rust deposit s
Should none of the special solvents, the application of which is without problems, be available, the removal of
calcareous deposits may, in cases of emergency, be effected - with diluted hydrochloric acid or amiclosulphuric
acid . in the application, the following isto be observed :
Heat exchangers made of stainless steel must by no means be treated with diluted hydrochloric acid .
If nonferrous metals (aluminium, red brass, brass etc .) are employed in the cooling system, inhibited
amiclosulphuric acid should be used for cleaning . This acid is to be added to the water at a ratio of 3 - 5% .
The solvent temperature should be 40 - 50*C.
Diluted hydrochloric acid may only be used for the cleaning of steel tubes .
in systems cleaned with hydrochloric acid there is always a risk of acid residues remaining even after
thorough neutralisation . Such residues are favouring corrosion pitting . We therefore recommend to
have the cleaning operation performed by a specialist company . 40
Carbon dioxide bubbles that are created in the dilution process of the calcareous layer may obstruct the access
of the cleanser to the water scaling . it is, therefore, absolutely necessary to circulate the water with the
cleanser so that the gas bubbles are rinsed away and can escape . The duration of the cleaning process
depends on the thickness and the composition of the deposits . Guide values are contained in Table 2 .
Following the cleaning of the cooling spaces with cleanser, the system must be rinsed several times . Inthe
process, the water must be changed . After cleaning with acids, the cooling system isto be neutralized with
suitable chemicals and subsequently to be rinsed . Thereafter the system must be refilled with treated water
in accordance with D36 5600E-1 .41 .
Caution
Do not start with the cleaning process prior to the engine having cooled down . Hot engine parts must not be
filled up with cold water . Prior to the ultimate refilling of the cooling system it mustbe checked if the
venting pipes are open . Choked venting pipe lines are obstructing the escape of air and thus represent a risk
for the engine as a consequence of thermal overload .
As concerns the disposal of cleansers or acids, the pertinent regulations are to be observed .
0
D36 5600 E 000 .08-1 4 .97 Page 2 of 2
IM .A .N .-DIESEL 100 0
MEASURING CRANKWEB
M *Aak* M DEFLECTION
Arbeitskarte .Nr.
Work card No.
Carfe travail No . 000 .10
0 Torieta trabojo No . I
TOOLS REQJIRED TOOL NO .
1 Crankweb alignment gauge . . . . . . . . . . . . 008 .171 = 070 .351

1 Pencil and 1 pa d
1 feeler gauge . . . . . . . . . . . . . . . . . . . . . . . 021 .440
KEY TO SYMBOL S
OT = Top dead centre 1 z Crankwe b
UT = Bottom dead centre 2 = Measuring point
ROT = 900 to the right of TDC 3 = Crankpi n
LOT = 900 to the left of TDC R = Crank radiu s
UTR = On the right of BDC Only when Ow - Crankshaft diameter
UTL = On the left of BOC connectin g
OT rod installe d
The criterion -is the position cf tinie crankpir, 11 .0"L the gauge !
0 The terms ""left" and "right" as well as the direction :J rotation

refer to the crark-haft as seen fror. the coupling flange .
UT UTR
UT
363587 6
0
The crankweb deflection is indicative of the alignment between the crankshaft bearings and the bearings of th,~,
Z 11 -
driven shaft . If the values measured exceed the permissible maximum, the cause must be eliminated and the cr-~n-h
re-alioned . The following causes are possible : uneven wear of crankshaft bearings, change in the position of the
driven shaft or change in the seating of the engine on the foundation or attachment to the foundation .
SEOIJENCE OF OPERATION S
1 . Remove or open covers on crankcase openings .

2 . Turn crankshaft cylinder 1 into original position, depending on normal direction of engine rotation UTL or UiR .
3 . Check whether crankshaft is being supported by the lower bearing shell, using a feeler gauge . If the journa l
is not resting on the bearinq shell, false crankweb deflection readings will be obtained .
4 . Insert gauge into measuring points (2) and set dial gauge at "Zero" near the middle of the measuring range .
If the measurements are being taken while the engine is warm, the crankweb alignment gauge must first be
placed into the crankcase near the running gear for about 15 minutes so that it reaches the same temperatur~~
as the engine .
5 . Turn crankshaft in the normal direction of rotation until it reaches the proposed measuring positions, (see
sketch) . Magnitude and direction (+ or - ) of the deflection of the dial gauge as compared with the original
values set are to be recorded in every position and to be entered in the table (see example) .
6 . Measure remaining crank throws in the same way .
V-
0 Betriebsstunden
Arbeitszeit - Stunden Alle
D36 5600 E Working time - Hour s Every s Operating hcv,i
Durke d .travail -
M pode Heures 0 .15 Toule I,, as required Heures de marct
000 .10-1 1 Ti e trobajo - H .ras 1 Ak Cada Horas de servic ;c
EXAMPLE (Measurements in 1/100 mm )
0
Cylinder N0 .
Crank positio n 11 2 3
1 Crank in UT R 0 0 NOTE : The crankweb deflection is the difference in the distanc e
between each pair of webs measured in two positions displace
2 Crank in ROT +3 +5 180 0 C . Datum position for vertical crankweb deflection is UT
(BDC), for horizontal deflection is LOT (900 to the left of
3 Crank in OT 4 +1 TDC) . When the crankweb deflection is measured with the
4 Crank in LOT ' +4 -4 running gear installed, the UT value must be formed from 0 .5
(UTL + UTR) whereupon deflection OT/UT can be calculated .
5 Crank in UT L 0 -2
An increment in the distance between a pair of webs -
Deflection OT/U T +8 +2 compared with the datum position - is to be entered in the
table with a plus sign (+), a minus sign (-) is to be used
Deflection ROT/LOT -1 +9 when the distance grows smaller .
Difference between OT values
of adjacent cylinders 7 R FL
increase in distance decrease in distanc e
The report must also include the following additional particulars the extent to which the engine was assembled,
10
particularly running gear components installed, coupled to sets, foundation conditions etc .
If the measurements were taken when the engine had the service temperature, oil and cooling water temperatures .
If the measurements were taken when the running gear was installed, the main direction of engine rotation .
1,"XIMUM', PERM!SSIBLE CRANKWEB DEFLECTIONS (Measurements in 1/100 mm)

If deflections are larger, the crankshaft requires realignmen t
Engine type 40/45 40/54 :,2/52 1 52/55 58/64 70/'1?5 78/155 90/160 10 NO
Difference 13 15 15 18 23 45 56 58 65
Note The difference between the OT measurements of adjacent cylinders should not exceed the permissible crank-
web deflection .
D36 5600 E / 000 .10-1

M .A .N .-DIESEL 000
M *Atk* M REPLACING PIPE S Arbeitskorte-Isir.
Work card No .
Carte travail No . 000 .15
0 Tariela tra bojo No .
associated work card . . . . . . 000 .16

000 .17
000 .1 8
GENERAL
When pipes of the fuel, luboil, cooling water and starting air system or pipes of the pneumatic controls are to
be repaired, modified or exchanged, the notes stated below must be observed so as to avoid trouble in subsequent
operation .
1 . Pipe sizes and Materia l

Seamless mild steel pipes as per DIN 2391 and seamless copper pipes as per DIN 1754 made of St 35 GY material
as per DIN 1629 and C-Cu F 25 or F 30 as per DIN 17 671 are to be used as replacements for pipes on the engine
or of the pneumatic controls . Normally, the replacement pipes to be mounted on the engine are of the same size
as the ones installed originally .
2 . Small pipes of a corresponding quality can be bent while they are cold with the aid of standard commercial pipe
nding devices . If solderless pipe joints (see Section 5) are used it is mostly possible to do without heat
treatment of the pipes .
0
3 . If pipes of a different quality or larger pipes are used and it is therefore necessary to bend them while they
are hot or if the pipes are soldered or welded, they must be treated with acid, caustic solution and water
when the work has been completed (see Work card 000 .16) .
4 . When installing pipe supports, it is necessary to ensure that the pipes and their mounts cannot vibrate .
Pipes should not be secured to swinging or vibrating parts . Even soft copper pipes get hard and brittle and crack
if they are subjected to vibration .
5 . Solderless pipe Joints as per DIN 2353 are normally used to connect pipes with each other o'r the units (see
Work cards 000 .17 and 000 .18) .
When air pipes of the pneumatic controls or of the starting system are to be replaced, only stainless,i .e .
chrome-plated, galvanised or brass joints are to be used . Since, depending on the point of installation
either metric or Whitworth threads of cylindrical or conical shape are required, particular attention must be
paid to the type of thread .
0 gol D36
Co 5600 E
,g 000 .15-1
0
0
Far stroke erigints
0 TREATING PIPES Arbeaskarle Nr
Work card No
Carle tfa .a,l No 000 . 16
lariela trat3al o
GENERAL
All pipes to be mounted on the engine as replacements must be mechanically or chemically cleaned on
completion of manufacture . If quite some time elapses between cleaning and mounting (replacement pipes)
the pipes must be preserved and their ends must be closed . For this purpose, plastic plugs or caps in
vivid colours are =st suitable because they will not be overlooked .
Pipes for cooling water, heating, exhaust gas and intake air system are normally cleaned mechanically .
Pipes for lube oil, fuel, compressed air, gas, steam and condensation system 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 until they have been cleaned .
Pipes that are to be bent while they are hot must be filled with sand, and, for this purpose, only
completely dry and fine-grain sand may be used . If wet sand is used, steam can develop and accidents are
likely to occur . Either the entire pipe systems or parts of them are to be subjected to a pressure test .
The entire lube oil, fuel and compressed air systems must be thoroughly flushed before the engine is put
into operation .
1. Mechanical cleaninq
Scale and welding beads must be carefully removed from the welds with the aid of a chisel, file or
grinding wheel . The entire pipe section must be hammered and, if possible, compressed air should
be blown through it at the same time, so that even minute particles (sand filled in for bending
while pipe hot) are removed . All pipe connections must be closed and must stay closed until they
are installed .
2 . Chemical cleaning
An acid bath is required for pipes that must be cleaned mechanically and chemically .
2 .1 7he acid bath equipment includes in general :

a hydrochloric acid bath for steel pipes
a water bath for washing off the acids
a lye bath for neutralizing and phosphatizing
a sulphuric acid bath for copper pipe s
In case of hydrochloric acid bath and sulphuric acid bath, acid fumes must be exhausted by
ventilators and diverted via wet separators . Also the fuels of the lye bath must be led into the
open by means of a ventilator . Attention has to be paid to the local precaution regulations .
The water bath requires a water tap and a drain .
The lye bath must be provided with a heating system allowing a heating temperature of up to 800C .
Protective measures
In compliance with the safety regulations on handling acids and lyes must all persons carrying out
acid and lye treatments wear acid-resistant overalls, rubber boots, rubber gloves and goggles .
A connected water house must be kept ready in the imediate vicinity of the acid and lye baths .
0 D36 5600E 000 .16-1 2 .91 Page 1 of 3

0
2 .2 Treating steel pipe s
First pickle in hydrochloric acid bath, next treat in trisodium phosphate bath for neutralizing the
acid and for simultaneously providing short-time preservation .
The hydrochloric acid (HC1) is commercially available with a concentration of 31 - 33% and an
arsenic content of less than 1% .
Mixing ration for bath HC1 : H20 3 : 2 (parts by weight) .
CAUTION : Pour the acid into the water and not vice versa !
The temperature of the bath should not be below 2011C .

The duration of the treatment has to be determined by visual appraisal .
If the threads have already been cut into the pipes, it is necessary to ensure that the tips of the
threads do not sustain damage . Decrease duration of treatment accordingly) .
After completion of the pickling process, the acid solution still adhering to the pipes should be
washed off in the water bath .
0
Any further remainders of the acid solution still left in the scores and pores of the superficial
structure are to be neutralized in a trisodium phosphate bath in course of which the pipes are
provided with a phosphate layer giving short-time protection against oxidation .
Mixing ration for the bath Na3PO4 : H20 = 1 8 (parts by weight )
Treatment temperature : 800C .
Note : Do not put any copper pipes into the hydrochloric acid bath if steel pipes are to be put in
after for pickling .
Owing to the reaction of the copper (Cu) with diluted hydrochloric acid (HCU, dissociated salt
cupric chloride (CUC12) forms in the water solution . If an iron pipe is put into the pickling bath
again, the less precious iron oxidizes because its positive charge is discharged and the ferric
ions enter the solution whereas the metallic copper is separated out . The iron or steel pipe is
then covered with a layer of copper which is not very adhesive . Copper deposits on the walls inside
of fuel conducting pipes are undesirable . Dissociated copper particles would cause operational
troubles in injection element such as pumps and nozzles .
0
2 .3 As an alternative to the conventional treatment sequence of acid bath - water bath - lye bath, it
is also possible to smoothly pickle and simultaneously phosphatize in onlv on sinqle bath with
PHOSPHATIN and water at a mixture ratio of 1 : 4 without intermediate or aftertreatment being
required .
Treatment temperature : 800C
Duration of the treatment depends on the acid content of the bath and on the degree of scale and
oxidation of the pipes .
PHOSPHATIN derusts, descales, removes the rolling skin and provides simultaneously a phosphate
protection . First of all, scores and pores in the superficial structure are freed from trapped
gases and electrolyte solutions or their reaction products are rendered harmless . Furthermore,
phosphatin prevents that aggressive substances remaining in the pores and capillary tubes in the
ground and recognizable only under the microscope can introduce any underground corrosion .
Phosphatin has no structure-changing properties and, when correctly applied, does not result in an
acid reaction . Thus, no destroying effects on subsequent priming and finishing paints will occur,
in the contrary, good adherence is achieved by the phosphatizing . The phosphate layer applied
should, however, not be thicker than 1 In . Phosphatin can be procured from Messrs . NMW=- 0
CHEMIE, V . Kuhmichel GmbH, Dornierstr4e 9, D-3000 Hannover/Germany .
D36 5600E 000 .16-1 2 .91 Page 2 of 3

0
2 .4 Treatincr copper pipe s
First pickle in sulphuric acid bath, next treat in trisodium phosphate bath for neutralizing the
acid and for phosphatizing .
The sulphuric acid (H2 S04) is commercially available in a 98% concentration (concentrated acid)
It must be transported in closed containers .
Mixing ration for the bath H2SO4 : H20 = 1 : 8 (parts by weight)
CAUTION : Pour the acid into the water and not vice versa !
Once the acid bath has been prepared, it should settle for 24 hours before it is used .
Duration of treatment : At the beginning, the copper pipes are to be treated for 15 minutes, and
the treatment period must be increased as the bath gets older .
When the pipes have been taken out of the sulphuric acid bath, they must be well flushed with
water and dried with a low flame .
0
Neutralization in the trisodium phosphate bath is not a must . However, it is recomiended in case
of long-term storage to prevent formation of verdigris .
3. Pressure-testing pipes
Water pipes are pressure-tested with water, lube oil, fuel and compressed air pipes with corrosion
inhibition oil .
Testing pressures are for :
Fuel injection pipes . .. . . .. . . .. . . . . 1600 bar

Fuel admission pipes ... . . .. . . .. . . . . 30 bar
Lube oil pipes . . . . . . .. . . .. . . ... . . . . 10 bar
Coolant pipes . . . . . . . .. . . .. . . ... . . .. 5 bar
Starting air pipes . . .. .. .. . . .. . . . . . 60 bar
Control air pipes . . . .. .. .. . . ... . . .. 12 bar
0
4 . Preservinq pires
For short-term storage under roof or in dry warehouse, phosphating and oil film are considered to be
sufficient as corrosion protection . Also for long-term storage and for the service, phosphating is a good
primary preservation prior to application of the final preservation with corrosion inhibitor oil, paint or
grease . Seal pipe ends and connections with coloured plastic caps . Plastic caps in signal colours offer
the advantage to be recognized very easy when the pipes are fitted to the engine . 7bey must be removed
prior to installation of the pipes .
0
D36 5600E 000 .16-1 2 .91 Page 3 of 3
0
0
ASSEMBLING SOLDERLESS SCREWED M .A .N .-DIESE L 00 0
M *Atk* M PIPE UNION S A r be itskorte . Nr.

Work cord Mo .
0 Carte travail
Tarjeta trabajo No .
000 .1 7
associated work card . . . . . . . 125 .01
KEY TO SYMBOL S
1 Union nut 4 Cutting and wedge ring
2 Stop 5 Inner con e
3 Pipe 6 Visible colour
7 Mar k
Deburring H - Union nut (1 )
2H - Minimum distance of one pipe bend
R - Bending radiu s
D - Outside diamete r
36 35 89 4
1. Cut off pipe at right angles and deburr i t
Pipe cutters (see illustration) are most suitable for suL'-,
Pipe cutter work . The pipe is cut through with a cutting wheel . Tha
0 inner edge of the pipe can then be deburred by means of
'q'gu the three blades inside the handle or by means of a coun-

terbore . The chips must be carefully removed by blasting .
2 . The thread as well as the cutting and wedge ring (4) must
be well oiled (not greased) . The nut and the ring must
then be pushed over the end of the pipe as shown in the
7, 77'm illustration . If the cutting and wedge ring cannot be
pushed over the end of the pipe, or only be using force,
the ring should not be expanded but the end of the pipe
should be made thinner by filing .
3 . Screw on union nut by hand until it can be felt that it ic
Before tightening in contact with the cutting and wedge ring . The pipe is th-,
to be pressed against the stop in the inner cone and the
6
union nut is to be turned by about 112 to 3/4 revolution .
The cutting and wedge ring then grips the pipe and there i!
no need to press the pipe any further . Final tightening is
effected by turning the union nut by about one revolution .
The ring then cuts into the pipe and builds up a visible
0 collar in front of its blade .
A marking line on the union nut facilitates adherence to
the specified revolutions .
After tightenin g
4 . Pipes with smaller outside diameters can be secured in
screwed unions without pre-assembly if they are firmly MI
screwed in on the engine .
Pipes with a larger outside diameter and all connection s
in free pipes should be pre-assembled 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 n,t
has been loosened a few times so that new oil can enter
between the friction faces .
NOTE It is necessary to ensure that every pipe end comes
into the same inner cone in which pre-assembly toolk
place .
Assembly on engine
p .t .o .
0
r-
D36 5600 E
000 .17-1
5 . After final tightening, release the union nut and
check if the visible collar (6) fills the space in 0
front of the blade . If it does n6t, re-tighten briefly .
It is meaningless if the cutting and wedge ring can be
turned on the end of the pipe .
When the joint has been made and each time the joint
has been loosened, the union nut is to be tightened
with a spanner that has not been extended and, for this
purpose, no excessive force may be used .
NOTE The straight pipe end that extends into the

Pre-assembly in vic e screwed joint should be at least twice as long
as the union nut is high (H) .
In the case of longer pipes or pipes that are sub-
jected to higher stresses, pipe supports must be
fitted .
For bending steel and copper pipes, a device with
exchangeable rollers is recommended (see illu-
stration) . The bending radius R must not be any
smaller than twice the outside diameter of the
pipe (R - 2 D) .
0
Chec k
Minimum distance and bending radii

0
Pipe bending devic e
D36 5600 E / 000-17-1

INSTALLING REINFORCING SLEEVES, M .A .N .-DIESEL 1000
INSERT NOZZLES AND HOSE Arbeitskarte-Nr.
Work cord No .
0 CONNECTIONS Carte travail No . 000 .18
Tarieta trabojo No .
KEY TO SYMBOLS
1 Reinforcing sleeve 3 Hos e
2 Insert nozzle 4 Hose clam p
SEQUENCE OF OPERATIONS
Sleeve inserte d
1 . If solderless screw connections are to be used for copper
pipes, reinforcinq sleeves must be fitted so that the pipe
cannot be squeezed together when the union nut is being
tightened .
1-77-7- 2 . The air admission and venting periods of units can be adjusted
Sleeve driven i n to the respective requirements by using insert nozzles . These
nozzles can be inserted into the screwed joints if the union
nut has been released and the pipe pulled out . The pipe end
0 must be reduced in length by the extent of the nozzle collar .
3. Inside compressed air systems, transitions between a pipe

and a hose and vice versa will be necessary whenever moving
parts are to be connected . If it is impossible to perfectly
shape pipe ends so that they form standard hose sockets, a
Completely assembled screwed hose joint must be used for such connections . It is not per-
joint with reinforcing sleev e mitted to slide the hose onto a pipe that has been cut off
flush . The hose (3) must be cut off at right angles and must
be slid onto the hose socket up to the stop . The hose must be
secured by a hose clip or hose clamp (4) so that it cannot slide
off .
insert nozzl e
r-)
0 I
dF`7
Screwed joint with insert nozzl e
..z~J. Jew-
MEa ~
Screwed joint with hose connectio n
40 036 5600 E
000 .18-1
0
0
4-stroke engines 1 00 0
APPLICATION OF LOCTITE ArbeaSkarte Nr .
0 Work card IYO .
C:rte tra .ad No 000.1 9
T rleta trabalo
LOCTITE PLASTIC PRODUCT S

The filling compound LOCTITE is a liquid plastic which automatically cures between snup fitting metallic
surfaces to a tough-hard layer and, exhibiting excellent adhesion to the ridges left by the machine tools,
indreases the surface contact between two parts considerably .1t is available in several types of differing
viscosity for various gap widths, for fastening, for securing, for sealing and for gluing .
LOCTITE must not be used inside the crankcase as a substitute for locking fasteners, fitted feather keys
etc .provided in the design . In the case of screw connections reguiring tightening to a given torque, LOCTITE
222 and 243 may be used as the lubricity of these two products corresponds to that of lubricating oil .
The curing time of LOCTITE can be shortened by adding Accelerator 7471 or by heating the joint .
SEQUENCE OF OPERATIONS1 : Assemblin g
I . Clean jointing surfaces with quick cleanser LOCTITE 70636 (evaporation time approx . 3 minutes) to
remove dirt and grease .
2 . If necessary, apply Accelerator 7471 by means of a spray can and allow it to dry for about 3 minutes . The
filling compound will cure in a shorter time if the accelerator is used (see table) .
3 . Apply a thin coat of the appropriate LOCTITE product (see table) to one of the two surfaces to be jointed .
Note : Both the jointing surfaces should be sparingly and evenly coated if the joint is a press fit or i f
the surface area is comparatively large . In the latter case, LOCTITE may be spread with a clean brush or
with a spatula .
In the case of blind-end bores, moisten walls to prevent the liquid LOCTITe product from being forced out
by the air pressure building up during assembly .
The contents of the bottle must not come into contact with metal parts before application!
4 . Join both parts in the correct position .

S . Scrape off and remove filling compound outside the joint, using care not to dislodge the jointed parts .
6 . Filling compound must be allowed to cure (cf instructions for use) before work is continued .
7 . If necessary, heatjoint to appr . 120*C to shorten curing time .
SEQUENCE OF OPERATIONS 2 : Disassemblin g
1 . Try if joint can be undone with the aid of normal tools and by hand force .
2 . Should this prove to be impossible, heat joint to approx . 200*C and separate parts (fire hazard!)
SEQUENCE OF OPERATIONS 3 : Reassemblin g
1 . Remove mechanically old LOCTITE layer on both parts completely, using care not to damage the jointing
surfaces . (The layer cannot be removed with the use of chemicals . )
2 . Degrease par-ts carefully and reassemble as described under sequence of operations 1 .
Note : Cleanness of the jointing surface can be checked by means of ultra-violet radiation . LOCTITE is
fluorescent and even the slightest traces of it will show .
Table : (Assortment of LOCTITE products used at Augsburg Works) . see overleaf
Attentio n
Loctite may'not be stored for more than approx . 1 year at room temperature
Longer storage time leads to an alteration in quality, making the product unusable .
Therefore always take note of the expiry date !
D 36 5600 E 000 .19-1 6 .92 Page 1 of 2

Controlled use Special us e
Fixing fixing Securing Sealing Fixing Securing Gluing
Type 586 270 243 572 640 222 307
International Index Number 0586 0270 0243
0640 0222 03070572
Colour of Product red green blue white green purple colourless
Bottle resp . tube, contents in CM3 F/50 F/50 F/50 F/50 F/50 F/50 T/100
Application : Fixing very good very good good very goo d
Securing almost almost good difficult to good
inseparable inseparable separat e
Sealing : Surfaces good
Sealing : Pipes good good
Qua ities :
Strength high high medium low high low high
Viscosity thick medium medium very thick medium medium medium
at 250 Cm Pa . s( = cP) 5000 500 1000 17000 600 1000 200 0
Gap (D-d) mm optimum 0,07 0,05 0,05 0,1 0,05 0,05 0,05
2
maximum 0,20 0,12 0,12 0,25 0,12 0,12 0,10
for thread up to maximum M56, G2" M20, G 1/2" M36 M80, G3" M20 M36 --
Thermal stability Oc -55to +150 -55to +150 -55to +150 -55to +150 -55to +200 -55to +150 -55to +125
Strengths :
Tensile strength -- -- -- - 42
Shear tensile strength 13 12 8 21 25
Shear impact strength 14 6 5 -- 4-6 -- 13
Static shear strength 1B2 15-25 12-15 8-12 4-6 15-30 3-5 --
Thread shear strength 'EB1 7,5-12,5 8-12 4-8,5 1,5-2 7,5-12 1,5- 4
Friction shear strength TP 10-15 10-15 2-4 1-1,5 12,5-17,5 1-2
Curing : 120"C/30min .
hand tight
at 22*C and plain steel 2h 10-*30 min 15-30 min 15-30 min 4h 15-30 min 10-30s
with accelerator 7471 with passi- 30 min 20-30 min 15 min 10-15 min 20 min 15-25 min 4 min
vated materia l
functional strength at 22 T - 45 min 45 min -- 6h 45 mi n
final strength at 220C 12-24 h 3h 3h 12-24 h 24h 3h 12 h
D 36 5600 E 000 .19-1 6 .92 Page 2 of 2
0 0 0 10
MAN B&W DIESEL 1 0 0 0
0 TRAFUL IMPREGNATION METHOD Art>eitskane N(
MAkm Work Card No
Carte travail No
000 .2 0
E3EkW Tarleta trabalo
GENERAL
The TRAnI impregnation method is used for sliding surfaces to improve antifrictional qualities . The
adhesion layer (absorption layer) is a crystalline layer of mlybdenumdisulphide NoS2) that delays
seizure of the nibbin4 parts in the event of a lack of lubrication (dry lubrication) .
7his impregnation method has proved to be especially effective in the case of fuel injection cams,
rollers and roller pins . The adhesive layer normally need not be renewed . When installing spare parts,
it is highly reccnTlended though that they be treated accordingly if their sliding surfaces will be sub-
jected to high pressures . The following should be noted when applying the TRAFUL impregnation method .
Semmmice of Operations
1 . Preparation of the surfaces to be treate d
The surface of the workpiece must be spotlessly clean and there should not be any traces of con-
tamination as they are likely to impair the formation of a uniform layer (local spots in the ab-
sorption layer) . A contaminated surface can also prevent the firm bonding of pigments on the work-
piece .
Careful cleaninq of the workpieces or the surfaces to be trafulated is, therefore, an essential
requirement for the application of this method .
In any case, the cleaning process must be acccmpanied by a thorough degreasing with the use of a
degreasing agent, for instance "Weral 590" . In the case of fast clinging greasy dirt, the workpiece
should be cleaned by mans of water-based systems utilizing ultrasonics (cleaning agent for instance
Flamil 4, free of phosphate, supplier Flore-Chemie, Koblenz) . Immediately after degreasing, the sur-
faces to be trafulated should be processed as quickly as possible by means of the TRAFUL impregnat-
ion method and protected against recontamination in any form (hand sweat) .
If, in case of repair, retrafulation is required, the surfaces to be retrafulated have to be

smoothened, e .g . with a honing stone or polishing linen, prior to applying the adhesive layer .
2 . Applyinq adhesive layer TRAFUL 7U/S Special
After cleaning and degreasing as described under 1 above, coat the surface to be treated with 7U/S
Spezial, using a plastic foam roller, to provide the adhesive layer (absorption layer) . The reaction
time at room temperature is at least 30 minutes as experience has shown . During this period the
liquid must be constantly spread with the roller so as to prevent the preparation from drying up and
becoming ineffective .
After this process the workpiece or the surface thus treated must be thoroughly wiped off with a wet
sponge, and the plastic foam roller is to be thoroughly washed out . 7he water must be clear, neutral
and free of salts and should therefore be changed frequently . Then the workpiece should be dried with
an air hose or a non-fluffy towel .
3 . DTheddinq the picrment TRAFUL Trockenfilm 3U
The lubricant pigment proper (molybdenumdisulphide) is applied with a brush . Before application, the
pigment should be shaken up well and filled into a small receptacle . Since the solvent evaporates
quickly, it is recommended that only small quantities be poured out into the receptacle that will be
used up in a very short time . For good embedding, the applied moybdenuTdisulphide layer should be
vigorously rubbed into the surface by means of soft chamois leather . 7he pigment will thus be firmly
bonded to the surface and an y, excess will be removed .
The treated surface will have a bluish-grey dull finish . once run in, the surface will have a mirror
finish .
D36 5M 000 .20-1 4 .92 Page 1 of 2

4 . Preservation of treated canponents with TRAFLI Hochleistungs-Mehrzweckfett 0
M
7b protect the surface against corrosion when the component is stored after treatment, it is to be
coated all over with 7RAFLJL Hochleistungs-Mehrzweckfett M
which is to be rubbed slightly into the
surface and after which it is to be wrapped in oil paper .
Other corrosion inhibitors are not permitted for preservation .
A thin grease coating need not be removed prior to the process of installation
. If the grease
layer should prove too thick, it will suffice to remove the excessive grease with a non-fluffy cloth .
Should the grease layer or the Traful layer be too dirty after a longer period of storage and wiping
would not suffice, cleaning can be effected with the use of neutral soap water . Fuels or other
organic solvents mist not be used for that purpose as otherwise the Traful layer will peel off .
If an organic solvent is required to remove the preservation of the component, the trafulated surface
must be protected against the effect of the solvent by careful covering up .
Note The material required for this process is supplied by :
Messrs .
TRAF=I 0
Physikalische Werkstätten
Friedrich V . Uhlmann-
Ludwigsfelder Straße 8
D-1000 Berlin 37
36 5600E . 000 .2D-1 4 .92 Page 2 of 2

KSZ-B
CHECKING COMPRESSION AND KSZ-C 00 0
M *Aftk* 14 FIRING PRESSURES Arbeitskartt-W .

Work card ~ I i4a
o .
0
Carte trava
000 .25
TOOLS REQUIRED Tool No .

1 MAIHAK indicator, type 30 . . . . . . . . 419 .351
Diagram pape r
Asbestos gloves
Cleaning towel s
High-temperature bearing grease or an equivalent
lubricant -
LEGEN D
1 Accessories box
2 Indicato r
3 Compression and firing pressure diagrams (example )
1 . Before taking indicator diagrams, open indicator valve briefly ,
two to three firing strokes, to blow out soot and combustion residues
0 deposited in the indicator pipe .
Caution! Do not step into the path of the fire jet !
2 . Check whether the spring fitted will meet the peak pressure to be
expected .
3 . Stretch diagram paper firmly over drum, there must not be any creases .
4 . After drawing the zero line, open indicator valve and turn drum
slightly to obtain firing pressure diagram .
5 . Now turn drum by hand at ignition intervals to obtain ciompression
and firing pressure diagrams .
Note : Taking a series of compression and firing pressure lines of
several cylinders on one indicator card will permit direct
visual comparison . Taking hand drawn diagrams requires som e
.I . I I praCLICe .
36 . 4-0-259/2
6 . Measure diagram heights and calculate pressures applying the calibrated spring pressure stamped on the
indicator spring .
7 . Having taken indicator diagrams from all cylinders, remove indicator and clean all parts, especially the piston,
thoroughly . After cleaning, rub high-temperature bearing grease or an equivalent lubricant into the surface of
all parts .
Note : Do not allow indicator to become overheated by too many firing strokes as it will affect instrument
readings .
I
f=
a compression pressure
b firing pressur e
f spring calibratio n
0
D36 5600 E Arbeitszeit - Stunden Alle Betriebssfunden
Working tirne - Hours Every Operating hours
000 .25-3 Dur&* de travoil - Heures Toutes les Heures de rnarch e
CO Tiernpo de trabajo - Horas Coda cis necessary Horas de servicio
0
0
KSZ - B 1000
M +Alk+ N_ TENSIONING BOLT S ArDeitskorfe-Nr.
Work card Nr .
0 Carle lra~oil No.
Torjelc trcoo)c No .
000 .28
applicable work sheets . . . . . . 000.29

GENERAL
000.30
Screwed connections are tightened to the following methods : 000-322
1 . Screwed connections of secondary importance are tightened with normal ring or open-end spanners or torque wrench .
2 . Important screw connections are mechanically tightened to a specified torque and to a defined tightenin g
.
angle (rounded to 30 0)
Note : The above method also applies to screwed connections featuring a designed gap which must be closed first
before actual tightening .
Torque spanners should only be used for tightening but not for loosening screw connections because
applying loads in alternate directions is likely to impair the correctness of the spanner readings .
Moreover, the working range of the torque spanner can be exceeded when attempting to loosen a nut that
has become tight . Torque spanners should be frequently recalibrated .
3 . Very important screwed connections are prelo2ded to a given pressure by means of a hydraulic tool or to 2
giver, bolt elongation-
40 RELEASING AND PRELOADING WITH HYDRAULIC TOOLS LEGEN D
1 Hydraulic nut 6 Bol t
2 high-pressure hose 7 Hydraulic cylinder
3 High-pressure pumps 8 Pisto n
4 Sleeve 9 Tommy bar
5 Nut All elongatio n
Note : Correct tightening of screwed connections
requires a reliable pressure gauge . '1-1'hen
in doubt, check gauge readings with a
master gauge .
Lubricate conical contacting surfaces
of hydrau'lic nut (1) and of pist
with ~OS2-Paste .
SEQUENCE OF OPERATIONS 1 : Releasin g
1 . Mouni sleeve (4) and cylinder (7) together with piston (8) centrically or, nut (5) .
2 . Connect hp hose (2) of hp pump (3) to hydraulic tensioning tool (7 and 8) and open relief valve .
Screw hydraulic nut (1) onto bolt (6) using tommy bar (9), tighten to snug fit thus pushing the piston (8)
completely into the hydraulic cylinder .
4 . Back off hydraulic nut by angle defined in table .
5 . Switch on hydraulic pump and raise pressure cautiously until nut can be loosened .
6 . Back off nut as defined in table, inserting tommy bar through recess in sleeve .
7 . Release pressure, unscrew hydrauli-c nut using tommy bar and set it aside .
8 . Disconnect hp hose from tensioning tool at push-pull coupling .
9 . Remove hydraulic tool and sleeve, unscrew nut .
SEQUENCE OF OPERATION'S 2 : Preloadin g
1 . Screw nut (5) onto bolt (6) and tighten by hand .-

2 . Mount sleeve (4) and hydraulic tensioning tool (7 and L8) concentrically .
3 . Connect hp hose (2) of hp pump (3) to hydraulic tensioning tool and open relief valve (of work sheet 009 .03) .
4 . Screw hydraulic nut (1) onto tensioning threads of bolt and tighten to snug fit, thus pushing the piston (8 )
completely into the hydraulic cylinder (7) .
5 . Switch on hp pump and raise to required pressure .
6 . Tighten nut to snug fit using tommy bar inserted through slot in sleeve .
7 . Release pressure and unscrew hydraulic nut using the tommy bar.
0 036 5610 E
000.28-1
Note : When pressure has beenreleasedi bolt elongation will be diminished by the amount of thread settling .
0
8 . Disconnect hp hose from tensioning tool at push-pull coupling .
9 . Remove hydraulic tensioning tool and sleeve .
Note : Correct tightening of screwed connections requires a reliable pressure gauge . When in doubt check readings
using a master gauge .
D36 5o,10 E/000 .28-1

KSZ 70/125 B I 00 0
BOLT PRELOADS
0 WA *AtL* N Arbeitskarle-IsIr.
Work card No.
Corte travail No.
Torleta trabojo No . 000.29
M-1
221-2
221-3
055-3
055-2
0 PA .0 .
Co
rl~
01
036 5612 E
000 .29-1
Z-Ozo
~-Ozo OOL 60Z
0 0 , . -
LVO
LIM
t-tzz Z-UO
MR L-fto
LZZ
r-
KSZ 70/12,5 B 000

1
*A&* 94
BOLT PRELOADS Arbe ifsk orte- N r
Work card No.
0 Carie travall No .
Toricto trabojo No . 000 .30
Lubricants : M Mos 2 paste (coefficient of friction 0 .09-0 .12) applicable work sheet . . . . . 000.2 9
0 : oil Note : When tightening bolts to fixed torques ,
L - Holes in circumference of : .nut only the specified lubricants should b e
x = see work card used .
oil press. backing Tightening torqu e
Comp . Screwed connections bar off angle NN Work
lubri-
Assy. elongation for re- + tight . aRgl 0 , car d
cant
ffim leasing 1 . stage 2 . stag e
010-1 Foundation-bedplate 600 010.01
010-2 Bedplate-split-joint M - 0
350+30
012-1 Engine frame - split-joint M - 0
450+300
012-2 Engine frame - bedplate M - 450+30
012-3 Engine frame - bedplate with spacer sleeve M - 0
450+60
013-1 Tierod (P - 115 bar) - 4 .7 405019L - - 0.13 .0 1
z
013-2 Tierod brace bolts 0 - - 200 013 .0 1
015 Piston rod stuffing box 0 - 80 0 015.0 2
01 7 hrutt bearin g - 1ON20 017-01
0
020-1 loun erweight bolts In crankshaft x 1
Y201- 12
Nuts ~or countefteight bolt s x -- 8000- NMI
Main earing bo s 300 135013L 021 .0 2
ud g be4gl a 0 :0 - 1000
SP-i Eranki eari g ~sits 500 360 18L - - 030 .01
030-2 Bearing bolts - connecting rod M - 320 030 .01
030-3 Crosshead bearing bolts -
400 -
1800/4L - - 030 .01
030-4 Bearing bolts - connecting rod M - - - 320 030 .01
030-5 Bolts in crosshead bearing cleats M - - - 550 030 .0 5
030-6 Bearing bolts - bearing covet M - - - 320 030 .01
031 Bolts in guideway - guide rail M - - - 1500 031 .01
035 Bolts in telescopic pipe brackets on guide shoo M - - - 800 035 .01
040-1 Bolts in piston rod foot 500 200015L - - 040.0 5

040-2 Bolts in piston for piston rod 1000 320 0 ~R - - 040.0 8
040-3 Studs in piston crown, outer M - - 600 1200+600 040.0 8
040-4 Studs in piston skirt M 600 1200+600 040.0 8
040-5 Studs in piston funnel 0 - - 150 040.08
055-1 Cylinder cover bolts - 225 0/5L -

500 055.0 2
055-2 Cylinder cover bolts, lower part 1000 270 0 - 055.0 3
0
055-3 Cylinder cover bolts, center - - 650 055.0 3
055-4 Bolts for starting and relief valve M - - 120 055 .0 3
100-1 Bolts in crankshaft wheal x - - 100+0 100 .01

100-2 Bolts in stubshaft of intermediate wheel 0 - - 200 + 90 0 100 .01
103 Bolts in fuel cams M - - 600 1200 103 .01
120 Bolts in reversing piston and piston rod M - - - 300 120 .01
200-1 Bolts in injection pump cover M - - - 250 200 .04

200-t Fixing bolts for injection pump 0 - '1100 200.02
201 ' Bearing cover bolts of in jection pump drive M - 1300
Coupling bolts in camshaf M 500, 9DO 00 200 .01
i Clamp nut of fuel injector M - 11 50 221 .04
221-2 Nozzle nut of fuel injector M - 200 221 .02
221-3 Fixing bolts of fuel injector M - 200 221 .02
036 5612 E
000 .30-3
0
0
TIGHTENING TOROUES M .A .N .-DIESELI 00 0
M*Ak*N FOR BOLTED JOINT S Arbeilskerfe-Nr
Work card No .
Carte Iro,ail No .
0 Toriet. trabojo No. 000 .3 1
applicable work card . . . . . . . . 000 .1 9
GENERAL
The load carried by a bolit tightened to a given torque is dependent on the lubricant used, the finished condition
of the surfaces and threads and on the materials paired . It is, therefore, of great impo~tance that the specified
lubricant be used for bolted joints tightened to a fixed torque .
The tightening torques applicable to the various threads and the listed values for the coefficient of friction IL
are listed in the table given below . The tightening torques are based on bolt material of the strength class 8 .8
with the bolts stressed up to approx . 70 % of the elastic limit . For other strength classes the corresponding
conversion factors must be used, by means of which the tightening torque listed in the table must be multiplied .
Strength classes ' 5 .6 6 .8 10 .9 12 .9

Conversion factor x 0 .47 0 .75 1 .40 1.7
Values for the coefficient of friction are approximately :
0 .08 for MoS lubricants (POLYKOTE Paste G-n or HSC , Optimoly Paste White T )
0 2
0 .14 for rough surfaces, slijhtly oiled,or when surfaces are coated with LOCTITE (cf work
card 000 .19) .
1AB',-E (Tightening torques for strength class 8 .8 )
Threa d Tightening torques MA in Nm Tightening torques MAin Nm

Coefficient of frictio n Threa d
Coefficient o friction p
Size Size 0 .08 0 .1 4
0 .08 0 .1 4
M 5 4 6 M 24 475 69 0
V. 6 7 10 M 24x2 500 750
M 8 17 25 M1 27 700 1020
M 10 34 50 M 27x2 730 1100
M 12 60 85 M 30 950 1380
M iff 95 135 M 30x2 1015 154 0
M 14X1 .5 100 14 5 M 33 1270 1870
t' 16 140 20 5 M 33x2 1350 2060
M 16xi .5 150 22 0 M 56 164o 2400
0 M 18 200 280 M 36x3 1710 2550
M 180-5 215 3? 0 14 39 2115 312 0
M' 18x2 205 30 0 M 39x3 2190 330 0
M. 20 275 40 0 M 42 2630 386 0
M, 200 .5 295 45 0 M 42x3 2760 417 0
M. 20x2 285 42 5 m 45 3260 482 0
M 22 370 540 M 45x3 3415 518 0
M 220 .5 395 595 N1 48 3950 582 0
M 22x2 380 56 5 M1 48x3 4185 6370
cli
Co
0 D36 5600 E
000 .31-1
0
0
HYDRAULIC TANDEM M .A .N .-DIESELI 000
*
M *AGL* N TENSIONING TOO L Arbeitskarte.Nr.
Work card No~o.
0 Carte travail 000 .32
Torieta trabojo No.
Described' Tbo l Tool No .

030-076
Hydraulic tensioning tool 030.117 So
OON~Z
030 118 030 .06 4
~30 .129 )
Effective piston area . . . . . . . . . . . 88 .8 1 .32 cm1-
Operating pressure . . . . . . . . . . . . . . max . 1100 max . 1100 bar
Effective lift . . . . . . . . . . . . . . . . . . 3 (8) 3 .5 mm
High-pressure pipe . . . . . . . . . . . . . . 030 .119
LEGEN D
1 Hp push-pull coupling
030 .117 2 Seal ring, larg e
3 Seal ring, small
4 Plate sprin g
5 Nut
6 Shi m
A Gap required for loosening screwed connection s
Lo t e : Hydraulic tensioning tool is automatically reset to
0 zero position by the set of plate springs (4) . The
connection with the pump unit must not be disrupted
during this operation .
Should it become necessary to replace the seal ring s
(2 and 3), be sure to install them in the correct positi o
SEQUENCE OF OPERATIONS1 : Releasin g

1 . Check to see that nut (5) is firmly ;crewed on the ten-
sioning tool . (The nut type to be used varies with the
engine type and the screwed connection- )
2 . Screw tensioning tool onto the bolt to be released . Be sure
to leave the required gap A - 2 mm (admissible max . width of
030 .11 8 gap (A) is 3 mm, which may be necessary to gain access to the
push-pull coupling (1) in some engine types) .
3 . Connect tensioning tool with high pressure hose to pump .
4 . Start pump to reduce gap (A) to zero and build up pressure
in pump to bolt-release pressure (cf separate work sheet) .
5 . Back off nut to be released through whole distance with the
use of the tommy bar.
0 364142 3 6 . Release pressure in hydraulic system, disconnect~hp hose
and remove tensioning tool .
7 . Unscrew nut completely .
SEQUENCE OF OPERATIONS 2 : Preloading I
1 . Screw nut onto bolt and tighten it by hand .

2 . Screw tensioning tool onto bolt tensioning threads until gap (A) becomes zero . (if, in some engine types, a gap
must be left to gain access to the push-pull coupling, keep gap (A) as small as possible . )
3 . Connect tensioning tool with hose to pump and raise pressure to nominal value (see separate work sheet
4 . Retighten respective-nut handtight with the use of the tommy bar .
5. Release pressure in hydraulic system, disconnect hp hose and remove tensioning tool .
Note!. Hydraulically preloaded bolts must be measured to establish the bolt elongation .
See separate work sheet for measuring elongation .
.
Note : The effective lift of the hydraul ic tool (030-0761117/118) can be increased to 8 mm by removing the shim
(6) .
0
_p . t . 0 .
D36 5610 E Betriebssfunden
Co
Arbeilszeit Stunden
Working time :: Hours I * 0.3 Alle
Every Operating hours
Dvr6e de travail - Heures #) Heures de marche
000 .32-2 0 .5 Toutei les
as necessary Horas de servicio
1 Tiempo de robajo - Horas ~ - AA I Coda ;
030-11 9 0
030L129
030-064
o3ali q
030-076
009.34 7
0
00la346
3641 423
D36 5610E/000-32-2
SAFETY INSTRUCTIONS M . A . N . -DIESELJ 0 0 0
(Hydraulic Tensioning Tools) Arbeitskarte Nr .
0 WOrk Card No
Carte travail No.
000 .33
Tvleta trabal o
1 GEMEM
Hydraulic tools are subject to wear and tear when used frequently and over a long period of time, or
its parts may become damaged due to the ingress of dirt and incidental matter, the use of an unsuitable
hydraulic fluid, or incorrect handling (e .g . overloading) . 1he instructions and safety measures given
below should therefore be strictly observed for the prevention of accidents .
2 HAZARDS
The high pressures and forces occurring in hydraulic tools require that serious attention be given to
the following points in order to control inherent hazards .
1 . Fracture of highly stressed parts during pressure build-up (preloading, releasing and routine
testing) . Broken parts will be flung in the direction of the force applied, i .e . the extension of
the bolt axis or the axis of the hydraulic tensioning tool . Such a hazard exists during pressure
build-up, or when the hydraulic tool is under full tension and additional stress is induced by
heavy blows .
2 . Ejection of needle-like or razor-sharp hydraulic fluid jets due to leaky sealing elements, bursting
hoses, or fracture of fittings . Injury of the skin or the eyes is still possible at a distance o f
1 M.
3 . Rupture of crankgear bolts during engine operation with serious engine damage .as a result of over-
tightening or undertightening of bolts because the tightening process has not been carried out with
the necessary care . The correct bolt load will not be attained if, for example, the specified pre-
loading pressures are not observed, if the connection of a hose has been overlooked, the coupling
not properly engaged, or the tightening angle of the nut, determined by the number of holes, has not
been observed (the tightening process should therefore be closely checked and the bolt elongation
measured) .
3 SAFE1Y MEASURE S
The following points should be noted when mounting and operating the tool :
1 . Pressure limit (100 bar above preloading pressure) . Set specified preloading pressure at the
adjustable pressure regulating valve on the pump .
0
2 . The safety ring, (knurled, threaded ring at the coupling half) must be screwed up as far as it wil l
go after the hose coupling has been locked home .
3 . Hose connection fittings that are not being used must be sealed with blind plugs .
4 . only low-viscosity corrosion inhibiting oil is to be used as hydraulic fluid (no lubricating
oil, no fuel) .
4 SAFE HANDLUIG
The following instructions should be observed when using hydraulic tools :
1 . Study work cards carefully and observe recommendations .

2 . Clean supporting surfaces on engine and tools .
3 . Tighten safety ring on hose couplings .
4 . Insert blind plugs .
5 . Put on safety goggles .
40 D36 560CE 000 .33-1 4 .89 Page 1 of 2

6. See that the extended line of the bolt or hydraulic tool axis is cleared of all persons .
is
7. Keep safe distance to hydraulic tools and high-pressure hoses .
.8 . Raise pressure slowly at the pressure regulating valve, do not exceed the specified pressure .
9. For loosening threaded connection, do not exceed the respective tiahtenina pressure bv more
than 5% .
10 . No attempt must be made to loosen connections by heavy hammer blows when bolts, nuts or hydraulic
tools are under load .
11 . High-pressure hoses must not be kinked or sharply bent around edges (min . bending diameter 400 mm) .
12 . Condemn defective parts and replace by new ones . ,
13 . After each tensioning process, check if hydraulic piston is in its lowest position . In doing so,
the relief valve on the pump must be fully opened, if necessary, push piston back by hand .
5 FrORING AND MAIVIEVICE
1 . Hydraulic tools are best stored at room temperature of from 15 to 250C to minimise aging of plastic
components and to keep the hydraulic fluid in a sufficiently liquid state . Plastic seals should be
be protected from bright daylight .
2 . Dust, dirt, chemicals and liquids should be kept off the tools to protect the sealing surfaces from
damage .
3 . Me hydraulic cylinders and high pressure hoses should be vented and filled with the specified
hydraulic oil before being stored . 0
Notice! After relieving the pressure, do NOT disconnect the high-pressure hoses immediately, but
leave them on the pump for appr . 3 more minutes with the relief valve opened in order to
prevent an internal pressure build-up which would block the hose coupling . In such a case
the high-pressure hose cannot be connected . Men open non-return valve for pressure
relieve, using the press-on/press-off device (009 .026) (see illustration) .Do not use any
other tools must be used as they can damage the internal parts) .
4 . Do not kink hydraulic hoses, join coupling ends .

5 . When overhauling hydraulic tools, only original spares should be used, as proper functioning
often depends on properties which may be considered of little or no consequence, e .g . the
hardness of O-rings .
6 . The pressure gauges provided on the pump should be regularly checked for accuracy of readings .
U=
1 Press-on device (tool No . 009 .026 )

2 CEJN hydraulic nipple (on high-pressure hose)
3 Knurled screw (for clamping )
4 Knurled screw (for pressing on of valve) 0
D36 5600E 000 .33-1 4 .89 Page 2 of 2

40
MAINTENANCE M .A .N . DIESE L 00 0
M*AAL+ M Arbeitskarfe .Nr.

0 PRESSURE-AIR RECEIVE R Worke card
traa~ a, 0 .
(capacity over 2000 Itr ) Carl I t~
Torieto lrobajo No .
000 .35
LEGEND TOOLS REQUIRE D

1 Connection for ship's air 1 Set of open-end spanners,
2 Relief valve size 17 - 4 6
3 Connection fitting for 1 Set of ring spanners, size 17-45
relief valve 1 Hand pump with connectio n
4 Connection from compressor
5 Cleaning hole cove r
6 Connection to typho n
12 7 Connection to pneumatic syste m
8 Connection to engine (starting air)
9 Connection to pressure gaug e
10 Water drain pipe
++ 11 Water drain valv e
12 Water drain valv e
0 only provided with receivers designed

++ for vertical installatio n
only provided with receivers designed
for horizontal installatio n
11 LoLe . Depending upon requirements, connections 1, 2, 6, 7, 8 and 9 can

also be mounted on the sides of the receiver and the cleaning hole
10 cover (5) on the front face side .
GENERAL
The pressure-air receiver is designed for an operating pressure of rax . 30
bar (test pressure 45) bar) . 4hen opening these valves, they should be opened
9
all the way so that the valve cone seats against the sealing edge of the
spindle guide and leakage along the spindle is thus prevented by both th e
2 stuffing box and the back of the cone . When closing the valves, they shoul d
be screwed down only so far as is necessary to obtain the fully closed
position . Excessive tightening will damage the valve seat . The amount of
water f condensation precipitated on refilling the pressure air receiver
is considerable (cf sheet 3 .26) . Therefore, after refilling the receiver,
the water drain valve (11) must be opened and kept in open position until the
0 4 water has been completely blown out . The pressure-air receiver sh)uld be
cleaned at the specified intervals and be checked and/or pressure-teste d
in accordance with the regulations of the insurance companies .
START I NS POSIT I O N
Before commencing any work on the pressure-air receiver or the attache d
valves, the pressure must be completely removed . The easiest way is to open the water drain valve (11) until the
receiver is empty (check at pressure gauge) .
1 . Disconnect all pipes .
2 . Remove all valves, including water drain valve (11) and drain valve (12), if provided ;also remove water-drain
pipe (10) in vertically mounted receiver .
3 . Clean valves and, if necessary, disasseTble and overhaul on work bench . The relief valve is sealed and, if
damaged, the complete valve should be replaced .
4 . 01 ean inside and outside of receiver, remove rust and paint with rust-resistar-L paint, in .-1luding the e an i n g
hole cover (-.i) .
For prpssure testing, if necessary, fill receiver with water and pressure-iest with a oressure of 45 bar .
All connection fittings must first be closed with screw plugs or blind flanges . One of the blind flanges ~, .Jst
be equipped with a ccnnection for the hand pu,-.o .
0 :36 :UDO
` F- Arbes'szeit rre :: Slunden
A~
Alle Eelrjebsslund n
Working li Hours Every Operal " g hours
Durke de Ir a il -Heures 10 Toules lei Heures de rnar~he
T .ern " a av
de trabajo - Horas Cada as necessary Hams de serviclo
6 . Reinstall all valves, including water drain valve and the water drain pipe in the vertically mounted
receiver. Seals must be in good condition, (anneal copper seals, if necessary) . 0
7 . Reconnect pipes, refill pressure-air receiver with the use of the compressor . Check valves for tightness
at operating pressure by listening or with the use of a fluid .
Note . Water of condensation should be drained every time the receiver has been refilled, unless an
automatic condensate trap is provided . The temperature of the pressure air receiver should not be
much higher than the air temperature in the engine room .
is
036 56CO E / 000-35-1

HIGH-PRESSURE HAND PUMP M .A .N .-DIESEL 009
M+AL+ M (H KP 1 0-1000-5,5)
Arbeitskorte .Nr .
0 Cart
Wo".Ctr.~.
or , ~l
Tariela trobojo No .
009 .02
applicable work sheet . . . . .490.30

LEGEN D TOOLS REQUIRED Tool No .
3 .3 6 .4 61 29 62
29 Pump lever 1 High-pressure hand purnp . . . OOc, .41O
33 Release valve 1 Set open-end spanner s
61 Oil tan k 1 Socket screw spanne r
62 Screw cap
64 Safety valve
3640383
"ote
, .: The hiiyii-pressure harid pump is a product o f
Fa . MEBO-Metallwerke Boxdor li GmbH, D-6472 Alten-
stadt 1 Industriegebie t
SPECIFICATIONS
Operating pressure . . . . . . . . . . . . . . . . 1000 bar

Tank cap ;city . . . . . . . . . . . . . . . . . . . . . 5 .5 1
Usable oil volume . . . . . . . . . . . . . . . . . 5 .0 1
Weicht incl . oil filling . . . . . . . . . . 11 .4 kg
PI unger diameter . . . . . . . . . . . . . . . . . . 10 mr,
3
Oil volume per plunger stroke . . . . . 1 .4 cir
OPERATION
1 . Fill oil tank (61) with corrosion inhibiting oil (appr . 13 cSt/200'v) . Pump is read), for operation .
2. Connect detachable pressure gauge and high-pressure hoses to tensioning tool .
3 . Close release valve ('33) on pump and open screw cap (62) on oil tank one full turn (aeration) .
4 . Operate pump lever (29) until required pressure is indicated by pressure gaug.e .
Note : When admissible pressure is reached, the safety valve (64) will-open and return the pressure oil to the
oil tank (indicated by a hissing sound) .
5 . Release pressure, i .e . turn release valve handle (33) on pump slowly in anticlockwise direction = valve is being
opened (turning release valve handle in clockvise direction - valve is being closed) .
Caution! High pressure hoses must not be disconnected unless the pressure has been released (pressure gauge on zero)
Close screw cap on oil tank if pump is no longer used .
MAINTENANCE
1 . Use care to prevent dirt from entering the oil tank or the pump .
2 . Change oil charge every six months if pump is frequently used or the atmosphere is very dusty, but at least once
a year .
3 . Top up oil filling every time the pump has been used .
OPERATING DIFFICULTIE S
When reconditioning the pump or when ordering spare parts, ref6r* to sectional drawing on work sheet 490 .30 .
1 . Pump fails to draw up oi l

Sign : Pump lever does not remain in top position .
Remedy : 1 . Open screw cap on oil tank by one full turn .
2. Check oil level, refill if necessary .
Pump should always be in the hocizontal position to allow the oil-to flow to the pump head .
3 . Check oil viscosity (trouble may arise during suction stroke if the oil is too viscous . )
4 . Expell air pockets by operating the pump lever quickly several strokes with the release valve (33)
opened .
p . t. 0 .
036 561 Arbeitszeit - Stunden Alle getriebssfunden
Working time - Hours E~ery Operating hours
009 .02-2 Durke de tro~eil - Heures Toutes Jes as necessary Heuresde.mar~he
.
Tierripo de trabajo - Horas Coda Horas ervicio
I
2 . Purz does nzt build uo Dressur e
Sion : Pump lever rising after it has been pushed down .

G
Remedy : 1 . Clean delivery valve or replace ball and sea', if necessary .
2 .. Opei release valve and operate pump lever quickly several strokes to expell air pockets .
Purr. does-nOTL reac~ mayimuir Dressure

Sign : Safety valve leaking .
Remedy : Check if there is air in the plunger space, if fault cannot be removed return pump to manufacturer's
works .
Pressure drocoin o
Sion : Pressure drop is unmistakably indicated by pressure gauge .
Cause : Release valve does not close properly or is leaking . Oil is flowing back through the defective release
valve into the oil tank .
Remedy : ]-I' valve cannot be made to close tightly by retightening the release valve handle or by milling the
valve seat in the purr.p body, screw in a new release valve . 0
Suction valve leakin o
'icn : Pump lever is slowly falling back into its rest position .
r,vause : Suction valve is dirty or damaged .
Remedy : Remove and clean suction valve, replace if necessary .
E . Cuff leakin o
Sion : Oil leaking from pump plunger
Cause an d
Remedy : The cuff is a normal wear part and must be replaced .
D36 5510 E/ 009 .02-2 -

HIGH PRESSURE PUMP GERUPRESS M .A.N .-DIESEJ00 9
M *Aftk* M TYPE 6
Arbeitskarte-Nr .
Work card No .
0 Carte travail No. 009 .03
Tarjeto trabojo No .

High pressure pump . . . . . . . . . . . . . . . . . . . . . . 009 .312
High pressure hose, 2 m . . . . . . . . . . . . . . . . . 009 .326
High pressure hose, 5 m . . . . . . . . . . . . . . . . . 009-330
LEGEND
1 Push Button for 2 . pressure range
2 Indicator for 2 . pressure range
3 Oil filling Socket with Strainer
4 Air Connectio n
5 Air Pressure Gauge (0-10 bar)
6 Oil Pressure Gauge (0-1600 bar )
7 Oil Pressure Gauge (0-400 bar) in cover lid
8 Hose Connection (Clamping Device )
9 Front Face Plat e
10 Return Flow Connection
0 11 Casing Cove r
Arm A Turning Knob

B Relief Valv e
*,"g4 "IR44W
- I C Pressure Regulating Valv e
TECHNICAL DAT A
Type Designation . . . . . . . . . . . . . .. . . . . . . . . . . M188-1600
Code letter denotes the ratio of 4e air piston
with relation to the hydraulic piston .area an d
the maximum pressur e
Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 6 bar
max 15 bar
Test Pressure . . . . . . . $440 .0-0 . . . . . . . . . . . . * 1600 bar
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360x235x340mm
Weight, empty . . . . . . . . . . . . . . . * . .* . . . . *** .** 29 kg
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1
Oil Quality : Corrosion inhibiting oil, viscosity
0
approximately 13 mm 2/s - cSt/20 C
0
The spare parts list and the wear kit for the high pressure pump are
enclosed in the pump casing .
The high pressure pump features 2 pressure ranqLS-, each provided with
a pressure regulator limiting the maximum pressure in each range.
The second pressure range is switched on by pressing a push button
(1) . When switched off and the pressure being relieved, the pump
switches automatically over to the first pressure range .
Pressure Range 1 0 - 700 bar

Pressure Range 2 . . . . . 0 - 1100 ba r
Application : for tensioning screwed connections with the aid of a

connecting hose and hydraulic cylinder .
For testing fuel injection valves .
For testing relief valves .
SEQUENCE OF OPERATIONS 1, Taking in Operation
1.Unscrew plug in oil filling socket (3) and check oil level in pump, if necessary fill up with corrosion inhibiting
oil .
Note Oil should only be filled in through the strainer as foreign particles are likely to cause trouble .
PTO and Sheet 2
Arbeitszeit - Stunden Betriebssivnden
Co 036 5617 E Working time - Hours 1 . 0 .2 1 k~ Operating hours
u~ 009.03- 3 Durie de tra~Gil - Heures As Necessary Hevres
0 de marche
Tiempo de trobajo - Horas 2 . 0 .1 H raq de servicio
2 . Connect high pressure pump by means of connecting hoses
0-10b~'
700 1100 to hydraulic cylinder of tensioning tool or to injection

valve or relief valve to be tested. 0
is tf
For pressure testing the injection valve or the
relief valve, take pressure gauge (7) from holder
in the casing cover (11) and attach it to one of
the hose connections (8) .
11 -1 r-N I -I iA- I I I C!
~::: a * Connect air supply line to air connection M .
1110Cba6 17005 .0 4 . furn Knob tA) in clockwise direction so that the arrow
points outwards (Position 111) .
5 . Set pressure regulating valve (C) so that the pressure gauge (5) indicates approximately 1 bar.
6 . Open relief valve (B) (in anti-clockwise direction) thus releasing the pressure on the oil side of the high press-
ure pump .
7 . Check to see that all connecting hoses are properly connected and that all unused connections (8) are closed by a
blind plug (arrest slip sleeve of coupling with arresting ring) .
8 . Turn knob (A) through 1800 into the position shown in the illustration - pump is running up .
9 . Close relief valve (B) (by turning in clockwise direction) .
Note When tensioning tools are connected, the connecting hoses and also the tensioning tools must be completely
filled with oil and all air expelled.
10 . Turn pressure regulating valve (C) step-wise in clockwise direction until the desired pressure is indicated by the
pressure gauge (6) or by the plugged in pressure gauge (7) (this occurs with a certain time delay which is 0
dependant upon the size of the tensioning tool) .
11 . For switching on pressure range 2 over 700 bar to 1100 bar - depress push button (1) briefl y . Pressure range 2
is maintained by a self-locking system and indicated at the pneumatic indicator (2 ) .
Note The pump runs up to the pre-set oil pressure, pressure losses due to oil leakages are automatically
compensated by subsequent delivery .
SEQUENCE OF OPERATIONS 2, Putting out of Operatio n

Note When the pressure is being released, the selfrlocking system of the second pressure range is tripped and the
pump reset to pressure range 1 .
1 . Turn knob (A) so that the arrow points outwards causing the air side of the pump to vent (see under 4, Sequence of
Operations 1) .
L Open relief valve (B), releasing the pressure on the oil side of the pump (pressure gauge drops to zero) .
3. Disconnect quick-release coupling of connecting hoses .
Caution! On no account must the quick-release coupling be separated under pressure (danger of injury!), pressure
gauge (6 or 7 ) must be on zero.
Note When several screw joints are to be preloaded at the same pressure, the pressure regulating valve (C)
should be left in the set position and need not be readjusted . Check reading of pressure gauge ( 6 or 7 0
4 . Connect hose to return fl ow connection (10) and force corrosion inhibiting oil from hydraulic cylinder back into
the pump by turning the hydraulic nut on the tool .
5 . Detach connecting hose.
MAINTENANCE
Check appliances and connections of HP pump for tightness and recondition them if necessary . The recommended set of
spares for pump and pressure regulating valve are fastened in the back of the face plate (9) and will help keep the
pump in proper working condition .
The oil filling should be checked and, if necessary, replenished every time before the pump is put to use . The pump
should never be run completely dry to prevent it from drawing in air . About once a year the oil charge should be
drained and new oil filled in. The oil space and the oil filter should be*cleaned with each oil change .
For draining the water of condensation in the filter of the pressure regulator, remove face plate (9) (6 screws) and
screw in the screw plug at the bottom of the pressure regulator to allow the condensate to run off (tighten screw
plug after the water has been drained) .
D36 5617 E / 009 .03-3

0
Air Portio n Hydraulic Portio n
1 . Pump is not running at low pressure 0.7-1 bar 1. Pump is running without deliverin q
Cause : friction of slide valve seal too high Cause : inlet obstructed or air in suction pipe
Remedy : lubricate or replace O-rings of slide valve . Remedy : vent hydraulic system or remove obstruction
2 . Pump is not runninq or only slowly Cause : suction pipe leakin g
Remedy : check suction system
Cause : leak on air sid e
Cause : ball valve leakin g
Remedy : replace O-rings
Remedy : check and clean both ball valves
Cause : vents iced u p
Remedy : remove ice, warm pump up 2 . Hydraulic oil escapinq from silencer
Cause : dirt in silencer of ven t Cause : piston seal worn and leaking
Remedy : remove silencer, disassemble and clean
Remedy : replace seal
3. Pumo is not buildinq ui) pressure or stops in Cause : see disturbance on air side, point 4
dead centre positio n Remedy : examine hydraulic oil for contamination by
abrasives, replace oil charge if necessary
Cause : air in pump iced up or lack of air
Remedy : replace O-rings of slide valve or 3. Pump is not movinq throuqh dead centre
replace air pisto n Cause : insufficient supply of hydraulic oil
0 Remedy : check whether oil filter is clogged
4. Condensate escapina from silencer or vent
Cause : control valve leakin g
Cause : air filter filled with water Remedy : remove ball valves, check and renew if
Remedy : drain condensate from air filter necessary
036 5617 E
009.03-3 Sheet 2
0
0
CHECKING KSZ 70/125 B
M *Abk* N FOUNDATION AND BEDIPLAT E Aroeitskerle-Nr .
Work co-d No .
CameaJrc,ail No. .
0 To-let lrooo,o N 0 010 .01
applicable work sheets
009 .02
009 .03
000-3 0
1 Hydraulic tensioning tool . . . . . . . . . . . 009 .370
1 Hydraulic nut M 52x3 . . . . . . . . . . . . . . . . 009 .364
1 Sleeve . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . . 010.353
1 High-pressure pump, pneumatic . . . . . . . 009 .302
1 High-pressure pump, manual . . . . . . . . . . 009 .410
1 Anti-skid grate . . . . . . . . . . . . . . . . . . . . . 030.439
1 Set open-end spanner s
1 Set double-ended open-end spanners
1 Impact ring spanner, size 8 0
1 Tommy bar, dia . 10
LEGEN D
1 Bedplate 6 Nu t
2 Oil strainer 7 Protection cap
3 Foundation bolt 8 Dowel bol t
0
4 Chock 9 Throughbolt
5 Foundatio n
M .'A I NT E N A NC E
Check, at specified intervals, tightness of foundation bolts, including those which are hard to reach, to make
sure that the engine is firmly supported and to avoid distortion .
A21e! The foundation bolts on the driving and on the free end of the engine are the most vulnerable
. After a bad
weather period and after average or touching ground, the position of the bodplate should be closely chocked
and all screwed connections in the foundation and in the split joint of the bedplate retightened if necessary .
SEQUENCE Or' OPERATIONS 1 : Checkin g
1 . Thoroughly clean bedplate and oil pan at overhauls and whenever changing the oil charge .
2 . Check for cracks .
3 . When removing oil strainers, cover drain openi~g ; to prevent foreign matter from getting into the service tank
.
4 . After completion of the work, check inside of oil pan for tools etc . that may have been left behind .
5 . Chocks and stops should .~e regularly check6d .by sounding .
HYDRAULICALLY PRELOADED BOLTS FOR SECURING ENGINE ON FOUNDATION
0 SEQUENC'E OF OPERATIONS 2 : Start out checking on driving end
1. Remove protection cap (7) .

2. Apply sleeve and tensioning tool and connect to high-pressure pump .
3.
4.
5.
Screw on hydraulic nuts and asceriain pressure required for loosening the nut (6) .
P~eload to the specified torque (see work sheet 000 .30) and tighten .nut .
Remove tensioning tool, grease 'threads to prevent them from rusting and apply protection cap .
7"
Note : For releasing the nuts, a little clearance must be left in the tensioning tool to provide for the lift
required for loosening the nut and thus removing the bolt preload .
Note : Do not attempt to fix the bolt by welding on the bolt head (3) or the nut (6) !
Before stepping into the crankcase, the anti-skid grate (tool No 030 .43~) should always be pla~ed on the
top flange of the bedplaie .
P. t . 0 .
Co D30'5612
5 E ArDeits2eit - Stuncen Alle Betrier~SIunden
ins ; t,0 ~r 5 1
r-
010 .01-1
,
Working time - Ho.r s
Ou . te ce ravcil - Hevres
Toempo de Jrotio ;o - horas N E,ery
Toutes les
Coda
6000
0 :)e'Cl .
heures ce mcrche
Horci ce servici o
DESIGN WITH DOWEL AND THROUGH-BOLT S
0
009 .364
009 .370
. -* -e- .
1 010 .35 3
6 ~JLJW
C)
Lr)
(D
UD
Outer row of bolts Inner row of bolt s

0
77/7~11~~~`,Vlll
Ul
to
C')
D36 5612 E / 010 .01-11

CHECKING, REMOVING AND KSZ 7Q4 25 B 1,01 3
M *Atk+ N INSTALLING TIEROD S Arbeitskcrfe.Nr.
Work card No.
0 Cade rovail No . 013 .01
TarjetoI Irabojo No.
applicable work sheets. . . . . . 000 .3 0

009 .01
009 .0 3
013-383
1
009-352
000 .266
009-302
009.410
009-312
0
36051 3
1 Bearing screw 6 Sleeve 10

2 Nut 7 Counternu t
3 Washer 8 Cylinder jacket ,TOOLS REQUIRE D
4 Tierod 9 Hp hos e 2 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . 013 .390
5 Bracing Ecrew 10 Nut 2 Hydraulic tensioning tool . . . . . . 009 .390
2 Hydraulic nut . . . . . . . . . . . . . . . . . . 809 .352
Dimension A - 138 m m
2 Tommy bar, dia 16 . . . . . . . . . . . . . . 000.266
SEQUENCE OF OPERATION'S 1 : Checking bracing screws (5) 1 H61'der . . .. .. . . . . . . . . . . . . . . . . . . . . . 013 .333
1 . Loosen counternut . 1 Dial gauge. . . . . . . . . . . . . . . . . . . . . 009 .461
1 Eyebolt M 30x2 .. . . . . . . . . . . . . . . . . 000 .146
2 . If bracing screws need retightening, at first screws should
1 Protection sleeve . . . . . . . . . . . . . . 013 .37 8
be screwed in until they make oontact, then tighten all-screws
1 Hp pump, pneumatic . . . . . . . * . . . . 009 . 302 /31 2
to specified forcue (cf work sheet 000 .30) .
manual . . . . . . . . . . . . . . . . 009-410
0 3 . Relighten counternuts .
1 Feeler gauge. . . . . . . . . . . . . . . . . . . 000 .451
STARTING POSITIO N 1 Set doubleTend open-end wrenche s
1 Note pad
The bracing screws of a pair of tierods between 2 cylinders ar e
released and thread protection caps removed. All other tierods are properly preloaded .
I
Note : Correct tensioning of tierods requires a reliable pressure gauge on the hp pump and comparing of bolt
elongation under oil pressure with the dimension-specified (cf work card 000 .30) .
SEQUENCE OF OPERATIONS 2 : Checking tierod s
1 . Screw bearing screw (1) into tierod down to a distance of approx . 5 mm .
2 . Apply sleeves and hydraulic tensioning tools concentrically . Connect hp hoses and open relief valve on hp pump .
3 . Screw on h~draulic nut, thus pushing the piston completely into the hydraulic cylinder, then back off hydraulic
nut by 300 .
4 . Raise pressure in hydraulic tensioning tool cautiously, ~etermine and note down releasing pressure of both nuts .
5 . Back off nuts (2) by about 50dD (backing-off distance for releasing bolt load) .
6 . Release pressure and then preload to 30 bar.
40 9
01
D36 5612 E
p. t. 0.
Arbeitszeit - Stunden Alle Beiriebssfunden
013 .01-3 Working firne - Hours Every 6000 Operating hours
Durie de fravoil - Heures Touies les Heures de morche
Tiempo de Ircbajo - Horas AA I Ccda 12000 Harps de servicio
7 . Set holder with dial gauge on hydraulic cylinder of one tensioning tool and set dial gauge to zero .
B . Reset holder with ~dial gauge on second temioning tool and zero gauge only by turning the bearing screw il)
9 . Raise pressure in tensioning tool until defined elongation hal .beeh reiched (cf work sheet 000 .30) ,
note down pressure applied . 0
it). Reset dial gauge to first tierod, correct pressure judiciously until the same elongation has been reacheds
note down pressure applied.
11 . Tiqhten both tierods . applyino the greater pressure . Tighten nuts to snug fit by inserting the tommy bar through
the slots in the sleeves, then release pressure and remove both tensioning tools .
12 . Apply protection caps onto threads at the top of the tierods .
Attention! Compare pressure required for tightening Vith the pressure readings noted down for releasing the
two nuts .-Should either of the two values deviate by more than 10 %, retighten all tierods .
Note : In the event of the dial gauge failing, the elongation A 1 of a tierod can be measured with a feeler
gauge (see'illustration) . In that case, measure distances between hydraulic nut and hydraulic cylinder
at opposite sides at a preload of 30 % and at defined final preloading pressure and calculate the
difference between a 1 1 and al 2' The desired elongation,&1 - 0.5 (Al 'al is the mean-valua.
1+ 2
Taking two measurements (on opposite sides) and calculating the mean value are necessary in order to
compensate for any out-of-squareness between nut and contacting surface .
;3 . Tighten bracing screws as .under sequence of operations 1 .
SEQUENCE 0; OPERATIONS 3 : Installing tiero d
1 . Slip washer (3) over threaded top of tierod and screw down nut (2), obs~rving dimension A, fasten washer on
tierod with a piece of wire.
2 . Slip protection sleeve over threaded lower end of tierod and fasten it with hexagonal screw .
3 . Hang tierod with eyebolt on tackle and cautiously lower it into the cylinder
, jacket .
0
4 . Remove protection sleeve, screw on lower nut, using tommy'bar, and remove eyebolt on top .
Caution! When installing tierods, a sufficient lapse of time (several hours) should be allowed to ensure that
temperatures between engine and tierod have equalized . Should the engine be in an inclined position, the
tierod must be installed in correct alignment with the tierod casing .
SEQUENCE OF OPERATIONS 4 : -Tensioning tiero d
When replacing a tierod, all other tierods should remain in preloaded condition and need not be released .
1. Remove protection cap .
2. Screw bearing screw (1) into tierod down to distance of about 5 Mm .
3. Apply sleeve and hydraulic tensioning tool cent~ically, connect hp hose, open'relief valve on hp pump .
11. Screw on hydraulic nut, pushing the piston completely into the hydraulic cylinder, and preload tierad to 30 bar.
5. Place holder with dial gauge an hydraulic cylinder and set diallgauge on hydraulic cylinder to zero .
6 . Raise pressure in hydraulic tool to obtain specified elongation, note down required pressure and tighten nut to'
snug fit through the slot in the sleeve with a tommy bar. Release pressure (the elongation will be diminished by
the amount of thread settling) .
7 . Remove tensioning tool .
i" Apply protection cap to threaded top of tierod .
9 . Tighten bracing screws evenly and secure with counternuts .
SEOUENCE Or OPERATiONS 5 : Releasing all tierod s
1 . Remove protection caps from all tierods and loosen bracing screws .
2 . Mount tensioning tools on two tierods on engine drive end and release load .
3 . Mount tensioning
. tools and release load of first tierod pair on free end of engine, then on drive and and so forth
up to t he middle until all rods are relieved (if timing gear is on drive end, start there and continue in order) .
Note : When all tierods of the engi~ne are to be released in a single sequence of operations, tierods need not be
released in steps .
SEQUENCE OF OPERATIONS 6 : Preloading all tierod s
1 . Mount tensioning tool on the two tierods next to the timing gear and preload by applying an oil pressure of approx .
200 bar .
2 . Mount tensioning .tools on pair of tierods opposite the timing geir and apply load, then proceed alternating the
sides, until all tierods on drive end and on free end of the engine are preloaded (with engines having the timing
gear on the drive end, preload all tierods successively itarting from the drive end) .
3 . Determine end pressure in accordance with points 6 - 10 of sequence of operations 2 on one pair of tierods situated
between two cylinders, then again reduce preload to 200 bar .
4 . Preload all tierods in the above described order, applying the higher of the two pressures ascertained and then
proceed as described under 11-13, sequence of operations 2. 0
D36 5612 E / 013 .01-3
KSZ 70/125 B 01 5
REMOVING AND INSTALLING
M *Atk+ N DIAPHRAGM CASING ArDeitskc~te .N,.
Work card No . .
0 Carte tro~oi : No 015 .01

Tcr)ei i rcbojo No .
TOOLS RErlUIRED Tool No .
1 Supporting cross . . . . . . . . . . . . . . . . . 015 .373

1 Lashing plate . . . . . . . . . . . . . . . . . . . . 01E .36E
5 Shackles . . . . . . . . . . . . . . . . . . . . . . . . . 002 .4-73
1 Set open-end wrenche s
LEGEN O
1 Rope
2 Fl ang e
3 Diaphragm casing
4 Engine fram e
STARTIN .) F~S[1`10 ;,'

Piston, pis1on rod and stuffing box are removed .
SE,X;E%!^,E OF OPERAT IDNS I : Removin g
1 . Sst crosshead to BDC .

2 . Re :."Ove flance (2) of
Hing box andDiston rod together
fasten supportingcross stutwith plate
lashir . g to
diapr,ragm casing (3) .
1 . Hang diaphragm casing with lashing plate on tackle .
0 Rsmove round-'section seal ring at the LOP 0 .1"The diaphragm casing and the flange of the drain pipe on the
exha,.,st side, paying attention to the one-piece seal ring .
5 . Screw out hexagon screws in flange at lower End and oil catch plate, with the casing supported from the hoist
.
6 CaUHOUSly lower diaphragm casing into crankcase, use second tackle to swing it round 0
90 and remove it side-
ways from the engine frame (4) .
I
Note : Before installing the diaphragm casing, insert one-piece seal ring for sealing at the top .
Recommendation : New seal rings should be used throughout .
SEQUENCE 0: OPERATION'S 2 : For installing the diaphragm casing, reverse sequence of operations
.
0
I
D36 5612 E ArDedszeit - Slunden Alle Beiri .n.,v,ndvi
015.01-2 '.Yorkinq limt - Ho--rs E~ery Operating hourS
.-JeIreS Ce MCrChe
Duree ce trc .,oi?
Tiempo de Imbojo
-
-
Heures
HDros kh
Touies le s
1 Caja as necessary Ho,as Ce ser,ic .o
0
0
KSZ 70/125 B 015
CHECKING AND MAINTENANCE 1
0 M *Atk* N Arbeitskarte-Nr.
Work card No. .
OF PISTON kOD ~TUFFING BOX Corte travail No
Tarieto trabojo No .
015 .02
aPPI-icab Tle work sheets . . . . . . 015.01
015 O~
015 :0
000-30
1 Installing and removing tool . . . . . . . 015 .375
1 Suspension tool, complete . . . . . . . . . . 015 .374
1 Torque wrench . . . . . . . . . . . . . . . . . . . . . . 008 .002
1 Socket wrench, size 24 . . . . . . . . . . . . . 001 .757
1 Set double-ended open-end wrenche s
LEGEND
1 Castellated nut, inner 13 Scraper ring
2 Castellated nut, outer 14 Chamber rin g
3 Holder rin g 15 Seal ring
4 Diaphragm casing 16 Press rin g
5 Seal rin g 17 Round-section seal ring
6 Castellated nu t 18 Ring casin g
7 Stuffing box gland 19 Dis c
8 Stu d 20 Chamber rin g
0 9 Stuffing box casing 21 Cylinder cover bolt
4 3 2
10 Seal rin g 22 Locating scre w
INSPECTION
11 Gasket 23 Drain pip e
Check piston rod for scoring during break-in of a new engine
12 Guide ring 24 Drain pipe
and after replacement of seal and scraper rings, if necessary
T,qhteninq torque nut (6) see work card 000 .3 0
recondition rod surface with oil stone or polishing ClUL11 .
Remove atrasive material fror, stuffing box after engine break-in
MAMENANCE
Stuffing boxes should be disassembled and cleaned at specified inteevals and the various rings should then be chocked
for wear . The ends of the ring sections must not abut, if they do,they must be remachined or replaced . When dis-
assembling, do not confuse the ring sections and the associated chamber rings . Scraping edges of seal and scraper
rings mus' be checked for damage and, if necessary, cautiously reconditioned with polishing cloth . Before re-
installation, check wear pattern of the individual ring sections on the piston rod with touching-up paint and replace
rings if they are found to be distorted .
Before reassembly, clean all parts in fuel oil and dry with low-pressure air . If piston and piston rod have been
removed, assemble stuffing box on the piston rod outside the engine as it will facilitate assembly . Secure all screw
connections carefully .
Nominal dimensio n Clearance Max . clearanc e
when ne w
0
220 H7
1 .5 0 .3„
0.8 ;0.3„
2 .5 -0 .3
+0 .01
E 14 .96
-0 .02
F 0 .11-0 .1 8 0 .40
G 15 .08 +0 .02
H 11 .86 +0 .0 2
-0 .01
0 .10-0 .1 5 0 .30 AF
11 .98 +0 .02
2
2
3
2 .5
4 I
17.05+0.02
0.21 - 0 .29 0 .40
17 -0 .16
is -0 .22
- Stunden Alle Betriebsstunden
Ak
Arbeitszeit
036 5612 E Working lirne H urs Ever y Operating hours
Heures de marche
P02 015 .02-3 Durie de travOil - Heures Toutes les
Tiempo de trobalo - Horas Cada Horas de servicio
C4 I
0
0
REMOVING AND DISASSEMBLING KSZ 70,A 25 B 01 5
PISTON ROD STUFFING BOX AroeITSKarte-Nr.
Work card No.
0
Corte travail No .
Tarleta trcbajo N 015 .03
applicable work sheets . . . . . . . 015-01
015 .0 2
TOOLS REOUIRED Tool No .
1 Clamp for installing and removing . . . 015-375

1 Set double-ended open-end spanner s
LEGEND
1 Castellated nut (inner) 9 Stuffing box casing

2 Castellated nut (outer) 24 Drain pip e
3 Holder ring 25 Drain pipes
4 Diaphragm casing 30 Clamp piece
6 Castellated nuts 31 Screw
8 Stu d
Note : The complete stuffing box can be removed
upwards together with the piston rod .
S EEOUENCE OF OPERATIONS 1 : Removing upwards
0
1 . Remove drain pipe (24) .
2 . Unscrew the inner four castellated nuts (1) in holder ring (3) .
3 . Fasten two-piece clamp (30) on piston rod under the stufling box .
Note : Mhen fastening the clamp piece on the piston rod, make sure that the contacting surfaces are spotlessly
clean and that no foreign particles are clamped in .
4 . Remove stuffing box in upward direction by moving the piston with piston rod towards top center .
Note : The complete stuffing box can also be removed downwards .
SEOUENCE OF OPERATIONS 2 : Removing downwards

1 . Remove drain pipe (24) and 2 drain pipes (25 )
2 . Unscrew the four cuter castellated nuts (2) in holder ring (3) .
3 . Fasten two-piece clamp, (30) on Piston rod below stuffing box and bolt it to the stuffing boy .
No'e
'Lal: When mounting the clamp piece on the piston rod, make sure that the contacting surfaces are spotlessly
clean and that no foreign particles are clamped in . Before loosening the clamp piece, secure stuffing
box by means oi a soft rope . Do not grip with the fingers below the stulfing box !
4 . Remove stuffing box in downward direction by moving the piston with piston rod towards bottom center by means
0 of the turning gear, see that stuffing box is not being unseated from the clamp piece .
Note : The ring pack is held together by two cheese-headed bolts (21) and the complete unit can be removed
downwards !
SEOUENCE OF OPERATIONS 3 : Removing and disassembling ring pack

1 . Remove drain pipe (24) .
2 . Loosen four castellated nuts (6), unscrew two nuts completely .
3 . ~bunt clamp (30) on piston rod with the running gear in mid-position between TDC and BDC.
4 . Connect clamp (30) and stuffing box gland (7) by means of four screws (31) .
5 . Unscrew two castellated nuts (6) and remove complete ring pack by moving the crankgear towards bottom center .
6 . Unscrew two cheese-headed bolts (21) and disassemble ring pack (watch toothed washers!) .
To disassemble, start with topmost seal ring and note ring order and the way they are fixed .
Note : The ring sections, rings end asseciated chamber rings should be reassembled in the same position as when
removed . The individual parts should be reasssembled on the support, the fixing screw (22) should be
left in the stuffing boy gland . The two through-holes forthe cheese-headed bolts, asymmetrically arrange
to the fixing screw, should be one above the other .
D36 5612 E
C, Aroeitszeit - Slunden Alle Betrieossfunden
,
Workirg time - Hours Every ODe, at ng hours
015 .03-2 D rie oe travail - Hevres Toules les 12000 Heures ce mc~~he
cl; TjeMD0
u de trabojo - Horcis Cada Ho ras de serviio
01
0
0
ASSEMBLY OF PISTON ROD KSZ 70/125 B 1 01 5
M*AL+M STUFFING BOX Aroeitskarte-Nr.
Work card ~4o
Ccrle tro~a
', ~0 .
015 .04
0 Tarleto trcba;o No.
applicable work sheet . . . . . . . 015 .0 2

1 Assembling device, complete . . . . . . . . . . . . . . . . 015-374
5 Hexagonal nuts M 1 6
01 ; .
4 Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 015-374-1
~ oil " 1 Eyebolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 015.374-2
1 Set of open-end spanner s
1 Set of double-ended open-end spanners
1 Feeler gaug e
STARTING POSITIO N
All parts are in clean condition . If new rings are fitted, check
whether they will move freely in their chamber rings and see
that specified gap clearance between ring segments is maintained .
Also check bearing pattern of ring segments on piston rod with
,C>
touching-up ink . The ends of the ring segments must not abut .
20
The rounded ends should slope neatly towards the sealing surface .
0
The scraping edges should be distinctly broken within the range
of the rounded off ends of the ring segments .
For measuring the axial clearance of all individual parts, clamp complete set into holder outside the engine . Seal
and scraper rings should be movable by hand in radial direction, if not they must be remachined .
For clearances see work sheet 015 .02 .
1 . Insert the 2 stuffing box gland halves and fasten them loosely to the clamp piece (30) by means of the 2
screws (31) .
2 . Solt stuffing box gland together with 2 dowel bolts and secure with castellated nuts .
3 . Place the 2 halves of the chamber rings on top, paying attention to the locating screw .
4 . Fit 4-piece scraper ring and tubular spring .
5 . Apply 2-piece disc .
6 . Install 4 piece scraper ring and tubular spring .
7 . Place the 2 halves of the chamber ring on top .
8 . Install 4-piece scraper ring and apply tubular spring .
9 . Apply 2-piece disc .
0 10 . Push 2-piece ring casing over the former .
11 . install 2 O-rings and check tension and whether they are in good condition, if ring casing had been dis-
assembled .
12 . Put both 3-piece seal rings in place, one on top of the other, paying attention to the locating pin .
13 * ' Install ~-piece press ring and tubular spring .
14 . Mount 2-piece chamber ring .
15 . Install 4-piece scraper ring and tubular spring .
16 . Place 3-piecee seal ring round piston rod and secure it by tubular spring .
17 . Insert seal ring, if necessary a new one .
18 . Place 2-piece chamber ring round seal ring and push both down onto the ring pack .
19 . Clamp complete ring pack together by means of the two cheese-headed screws, do not forget toothed washer .
The ring pack is thus completely assembled .
20 . Turn ring pack into the correct angular position, paying attention to the locating pin and move it up into the
stuffing box casing by switching on the turning gear .
21 . Screw4 castellated nuts onto threaded bolts, tighten them crosswise and secure with lockwire .
22 . Unscrew screws (31) and clamp piece (30) and remove them from the piston rod .
23 . Reconnect discharge pipe and secure screwed connections with lockwire .
0
D36 5612 E ArDeit$Zeit - Stunoen [TA
TCa~
OIJle
I ry
Ev
Coda Betrieossfunden
,
Working firne - Hours Operal ng hours
C=)
9 015-04-3 r6e de trcwoil - Heures 4 .5 a r, I. 12000 Heures de mQrche
cy, TieniDo
Du de trcbojo - Horas 10 Coda Horo% ce servicio
0
0
101 7
CHECKING AND DISASSEMBLING K4-6SZ 70A 25 B
0 M *Ak+ N THRUST BEARIN G
Arbeitskarte-Nr .
Work card No .
Carle travoil N 017 .01
Torieto irabojo No .
5 017.372
LOOLS REQUIRED Tool No .
1 Driver . . . . . . . . . . . . . . . . . . . . . . . 017 .372
2 Eyebolt M 24x2 . . . . . . . . . . . . . . . . 000 .145
1 Eyebolt R 1 1/4" . . . . . . . . . . . . . 000 .16 6
1 Thrust bearing flange 8 Thrust pa d 1 Dodecagonal slugging box wrench, size 65
2 Bol t 9 Bearing casing 1 Set single-head open-end wrenche s
3 Thrust pad holder (408 kg) 10 Straight pin 1 Set double-head open-end wrenches
4 Rop e 11 Shi m 1 Rop e
5 Bearing shell (96 kg) 12 Bearing cover (172 kg)
6 Hexagon scre w 13 Cover
7 Holding bracket
CHECKING
The bearing clearance is measured in the same way as the main bearings ; the bearing clearance is adjusted
by means
of graded thickness washers in the split-joint (minimum distance of shim edge to joint edge in extreme inner position
at lanef n ') . .I
0
B C D
Nominal clearanc e 0 .15-0.175 0.30-0 .3 5 1 .0 0
Max. clearance 0.25 0.45 1 .50
I
Measuring axial clearance with enoine-atstand'still

1 . Drain oil charge completely .
2. Remove cover.
3 . Check condition of thrust pads .
4 . Measure axial clearance, bearing in mind that thrust pads are filtable .
Measuring axial clearance during engine operatio n
1 . Measure position of coupling flange with engine running in ahead and then in astern direction
.
2 . The bearing clearance is the difference between the two measurements .
0
. t. 0
036 5612 E Arbeitszeit Betriebsslunden
- Stunden Alle
cli 017.01-3
9
U1%
Working time
Durie de travoil
-
-
Tiernpo de trobajo -
Hours
Heures
Horas kk Every
Toutes les
Cada 24000
Operating hours
Heures de morche
Horns de ser~icio
DISASSEMBLING THRUST BEARIN G
0
STARTING POSITION
Drain oil charge, remove cover (13) and lateral covers of t iming gear casing .
SEQUENCE OF OPERATIONS 1 : Removin g
1 . Lift off bearing cover (12) and upper bearing shell, using eyebolts, rope and tackle .
2. Extract straight pins (10) .
3. Fasten driver to lower bearing shell (5) and rope on thrust pad holder (3) (cf illustration) .
4 . Roll out thrust pad holder (3) together with bearing shell (5) with the aid of the rope, lift off and place
on wooden supports .
Notice! If the turning wheel is of the very heavy type, it may become necessary to relieve part of the load
sustained by the lower bearing shell . To do so ., eithe r
- place a roller-mounted support under the shaft coupled to the turning wheel, the support should be
close to the wheel, and raise the support until the load on the lower shell is relieved, o r
- fasten a rope to a suitable beam in the engine room, located above the shaft coupled to the turning 0
wheel, and run rope below the shaft, close to the wheel, and up again and fasten it to the engine
house crane . When using a wire rope, protect shaft by means of a strip of sheet-metal (lubricate
surfaces metal strip to shaft with grease) . Haul rope tight with crane until load on bearing shell has
been relieved .
Cauti,on! Do not exceed admissible max . crane load !
If the engine must be turned with the turning wheel shaft supported from above, it should be turned
in the direction that will not impose additional load on the crane due to frictio n
- Circumstances may require that the above two methods are applied at the same time .
5 . Remove bolts (2), take out thrust pads (8) and clean all parts and the bearing casing .
6. Unscrew nuts, lift off holding bracket (7) with the use of eyebolts, rope and tackle and place on wooden
supports .
7 . Extract straight pins from thrust pad holder (3) .
8 . Fasten rope to thrust pad holder (3) and roll out thrust pad holder with the use of the tackle and put it
down on wooden supports .
9 . Extract bolts (2) and take out thrust pads, clean all parts .
lote- The graded thickness washers between the two bearing shells are only changed when the radial bearing
0
clearance must be adjusted.
Recondition or replace damaged thrust pads, smooth thrust bearing flange - if this is not feasible,
engine should only be run at reduced load .
SEQUENCE OF OPERATIONS 2 : To install thrust bearing, reverse sequence of operations outlined abov e
Note position of locating holes !
To tighten bearing cover bolts, at first tighten bolts on both sides until bearing cover seats squarely on
the crest of the upper bearing sfiell, then tighten bolts by a further tightening anole of 1200
Measure axial and radial bearing clearances and enter in engine log .
D36 5612 E / 017-01-3

CHECKING AND DISASSEMBLING ~7-1 OSZ70/1 25B 01 7
0
M*Ak* N THRUST BEARIN G ArDeitSkcrfe-Nr.
Work card No .
Corte travail No . 017 .01
Tarieto trobwo No.
000.16 6 00 0 .14 5 2pplicable work sheef . . . . 000 .3 0
10 11 1 12 1 11 3
LEUEND TOOLS REQUIRED Tool No .

9 8 7 6
1 Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 017 .371
1 Bearing shell (96 kg) 8 Thrust pad
1 Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 017 .372
2 Hexagonal screw M 20x2 9 Straight pin
2 Eyebolt M 24x2 . . . . . . . . . . . . . . . . . . . . . . . . . 000 .145
3 Thrust pad holder (403 kg) 10 Shi m
1 Eyebolt R 11/4, . . . . . . . . . . . . . . . . .. . . . . . . . 000 .166
4 Hexagonal screw M 24x2 11 Bearing cover (172 kg)
1 Oodecagonal slugging box wrench, size 6 5
5 Thrust bearing flange 12 Cover (254 kg )
1 Set single-head open-end wrenches
6 Bearing casing 13 Holding bracket,
1 Set double-head open-end wrenche s
7 Bol t
CHECKING
The bearing clearance is measured in the same way as the main bearings ; the bearing clearance is adjusted by
means of graded thickness washers in the split-joint (minimum distance of shim edge to joint edge in extreme
inner position at least 0 .2 mp) .
8 C 0
0
Nominal clearanc e 0 .15-0 .17 5 0 .30-0 .3 5 1 .00
Max . clearance 0 .25 0 .45 1 .50
0 I
Measurinq axial clearance with enqine at standstill
1. Drain oil charge completely .
2. Remove cover (12) .
3. Check condition of thrust pads .
4. Measure axial clearance, bearing in mind that thrust pads are tiltable .
Measurinq axial clearance durina enqine operatio n
1 . Measure position of coupling flange with engine running in ahead and then in astern direction .
2 . The bearing clearance is the difference between the two measurements .
p.t. 0.
D36 5612 E Arbeitszeit - St-unden Alle Beiriebssfunden
Working time - Hours E~ery Operating hours
Oct
r_ 017 .01-4 Durie de t r(wail - Heures Toutes les He res de marche
CA
Tiempo de Ircocio - Horas Cada 24000 Harps
0 de servicio
DISASSEMBLING THRUST BEARIN G 0
START I 'NO POS IT 1 101
Oil charge has been drained, cover (12) removed .
M'UENCE 01 OPERATION'S 1 : Removin g
1 . Lift off bearing cover (11) and upper bearing shell, using eye bolts, rope and tackle .
2 . Extract straight pins (9) .
3 . fasten drivers with screws to thrust bearing flange and to lower bearing shell .
4 . Switch on turning gear to roll out thrust pad holder (3) together with bearing shell (1), attach rope,
lift off with tackle and place on wooden supports .
5 . Remove bolts (7), take out thrust pads (8), clean individual parts and the bearing casing .
6 . Unscrew nuts, lift off holding bracket (13) with the use of eyebolt, rope and tackle and place on wooden
supports .
7 . Extract straight pins from thrust pad holder, turn driver on thrust bearing flange through 1800 and roll out
thrust pad holder by switching on turning gear, lift off and place on wooden supports .
8 . Extract bolts (7) and take out thrust pads, clean all individual parts .
0
Note : The graded thickness washers between the two bearing shells are only changed when the radial bearing
clearance need be adjusted.
Recondition or replace damaged thrust pads, smooth thrust bearing flange - if this is not feasible,
engine should only be run at reduced load .
St"LlIJENvE OF OPERATIONS 2 : To install thrust bearing, reverse sequence of operations outlined above
Note position of locating holes !
To tighten bearing ccver bolts, at first tighten bolts on both sides with sDecified torque until bearing cover
seats squarely on crest of the upper bearing shell, then tighten bolts by a further specified fightenino anqle .
Measare axial and radial bearing clearances and enter measurements in engine log .
0
I
036 5612 E / 017 .01-4

dZ 01 9
CHECKING AND REMOVING
M*A&*M ECCENTRIC BRACING Arbeitskorfe-Nr.
Work card No.
Corte trovai; No . 019 .01
Tarleta trobojo No.
0
TOOLS REHIRED Tool flo .
1 Torque ..,rench 80-300 Hm . . . . . . . . 006 .003
1 Socket wrench, size 32 . . . . . . . . . 001 .700
Slugging box wrench, size 6 5
1 Double-end open-end wrench, size 24x27
1 Double-end open-end vrench, size 300 2
1 Slide laquer spray Optimol-Opticoating TL
1 Molycote paste G n
LEGEN D
1 Plate spring 5 Bearing plate
2 Eccenter bolt 6 Shi m
3 Ilarkin g 7 Clamp piec e
4 Scale
SEQUENCE OF OPERATIONS 1, Checkin g

0 Check preload of plate springs (1) at regular intervals .
1 . Remove cotter pin in castellated nut and loosen nut by use of open-end wrench size 32 .
2 . Retighten castellated nut of plate springs by use of torque wrench and socket wrench, applying a torque of 60 Nn,
Note : The spring load can be ascertained by measuring the spring deflection vith the use of a vernier gauge .
The spring deflection at the specified torque will be 3.2 mr. .
Rith this adjustment, it is ensured that the Eccenter bolt (2) will be in steady state when the ship is
making vay in calm waters . Marking should then line up with the graduation line in the middle of the sc .,1-
(4) engraved on the cc .-enter bolt .
SEOUENCE OF OPERATIONS 2, Maintenanc e
1 . Release spring load by unscraiting the castellated nut on top of the plate springs (1) .
2 . Unscrew 4 castellated nuts of bearing plate (5) and remove bearing cover .
3 . Remove cc .-enter bolt (2), if necessary together with bearing plate (5) .
4 . Degrease all bearing point .- (drill hole and pin) by use of a solvent and allow them to dry .
5 . Spray on a thin and even coat of sliding laquer spray Optimol Opticoating TL from a distance of approxirp . :tely
15-20 cm .
Flotc : Curing tire at room temperature : 5-10 minutes .
Recommended thickness of layer : approx. 10 m
Observe manufacturer's recommendations !
0
6 . When reassembling, check to see ihat the eccenier bo]ii ~~) in ~Ihe bearing plates (5) has no clearance, if
necessary remove any pla~_by changing the shims (6) .
7. Coat plate springs (1), threads and nut seating surfaces with Molycote paste Gn .
8 . Reinstall c center bolt and tighten bearing plate nuts .
9 . Tighten castellated nut on plate springs by use of torque wrench (cf Sequ~.nco of Operations 1) .
10 . Again secure all nuts by cotter pin .
0
Belriebsslunden
cli 036 5610 E Arbeitszeit - Stunden Alle Operatin, hour$
Working lirne Hours Every
019 .01-1 Durte de tr(wail - Heures
Tiernpo de Irobajo - Horas
Toutes leg 24000 Heures de Marche
Horas de servicio
1 kkA Cada
0
0
KSZ 70/125A+B 1 02 0
CHECKING CRANKSHAFT
M*AA+N SEALING OIL PASSAGES Aroeitskarte-Nr .
Work cord No . .
Carle .travail N 0 020 .01
lrcbo,o No,
0 Toriet
applicable work sheets . . . . 000 .10

000 .19
I
000-30
TOOLS REQUIRED tool No .

1 Crankweb deflectio n
gauge . . . . . . . . . . . . . . . . . . . . . 020 .351
1 Pencil and note pa d
LEGEN D
1 Twist marking
2 Measuring poin t
0 2
STARTING POSITION
Crankgear of all cylinders assembled and tierods correctly preloaded .
CHECKING CRANKSHAFT
1 . Check position of crankweb with relation to shrink-fitted journal at twist marks whenever crankcase is open
in order to determine possible twisting of the shaft at an early stage .
2 . Measure crankweb deflections, i .e . distance between a pair of webs at the measuring points in four crank positions
with the aid of the deflection gauge and enter in engine log .
Admissible maximum difference measured between a pair of crankwebs 0 .45 m m
Note : An example of measuring crankweb deflections is given in work sheet 000 .1 0

On-board measurements will diff~r from those taken in the manufacturer's shop, but they must not
exceed the admissible maximum . Measurements should be taken with the engine in cold and i n
warm condition and under various ship loads . Deviations from correct alignment of the crankshaft
0 will cause variations, increase and decrease, in the distance between a pair of webs at the open
end of the crank during a full turn of the crankshaft . Crankweb deflections (particularly those
of the crank of cylinder No 1) should be checked whenever parts of the thrust bearing or propeller
shaft bearings are removed .
WORK ON COUNTERWEIGHTS
If the crankshaft is fitted with counterweights and any work must be done on them, only trained personnel should be
entrusted with such work . The following points should then be strictly observed :
1 . Coat threads of studs with LOCTITE Type 242 (cf work sheet 000 .19), screw stud into crankshaft and tighten it
to specified torque (cf work sheet 000 .30) .
2 . Place counterweight into position and coat threads and nut supporting surface with LOCTITE Type 242 .
3 . Screw on nuts and tighten them to specified torque (cf worksheet 000 .30) .
0 p. t. 0.
036 5612 E Aroeitszeit - Slunden Alle Betriebsslunden
Co 020 .01-1 Working time - Hours Every Operating hours

Heures de marche 0
Durie de travail - Heures Toutes les
Tiempo de trabojo - Harps Coda 6000 Harps de servici
SEALING OIL PASSAGES IN CRANKPIN
(Crankgear removed in emergency operation ) 0
2 020 .3bO 3 applicable work sheet . . . . . . . . . . . . . . . . . . 050 .08

TOOLS REHIRED Tool No .
2 Clamping strap-halves . . . . . . . . . . . . . . . . 020 .360
1 Dodecagonal slugging box wrench, size 80, 115
1 Socket wrench DIN 3124-36x2 O
1 Adaptor DIN 3123 A-20x12 .5
1 Ratchet DIN 3122 C-12. 5
1 Socket A 44-2 2
1 Socket S 533-D41x2 O
1 Spanner socket DIN 3124-27xl2 .5
1 Extension DIN 3123 B-12 .5x12 5
LEGEN D 0
1 Oil outlet opening 5 Pin

2 Crankpin 6 Pi n
3 Axial oil hole 7 Worm screw M1 2
4 Clamping strap half 8 Round-section seal ring
9 Scre w
STARTING POSITION
Running gear removed .
1 . Place clamping strap halves (4) over cil outlet opening (1) so that the screws (9)
with the round-section
seal ring (8) come to lie in the oil,holes .
2 . Pretension both halves and secure worm screws (7) with lockwire .
Note : At general overhauls, when covers, oil conducting tubes and screw plugs of axial passages
(3) have
been removed, make sure that no foreign matter remains in the oil ducts . The castellated nuts of the
threaded rods and the screw plugs in the journals must be carefully tightened and secured .
40
0
D36 5612 E / 020 .01-1
MEASURING CRANKSHAFT
KSZ 70/125 B 021
M *AJL* N ALIGNMENT
Arceitskarle-Nr.
Work Cara NS .
Came travail No. 021 .01
0 ,c, .e,c t,cdc,o No .
TOO ; S REQUIRED Tool No .

021 .405-2 1 Measuring tool, COTPle'Le . . . . . . . . . . . . 021 .40c.
021 .405-1 1 Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 021 .405-1
Micrometer screw . . . . . . . . . . . . . . . . . . . . 021 .405- 2
1 1
1 Extension rod . . . . . . . . . . . . . . . . . . . . . . . 021 .40o-3
021-405-4 1 Plate ------------------------------- 021-4n.S-4
1 uuioe Tuoe . . . . . . .. . . . . . . . . . . . . . . . . . .
021-405-3
1 Set of feel er gauge s
;~"X 2 1 Open-end wrench, size 55, 60
LECEND
3
4 1 Bearing cover
G, 2 Bedpl2-1, e
3 Main bearing
4 Shaft journal
0
SEO'~,ENCE OF OPERATIONS
1. Rem.ove luboil pipe between 11-he two bearing covers (1) .

2. Insert bridge between the two bearing covers, flittirg it on the bedplate .
3. Measure dittance down to shaft j .-urnal (L), inserting the extension rod of ths imicrometer screw through
the oil hole in the upper bearing shell (3) . Be sure no- to measure down into the oil hole in the journal .
Note : Plate fastened -.on bridge .

Measurements taken of ne .; engine are staTped on the plate fixed on .Lhe bridge .
The difference between these measurements and the measurements taken shows how much the journa l
has sagged . After reDlacing a bearing shell, determine position oil shalt journal using the measuring
Itool and determine crankweb deflections of adjacent cranks .
This Measuring tool is also used for checking the thrust bearing .
The bearing clearance oil the assembled bearing is measured with long feeler gauges and the guide tube .
0 Measuring point 6 C
Nominal clearanc e 0 .15-0 .17 5 0 .30-0 .3 5

Max . clearance 0 .25 0 .4 5
B
36 40 346/ 2
Note : The shell thickness (F) can only be measured after removal of the bearing shell .
The thickness of the new bearing shell is stamoed on the front face side of the bearino shell . ,
THE MEASURING TOOL IS SUPPLIE D

ON SPECIAL ORDER ONLY
40
D36 5612 E Aroe .Weit - Siancen Alie Beiriet5stunden
\Norkmg time - Hovr s Every Operating t1crs
021 .01-2 1 Duree ce travail - He~re s
TiernDo de trcbojo - horas
Tovies les
Coda 24000 He~res ce marcte
Hares oe se-~icio
0
0
RELEASING AND PRELOADING KSZ 70/125 B 02 1
M *A&* N MAIN BEARING BOLT S Arceifskortt-N . .
Work cc . No . C .
Corte Ira " N 021 .02
0 Tcrjeic trct)oic
'o*1 No .
applicable work-shee-LS . . . . . . . . . . . 000 .30

009 .02
009 .302 009 .03
009 .41 0 000 .264 021 .1.2 2
009.37 0
-3
4
--000.264
021 .407
0 36 40 363/1
2Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . 021 .404
2Hydra~,lic tensioning too] . . . . . . . 009 .360
Tom-my bar, dia . 10 . . . . . . . . . . . . . . 000 .263
'2
2Hydraulic nu . . . . . . . . . . . . . . . . . . . . 009 .368
2 1
I EG
IND 1Hp pum .p, pneumatic . . . . . . . . . . . . . . 009 .302
L C
manual . . . . . . . . . 6 . . . . . . . 009 .410
I Bearing cover 3 Nu' 1 Set open-end wrenche s
2 Bearing cover 4 Stud'- 1 Set double-head open-end wrenche s
STARTING POSITIO N
Protection cap of tensioning threads removed .
SEQUENCE OF OPERATIONS 1 : Releasin g
'I . Mount the two tensioning tools on the nuts of one bearing cover (1), connect hoses to Dump and release bearing.
bolts (cf work sheet 009 .031009 .02) .
2 . Mount tensioning tools on the other bearing cover (2) and release bolts .
Note : For releasing bolts, there must be a little clearance left in the tensioning tool to enable bearing
bolts to be released . Back off nut (3) by approx . 135" .
SEQUEE.E OF OPERAT10,NS 2 : Preloadin g

Note : Correct preloading of bearing bolts requires a reliable pressure gauge .
1 . Mount sleeves and tensioning tools in pairs on bearing cover (1) and preload bolts to half of final preload,
draw up nuts with tommy bar .
When mounting the hydraulic nuts, note that the piston must be completely oushed back into the cylinder
for oreloadino, while the relief valve on the hp pump must be open .
2 . Mount pair of sleeves and tensioning tools on bearing cover (2), preload bolts to final oressure (c f, work sheet
000 .30) and tighten nuts (3) .
3 . Replace sleeves and tensioning tools on bearing cover (1) and a ' Dply final tichteninq Dressure -.
4 . Remove tensioning tools and secure nuts (3) by means of the protection caps .
0
D36 5012 E Aroeaszeii - Sivncen Alle Betriecivunden s
0211 . 02-2 Working time - Hours E,ery Opercting hour
Durie ce frovoil
Tiernpo de Ircbojo
-
-
Hevres
horas
Touies les
Coda
24000 Hevres oe marChe
Ho,os ce servicio
0
0
REMOVING AND INSTALLING KSZ 70/125 B
0
M*AL+N MAIN BEARING Aroeitskarte-Nr .
Work card
Carte travail
Torieto trcoajo No .
021 .03
applicable work sheets . . . . . . . . . . 009 .0 2
009 .03
021 .01
021 .02
000-14 8
\-Ant-
009.415 -.-OU39B z
LEGEND TOOLS REQUIRED Tool No .
1 Bearing cover (153 kg) 1 Eyebolt R 1 114 . . . . . . . . . . . . . . . . . . . . . . . . . 000 .166
2 Frame box, uppe r 1 Eyebolt M 42 .3 . . . . . . . . . . . . . . . . . . . . . . . . . . 000.148
0 3 Tackle (500 kg) 1 Hp pump, pneumatic. . . . . . . . . . . . . . . . . . . . . . 009 .302
4 Bearing pedestal manual . . . . . . . . . . . . . . . . . . . . . . . . . 009 .410
5 Bearing shell, top (120 kg ) 1 Hand lever press. . . . . . . . . . . . . . . . . . . . . . . . 009 .415
6 Bearing shell, bottom (120 kg) 1 Threaded fitting F1 14 with seal . . . . . . . . . 021 .398
7 Crankshaf t 1 Clevis eye M 24x2. . . . . . . . . . . . . . . . . . . . . . . 021 .391
4
8 High pressure hose 1 Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 021 .420 or .432*
9 Oresba belt stra p 1 9'e. 0211 .421
2 Jack. . . . . . . . . . . 050.429
1 Shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 002 .453
1 Catwalk grate. . . . . . . . . . . . . . . . . . . . . . . . . . . 030 .439
1 Dresba belt strap . . . . . . . . . . . . . . . . . . . . . . . 021 .419
1* Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 021 .432
as per engine executio n
0
p .t .o .
D36 5612 E Arceitszeil - Stunden Alle Betriebsstunctn
021 .03-3 Working time
r6e de travail
-
-
Hours
Heures 2 Every
ToutLs le s 24000 ' ODeroting hours
Heures de Marche
Tiempo
Du ce Irobojo - Horas kk I Cado Floras ce servicio
STARTIN6 POSITION
ILubricating oil pipes, nuts of bearing bolts and locking devices are removed
.
0
SEQUENCE OF OPER_ATIONIS 1 : Removing top bearin, shel l
Attach shackle and eyebolt to upper frame box and fasten tackles (3) .
2 . Screw clevis eye into bearing cover (1) and attach tackles .
3 . Lift off cover, turn it round and take oftr with other tackle, lift it out sideways and put it down on wooden
supports .
4 . Fasten top bearing shell (V with eyebolt or, tackle, lift it up and remove if
.
009 .410
009-302
021 .420
021-432
SEJUPENCE F OPER,'TIOINS 2 : Removing bottom bearing shell

1. Set -rankgear to top center .
2. Place two jacks under the crankweb rounding (see illustration) .
3. Connect hoses of ~p pump to the two jacks (see work sheet 009 .002/003) .
4. Connect hose of hand lever press to bearing pedestal .
5. Lift crankshaft by raising the pressure in the hp pump to approx . 440 bar, check lift (0 .35
mm) with dial
gauge or feeler gauge and operate hand lever press until grease escapes at the sides of the bearing shell .
6 . Loop Dresba belt strap over shell joint, hang it on tackle and roll out load-relieved bottom shell
.
7. Screw eyebolt Into bearing Shell, lift shell with the Use Of
the tackle and swing it out sideways and place
it on wooden supports .
8 . Rejease pressure in hp pump, remove jacks or leave them in place for reinstalling the bearing shell
.
STARTIN3 POSITIO N 0
bearing shell and bearing pedestal. have been thoroughly cleanad, smoothed and grease rubbed into the outside
nt .rface . Care has been taken to prevent foreign ma~ter from gettIng between bearing shell and the bore hole in
the bearing pedestal and that the drilled hole or thi connection of the hand lever press has always been filled
.th grease .
~EQIUSNCE OF OPERATIONS 3 : Installin g

1 . For insialling the bottom bearing shell, reverse procedure outlined above .
'When rolling in the bearing shell, again reduce frictio-I by pressing grease into the bearing pedestal when
bearing sheil has covered the drill hole in the bearing pedestal .
Wher. bearing shell has been completely rolled in, remove grease squeezed out at the sides .
4 . Cefore mounting the upper bearing shell, check to see that crankshaft journal and bearing shell are spotlessly
:1 ean .
M-ouni both bearing covers and screw down nuts .
Preload bearing bolts (cf work sheet 021 .02) .
Msasure bearing clearance and enter in engine log (cf work sheet 021 .01) .
D36 5612E/021-03-3
KSZ-B
TURNING GEAR WITH ELECTRIC KSZ-C 02 6
M *Atk* M MOTO R Arbeitskarte .Nr .
Work card No .
0 (Cavex-Flender C-Sander 250-400 ) Carte travail No . 026 .01
Torieto trabojo No.
TOOLS REOUIRE D
1 Hand crank, size 2 4
I Set open-end soanners
1 Set double-ended open-end spanner
Lubricating oi l
Lithium-soap multipurpose greas e
LK ENI D
1 Electric motor 10 Interlocking lever
2 Cover 11 Interlockino valv e
3 Casing (2nd stage) 12 End switch 6ndicator)
4 Turning pinion 13 Worm wheel (1st stage)
5 Flywheel 14 Casing (1st stage )
6 Spindle 15 Worm (1s 4., stage j
7 Handwheel 16D Worm wheel (2nd stage)
8 Locking pin 17 Intermediate casin o
0 9 Worm (2nd stage)
GENIERA L
The turning gear essentially consists of the -cear
comprising the first and second stage, the electric
motor (1), the interlockino cear (10 - 12) and the
disengaging and enoacino oear (E - 8) . The drive
motor (1) is designed as break motor and prevenis
the engine running gear from being turned by an
eXternal force wher. the turning gear is engaged .
The inierlocking gear prevents engine start-up when the turning gear is engaged .
The turning gear can be turned manually by means of the shaft end of the drive motor . A built-in safety device
prevents switching on of the drive motor when the turning gear is being turned by hand .
.ENGAGING THE TURNING GEA R
1 . Switch on electric motor and run gear for about 5 minutes to lubricate all bearings and the worm gear .
2 . Shut off electric motor .
3 . Check if relative position of pinion and flywheel is such that the teeth of one line up with the tooth gaps
0
of the other, and if they do not, switch on electric motor briefly or use hand crank to turn the gear .
4 . Full out locking pin (8) .
5 . Turn hand wheel to bring pinion in mesh with the flywheel .
Note : When pinion of turning gear is being engaged, the interlocking valve (11) and the end switch 62) are
actuated via the interlocking lever (10) . The supply of control-air of the starting system is thus inter- I
rupted and the position Iturninggear engaged" is indicated by the end switch on the manoeuvring. stand .
In this position the engine cannot be started .
6 . To turn crankgear, switch on electric motor in the desired direction of rotation .

7 . After crankgear has been turned, disengage pinion by turning the hand wheel and secure it in this position by
means of the locking pin .
MAINTENANCE
1 . Lubricate teeth of pinion and of flywheel as well as the spindle for engaging the pinion with lithium-soap greas
at specified intervals .
2 . Check oil level in casing at tight glass . Change oil charge after four years at the latest as lubricating oils
are subject to aqinq .,(cf oil change) .
10 036 5610 E
p. t .0.
Arbeiiszeit . - Stunden Alit Beiriebsitunden
Cn
026 .01-2 Working time
Durie de travail
Tiernpo do trobojo
-
-
-
Hours
Heures
Horas Ak Every
Toutes les
Coda as necessary
Operating hours
Heures de morche
Horas de servicio
Check whether teeth of pinion have worked into the teeth of the cast flywheel, smoothen teeth by grinding
if indicated, clean and lubricate with MoS based grease .
2-
4 . Check whether interlocking gear prevents engine start-up when turning gear is being engaged . 0
Note : As pinion is being engaged, venting of pressure air line should commence at the latest after 16 mm
travel of three-way valve lever and end switch should have beer, tHpped in this position .
5 . Check proper functioning of safety device when turning gear is operated manually :
The ele .^tHc motor must not be switched on unless the cover has been properly mounted :
Caution! Interlocking and safety devices must not, under any circUMS'Lances, be put Out of operation (danger of
accident) .
01! ruam-
__U t
___
1 . Unscrew oil drain screws in casing (3 and 14) and drain oil completely .
Note : Check used oil for metal abrasives as they are an indication of wear of the worin gear . In that case
check worms and worn wheels closely .
2 . Remove cover (2) and check condition of worm wheel .

Flush casing with low-viscosity lubricating oil (viscosity --z40 cSt/50 0 C) .
Reolace oil drain screws in casing (3 and i4) and fil
I l in lubricating oil up to the mark on the sight glass
(the two casings are interconnected by a venting pipe) . The highly viscous oil should be heated up before
40
fillino in .
Note : Oil viscosity approx . 324 cS+/5OoC (SAE 140) or hiaher oil content C-Sonder 250 70 liter
320 140 liter
360 200 liter
400 250 lite r
S . Replace cover .
E . Switch on turning gear briefly and recheck oil level .
ELECTRIC DRIVE MOTOR
The electric inotor (1) of the turning gear needs no servicing except cleaning of the casing surface when necessary .
Oust, sand or any objects placed on 'the casing reduce surface cooling with the result that the motor may become
overheated .
At major overhauls or when the inside of the motor should have become wet for any reason whatsoever, check
insulation cesistance of the winding .- against the casing (Mega test) with the use of a megger . For low voltage
current it Must not be less than --l megohm, at a winding temperature of 20 0C .
Normally, no supply of fresh lubricant is required for bearings, unless they are equipped with facilities for
adding lubricant, as the rated life of 2000 - 3000 hours will not be reached by the bearings in the driving 0
rotor because the turning gear is only run intermittently . Should the bearings be equipped with facilities for
adding lubricants, observe manufacturer's recommendations given on a plate fastened on 'he motor .
When it becomes necessary to replace the bearings, observe manufacturer's recommendations, which differ with the
model and the make, or have electric motor repaired by a firm specializing in this trade .
is
D36 5610 E/026-01-2
ADJUSTING DISC BRAKE OF KSZ
0
M*AL+N ELECTRIC MOTO R Aroeitskarte-Nr.
Work card No .
Carle travail No . -026 .03
Toriela trobojo No .
2 3 4 5 6
,If I KN in
P-1A I IF/I
: 1!
-I i
1
1)
E MR. I I
rr~ ~
C]
12 11 10
LEGEN D TOOLS
1 Hand "lever 9 Spacer disc REQUIRED oen-end
1 Double-ended p spanner size 13x17
2 Tension bolt 10 Spacer sleeve
3 Carrie r 11 Ball bearin g
4 Magnet core with coil 12 Brake disc with linings
5 Fixing screw 13 Armature plat e
6 Micro switch 14 Pressure springs
7 Counternu t 15 Terminals
8 Set screw
1 . Releasing currentless brake by han d
Move hand 1 ever (1) in the direction of the arrow, thus pull ing the armature plate (13) by means of the tension
bolt(2) against the magnet core which will cause the brake disc to become unseated .
0 2 . Adiustinq brak e
The brake must be adjusted when the air gap between magnet core (4) and armature plate (13) has become greater
than 0 .8 mm .
I
Release three fixing screws (5) and remove one or more spacer discs (9) from each set until nominal dimension -
0 .8 mm has been re-established .
If the brake lining has been worn off, replace brake disc with linings and spacer discs . The ball bearing
should be cleaned as necessary and then refilled with grease .
3 . Microswitch settin Q
The pressure pin of the microswitch (6) is actuated by the set screw (8) in the armature plate (13) . Actuating
motion is approx . 0.3 mal (advance motion and actual switching motion of approx . 0 .05 + overrun of approx . 0 .10 -
0 .15 mm . )
1 . Remove fuses, disconnect control lines to M-M and connect battery buzzer to M-M .
0 p. t. 0.
CoC,p1 : D36 5610 E
026 .03-1
[
VAbi!"oi
Walking time
e .,
TDurte
T,
- Slonden
- Hours
oe travail - Hevres
Alle
E very
Tou es les
Beiriebsslunden
cis necessary
.
Operal nq ?,a . I
Heures oe morChe
Horos de servicio_
Tiempo de lrobo ;0 - Horas A I Cado
2 . Loosen counternut (7) of set screw (8) and turn the latter in clockwise direction .
3 . Screw in fuse in control line .
4 . Release brake electrically and turn set screw in the direction of the pressure Oin of the microswitch 0
until the buzzer indicates closing of the microswitch .
0, 0
5 . Back off set screw by 45 but not more than 60 , and tiahter, counternut . Check proper functioning of
microswitch by electrically operating the brake repeatediy .
Note : With the switch closed (magnet energized) brake is released .

With the switch open (magnet de-energized) the brake is aoolied .
6 . Remove once more fuse in control line and reconnect control line to M-M .
4 . Schematic connection diagram for three-phase motor with squirrel-cage rotor, spring-loaded brake, interlockin g
switch and PiG resistors.
Pi
LEGEN D
bl Limit switch
d'. Switc h
k FTC resistor s
m2 Magnet core of brak e
r Voltage-dependent resistor
v1/v2 Silicon rectifie r
To energize magnet core, apply DC voltage to
terminals (15) .
Note : A silicon rectifier connected in a one-
way circuit with zero annode may be used
Li
as power supply instead of the trans-
x Connections only with el . motors with standstill former and selenum rectifier .
heating (on special order)
C,12ution! The built-in PTC resistors M should only be tested with the use of a Wheatston bridge (measuring rang e
100x) or a directly indicating ohmmeter having a battery voltage of max . 2 V . . 0
PTC resistors will give full motor protection only in connection with reliable tripping devices.
Example of switching diagram

LEGEN D
b 0 - Off-key
b 1 ' n-key
M3tor contacto r
c1'
e Fuse in control line
e1 2' Tripping devic e
f PTC resistors, either 3 or 6
h Disturbance display
1
40
I D36 5610 E / 026-03-1
KSZ 70/1 25A+B 1 02 7
CHECKING
Arbeitskarte-Nr .
TORSIONAL VIBRATION DAMPER Work card No.
0 Carte travail No. 027 .0 1
Tarieta trcbcio No .
TOOLS REQUIRE D
1 Open-end wrench, size 75
1 Slugging box wrench, size 75
1 Eyebolt M240, M64 A
2 Puller screw M24x2x2OO
LEGEN D
1 Damper mas s
2 Sleeve spring pack (18 kg)
3 Stop bolt (26 kg )
4 Damper hub
5 Crankshaft
6 Fitting bol t
7 Cover, three-piec e
Note : The vibration damper should be checked at
0 every extensive engine overhaul .
Heavy banging during operation is an indication

of disturbances .
STARTING POSITION
Covers removed, vibration damper accessible .
1 . Remove three-piece cover (7) .
2 . Extract stop bolts (3) and sleeve spring packs
and inspect parts . "Nhen reassembling, make sure
that all springs and stop bolts are installed in
the same bore hole as when removed .
No If all sleeve spring packs have been removed, make sure when reasseobling that match-marks on damper hub
(4) and damper mass (1) are in alignment . The oil passages in the hub and the oil supply passage in the
410 crankshaft (5) must be thoroughly cleaned . In the case of broken springs, replace the whole spring pack .
Springs should be,inserted into the bore hole one at a time and the stop bolts coated with MOS2-based
lubricants . The discs glued into the covers (7) should be coated with a lubricant . Screw joints must be
carefully secured !
p .t . 0 .
D36 5612 E Arbeitszeit - Stunden Alle Betriebsslunden
Working time - Hours Every Ope . of ing 1,c~rs
027 .01-1 Duree de trovail
Tiernpo de trobajo
- Heures
- Hores
Tovtes les
Cad 24000 Heures de rrarChe
Horas ce servicio
TOOLS REQUIRE D
1 Set open end wrenche s 0
1 Socket screw key, size 17
2 Puller screw, rl 1 6
2 Puller screw, 14 20x2
1 Eyebolt M 48
2 Eyebolt M CA
1 Receptacle
Hylomar SQ 32/M
Hyl o ma r
1103 2 lubrican t
LEGEND
- 1 Fitted bolt 9 Fitting bol t
2 Damper mass 10 Hexagon socket head screw
3 Lateral dis c 11 Balance weight, if provided
4 Sleeve spring pack 12 - Lateral ring with insert
5 Stop bol t dis c
6 . Damper hu b 13 Lateral dis c
7 Coupling bolt 14 Oil filling screw
8 Crankshaft 15 Gear ri m 0
SEQUENCE OF OPEPATION S
1 . Turn crankshaft until one oil filling screw is at IL Llop,
then remove screw . he
2 . Place receptacte under vibration damper and remove drain
screw at the bottom .
3 . Screw off castellated nuts and force off balance weicht
(11), if provided, and lateral disc (13) from gear rim
(15) and damper hub (6), using puller screws M20x2 . Pay
attention to matchmarks on lateral disc (and balance
weight, or match-mark, if necessary .
4 . Hang late r3l disc on 1 if ting gear and withdraw in s4hai L direction unti I sprin a packs are readi I y accessible .
5 . Screw Out hexagor.31 socket head screws (10), using socket screw key, size 17, and force lateral ring (12) from
damper mass (2) with the use oil puller screws M 16 .
6 . Extract and check stop bolts (5) and spring packs (4) . Thoroughly clean bore holes and make sure to install
springs and bolts in the same bore hole as when removed .
-Note : If a spring should be damaged, replace the whole pack .
When removing all spring,packs, note matchmarks determining the relative position damper hub to damper mass .
Is
7 . Coat all sleeve spring packs and stop-bolts with V' .0 S2-based lubricant ard reinstall them . Screw down lateral
ring, smooth spring abutting marks on insert discs, if necessary . Carefully secure all hexagon socket head
screws with lockwire .
8 . Clean outer and inner annular seating surfaces of lateral disc (13) and coat with sealing compound Hylomar
SQ 321M .
9 . Reinstall lateral disc in the correct angular position (watch matchmarks) (reinstall balance weight, if
-applicable) and secure castellated nuts with cotter pins .
10 . Screw in drain screw at the bottom of the lateral disc and secure with lockwire .
11 . Fill acidfree mineral oil SAE 40 or 50 to capacity through tap hole at the top of the lateral disc, screw in
and secure oil filling screw with lockwire .
Note : The hollow spaces of the torsion vibration damper must be filled to 95 % with oil, i .e . the oil level
should reach as far as to the threads of the oil filling screw, in order to achieve proper dampening .
It is recommended that t-he oil charge be replaced every 3 to 4 years because lubricating oils are*sub-
jected to ageing .
12 . Check oil level in torsion vibration damper after a short period of operation and replenish, if necessary .
D36 5612 E / 027 .01-1

RELEASING AND PRELOADING KSZ 70/125 B
CONNECTING ROD BOLT S Arbeitskarte-Nr.
Work cord No .
0
Carte travail No .
Tarieta trobojo No. 030 .01
009 .02
009 .0 3
Crosshead bearinq
030 .43 4
021 .422 009 .370

2 Hydraulic tensioning tool . . . . . . . . . . 009 .370
0 2 Hydraulic nut . . . . . . . . . . . . . . . . . . . . . . 021 .422
2 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 030 .434
2 Tommy bar, di2 12 . . . . . . . . . . . . . . . . . . 000 .264
1 Socket wrench, size 30-20. . . . . . . . . . 001 .770
1 Torque wrench 280-760 Nm . . . . . . . . . . . 008 .004
1 Bit, size 17 x 20 . . . . . . . . . . . . . . . . . . 001 .867
1 High-presssure pump, pneumatic . . . . . 009 .30 2
M21!Ual . . . . . . . . 009.41 0
H ! I/ I ~ I il I C) Crank bearin q
030 .442
009 .39 0
IN
LEGEND
1 Protection cap 5 Sleev e
2 Hexagon screw 6 Hydraulic tensioning tool
3 Bearing bolt 7 Hydraulic nu t
0 4 Nut 8 Connecting hos e
Note : For checking bolt connections, mount and connect \\\3'66 4 0 55 1 a

tensioning tool (cf work sheet 009 .02/03) and ascer-
tain pressure at which nuts (5) can be released . TOOLS REQUIRED Tool No .
Preload bolts to specified pressure, tighten and Hydraulic tensioning tool . . . . . . . . . . . 009 .390
2
secure nuts . Hydraulic nut . . . . . . . . . . . . . . . . . . . . . . . 009 .353
2
The two bolts of a bearing should be released or Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 030 .433
2
preloaded at the same time with the use of the Tommy bar, dia 16 . . . . . . . . . . . . . . . . . . . 000 .266
2
hydraulic tensioning tools . Bit, size 17x2O . . . . . . . . . . . . . . . . . . . . . 001 .867
1
Torque wrench 280-760 Nm . . . . . . . . . . . . 003 .004
1
STARTING POSITIO N High-pressure pump, pneumatic . . . . . . . 009 .30 2
1
Protection caps of tensioning threads are removed . manual . . . . . . . . . . 009 .410
Crankgear moved to top center for working on crankbearing, or moved close to botton center for work o n
crossh6ad bearing .
0 p .t .o .
036 5612 E Arbei szeit - Slunden Alle Beiriebsstunden
,
030 .01-3 Work,!,,, g time Hours Every Operating hours
Duri~ de travail Hevres
Tiempo de trabojo - Horos AA
Tovtes les
Cada
24000 Heures de marche
Hares de servicio
RELEASING AND PRELOADING CONNECTING ROD BOLT S
SEQUENCE OF OPERATIONS 1 : Releasin g 0

Crankbearing Mount two tensioning tools (009 .390) on nuts of bearing bolts, connect hoses to pump and open
relief valve on hp pump, then relieve bolt load (cf work sheet 009 .03) . Backing-off angle of nut is
0.
360
Crosshead bearin a
1 . Mount two tensioning tools (009 .380) on nuts of one bearing cover and connect hoses to pump .
2 . Switch on hp pump and raise pressure slightly above specified pressure, back off both nuts with tommy bar .
3 . Mount tensioning tools on other bearing cover and release both bolts .
Note : For releasing bolts, leave a little clearance in the tensioninq tool to enable nut to be backed off
and thus bolt load to be removed . Nut (4) is to be backed off by about 180r .
SE06ENCE OF OPERATIONS 2 : Preloadin g

Note : Correct preloading of connecting rod bolts requires a reliable pressure gauge .
Crankbearing Mount two tensioning tools (009 .390) on nuts of bearing bolts, connect hoses to pump and preload
bolts by applying the specifiad pressure (cf work sheets 000.30 and 009 .03) .
Crosshead bearing The two bearing covers are preloaded in two steps . 0
1 . Mount nuts, sleeves and tensioning tools (009 .370) on the two bolt's of a bearing cover and raise pressure
to half the pressure defined for final tightening .
2 . Mount tensioning tools on nuts of the other bearing cover and tighten bolts applying the specified pressure
for final tightening (cf work sheet 000 .30 and 009 .03) .
3 . Reset tensioning tools to first bearing cover and tighten to recommended final tichteninq pressure .
4 . Secure nuts by applying protection caps .
~i Lote- For preloading bolts, see that pistons are completely pushed back into the cylinders as hydraulic nuts
are screwed on .
TIGHTENING CO.NNECTING SCREWS IN CROSSHEAD- ANDCRANK BEARING S
The connecting screws provided between bearing body and bearing cover should be tightened to the specified
torque .
CROSSHEAD BEARING CRANK BEARING

0
008 .004
008 .004 001 .867
001 .770 MA-- 320 Nm
MA~-- 320 Nm
008 .004
001 .867
MA= 320 Nm
0
KSZ 70/125 B 1 03 0
M*AL* N CRANKBEARIN G
ArDeilskarte-Nr .
Work card No .
0 Ta,leto trabojo No.
applicable work sheet 030.01

000 .155 TOOLS REQUIRED Tool No .
002 .45 3 2 Holding plate . . . . . . . . . . . . . . . . . . . . . 030 .440
4 Shackles . . . . . . . . . . . . . . . . . . . . . . . . . . 002 .453
2 Eyebolt, M 12 . . . . . . . . . . . . . . . . . . . . . 000 .142
000 .14 2
4 Eyebolt, M 20 . . . . . . . . . . . . . . . . . . . . 000 .155
1 Eyebolt, M 42x3 . . . . . . . . . . . . . . . . . . . 000 .148
030.44 0
1 Set open-end spanners
2 Tackle 500 kg
1 Tackle 1000 kg
LEGEN D
1 Hclding bracket with screw 4 Tackle 500 kg
2 Hexagonal screw M 20 5 Tackle 1000 kg
3 Connecting rod
0 000 .14 8 SEQUENCE OF OPERATIONS 1 : Removing
1 . Set crankgear to top centre.
2 . Fasten bearing cover to bearing body by holding
plates.
3 . Clamp down bearing bolts, using holding bracket
and screws (1) .
4 . Release nuts with hydraulic tensioning tool and
unscrew them (cf work sheet 030 .01) .
5 . Hang bearing bolts and holding plates by mears
of tackles on eyebolts in crosshead.
6 . Remove the upper hexagonal screws (2) in holding
plates, lower bearing cover and put it down .
7. Flove connecting rod (3) out of way, take over
bearing cover and/6r bearing shell with tackle
and remove it .
1 Single-track travelling crab . . . . . . . . 030 .359
1 Supporting pin . . . . . . . . . . . . . . . . . . . . . . 030 .371
0 1 Eyebolt M42x3 . . . . . . . . . . . . . . . . . . . . . . . 000 .148
1 Tackle 500 k g
1 Tackle 1000 k g
030 .37 1 R Lower guide shoe onto upper supporting pin .

9. Move crankpin towards bottom centre while
holding the connecting rod by tackles (4 and 5) .
10 . Hang upper bearing shell on tackle and loosen
fixing screws . Lower bearing shell with, tackle
and remove it .
SEQUENCE OF OPERATIONS 2 : For installing reverse
the sequence of operations
outlined above . '
0
A,tei -. :tit - sto .den A[ e
DliE 5612 E Operct ;nq hours
kk-
Workin
I ; tome - Hours Every
1,
r-
030 .02-3
Durke de travail
Toempo de trabojo
- Heures
- Horos
Toutes les
Cada
24000 Heures Ce Marche
Horas de servicto
I
0
9
REMOVING AND INSTALLING KSZ 70/125 B 030
M *AftL* N CONNECTING ROD Arveitskcr,e.Nr .
Work card No.
0 Carte travail No.
Torleic trobalo No . 030 .03

030 .01
030 .02
030 .04
1 Single-track travelling crab . . . . . . . . 030.359
030 .371 1 Supporting pin . . . . . . . . . . . . . . . . . . . . . . 030.371
1 Lifting tool . . . . . . . . . . . . . . . . . . . . . . . . 030.423
Tackles, 1500 kg, 2500 kg, 5000 k g
LEGEN D
1 Tackle 1500 kg
2 Tackle 2500 kg
~11_7_
36 40 520/3
3 Tackle 5000 kg
0 STARTING POSITION
Crosshead- and crankbearing covers are removed .

1 . Lower guide shoe onto lower supporting pin and secure
connecting rod by two tackles (1 a~d 2) .
2. Clamp lifting tool onto tapered connecting rod shaft
and secure it from sliding off by,means of a rope (see
illustration) .
3 . Pivot connecting rod round crankpio by slackening one
tackle (1), alter fixing points of both tackles (1) .
4 . Pull out connecting rod in inclined position by pulling

0 taut tackle (3) and relaxing tackle (2), remove it
completely and set it down .
SEQUENCE OF OPERATIO'NS 2 : For installing reverse procedure
outlined above .
2
Arotimee. - Stunce, Alle Betriebssturden

D36 5512 E Working time - Hours E~ery ODerating hoVrs
030 .03-2 Durie de trc~oil
Tiernpo de trabojo
-
-
Heures Toules les
Horas I Coda as necessary
Heures de marche
Hares ce ser~icio
0
0
K SZ 70/125 B 1030
M *Atk* N CROSSHEAD BEARING S Aroeitskcrte.Nr.
Work cara No . 030 .04
0 Carte tro~oil No.
Tc-jetc trabolo N
applicable work sheet . . . . . . . . . . 030 .01

1 Catwalk grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 030 .439
4 Eyebolt r, 20x2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .144
4 Eyebolt M 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .142
1 Eyebolt F, 420. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .142
1 Shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 002 .458
1 Set double head, open-end wrenche s
1 Set keys, hexagon socket screws
tackles 500 kg, 1000 kg, 1500 k g
LEGEN D
1 Tackle 500 kg
2 Tackle 1000 kg
3 Tackle 1500 kg
4 Diaphragm casin g
0 SEQUENCE OF OPERATION'S 1 : Removing
1 . Loosen 4 nuts with hydraulic tensioning tool (cf work
sheet 030 .01) .
000.144 2 . Pull bolts upwards with the use of tackle (1) and either
remove or secure bolts in this position with clamping
1 screws .
1 Single-track travelling crab . . . . . . . . . . . . . 030 .359
000.144 1 Eyebolt M 20x2. . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .144
3 . .Remove 2 taper pins and bolts .
002 .458 4 . Hang bearing cover on tackle (1), lift it, take it over
on other tackle and set it down .
3 5 . Remove second bearing cover .
6 . Disconnect both linkrods driving the crosshead lubricator s
Supporting pins . . . . . . . . . . . . . . . . . . . . . 030 .371
Eyebolt M 42x3 . . . . . . . . . . . . . . . . . . . . . . 009 .148
Eyebolt M 8 . . . . . . . . . . . . . . . . . . . . . . . . . 000 .17 1
7 . Lower guide shoe onto supporting pin inserted into the
0 lower drill hole in guideway, secure connec tAng rod by
two tackles .
8 . Swing connecting rod on crankpir, towards exhaust sid e
by relaxing tackle (3) and taking up slack of tackle (2) .
9 . Remove fixing screws and straps, lift up bearing shell
with tackle (1), remove it sideways and set it down . I
SEQUENCE OF OPERATIONS 2 : For installing reverse the

sequence oil operations outlined
above .
0
036 5612 E Artedszet! Stuncier, Alle Beiriemsslunden
Working litne Hours Ever, Operoting hours
030 .04-2 DurAe de tro~ciil - Heures Tovies les 24000 Heures de rnarche
Cn ['rriernoo de frobajo - Hores Ak I Coac Harcs de servicio
0
0
REPLACING BEARING SHELLS OF
KSZ 70/125 B 1 030 _
M *Aek+ N CROSSHEAD AND CRANK BEARING S Arbeitskarte-Nr.
Work card Nc.
Corte travail No.
Tcrjeto trabajo No . 030 .05
applicable work sheets . . . . . . . 000 .30
009 .03
030.01
030 .02
030 .0 4
TOOLS REQUIRED Tocl No .
1 Torque spanner 280-760 Nm. . . . . . . . . . . . . . . . . 008 .004
1 Feeler gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .451
-LEGEN D
1 Cleat on guideway side E Connec-ting rod
2 Cleat or, opposite side 7 Bearing body
3 Bearing cover 8 Locating screw
4 Crosshea6 pin 9 Bearing bolt (26 kq
5 Bearing she'll 10 Shim, (40 kg )
Gap D 0 .20 0.2 7
STARTING-POSITION Dim . K 0 .15 0.2 0
Total projection at cleat K - J - H (mm )
Bearings are completely disassembled . Bearing clearances
exceed admissible limits . Ready-machined spare shells Ground clearance of bearing surface L . 95 ' a
are on hand . Shells must not be reworked . neither at the
0 split-ioint nor at the shell back .
SEQUENCE OF OPERATIONS 1 : Crosshead bearing
1 . Clean bearing body, bearing cover, shells and crosshead pir., check for damage and mark cylinder number on
new bearing shells (mark old bearing shells with felt pen) .
2. Insert bearing shell (5), mount cleats (1 and 2), torque all 12 bolts crosswise and evenly to U3 Nm and check
that cleats seat squarely .
3 . Apply a thin coat of touching-up pa'Int to crosshead pin, lower crosshead pin onto shells and put both bearing
covers in position .
4 . Insert 'and tighten four bearing bolts (9) (cf work sheets 000.30 and 009 .01) .
5 . Loosen two bearing bolts (9) on guideway side and remove cleats (1 and 2) .
6 . Measure gzp (0) in range of cover and the projection and the off-distance in the range of the cleats .
Total projection K - J - H (mm), cf table .
Note : Should the values defined in the table not be attained, the following should be borne in mind :
Remachining of the cleat or the bearing shell to attain the dimensions defined in the table is only
permissible in an emergency (i .e. if another spare shell is Plot available) . Installation of a bearing
shell that does not reach the defined projection (projection smaller than defined in the table) is nut
permissible under any circumstances .
7 . Tighten bearing bolts and boltsin cleats in accordance with the recommendations given .
0
p .t .o .
D36 5612 E Arbeitszeit - Stunden Alit betriebsslunoen
Ak
Wcrking lime - Hours Every Ctcwcit ng hours
030 .05-2 cis necessary
Heures cc morChe
C9 Durie da travoil
TiemDo ce trGbaio
-
-
Heures
Horai
Tattles les
Caac Hares cie serv.c .,
LrN
B . Chock bearing clearance and obtain bearing pattern with touching-up paint by swinging the crosshead pin back
and forth several times .
9 . Remove crosshoad once more and check bearing pattern on both 3idIS up to dimension (Q .
10 . After final installation, recheck bearing clearance, enter dimensions in Engine Records and romeasure and 0
if necessary correct alignment of piston in cylinder liner (cf work shoots 040 .06 and 040.07) .
SEQUENCE OF OPERATIONS 2 : Crank bearing

1 . Clean bearing body, cover, shells and crankpin and in3POCt f9r
damage . Mark cylinder number on now shells (mark old bearing
shells With-f6lt pen) .
2 . Place bearing shells into bearing cover and bearing body, clamp
them in place with locating screws(8) and assemble in crankcase
(cf work sheet 030.02) .
3 . Tighten both bearing bolts to defined torque (cf work sheets
000 .30 and 009'.03) .
4 . Check bearing clearance, clearance on guide shoo and alignment
of piston in cylinder liner and enter clearances in Engine Log .
DIMENSIONS AND CLEARANCES see Section 1 .
V36 5612 E / 030-05-2

CHECKING KSZ- B 030
r", +A%k* M CROSSHEAD BEARING S Arbeitskame-W .
WorK card No . .
Corte travail No 030 .06
0 Tarieta trabojo No .
009 .461
009 .01 4
2 Pressure gauge . . . . . . . . . . . . 003 .1011
1 Dial cauoe . . . . . . . . . . . . . . . . 009 .461
1 Viagnelic'gauge holder . . . . . 009 .01 4
I Double-ended open-end spanner
size 19x22 +
size 30x32 +
size 36x4l
1 Angle-type socket screw spanner size
10, 17, 1 9
LEGGEND
008 .101 1 Lever
5 2 Pi n
3 Strainer element
0 4 Lubricato r
5 Screi plu g
~'L,[:rICE
Spr@ ,
0:' OPERAj- ION' S
1 . Switch or, lubricating oil pump .
2 . Turn crankgear to bottom centre .
3 . Remove both pins (2) in joints of drive linkage .
Attach magnetic gauge holder with dial gauge to crcsshead in such a way that the feeler is seating either or,
piston rod foot or on one of the eccentric rings . Set dial gauge to zero !
Operate both levers (1) of lubricator (4) until crosshead pin is floating and its upper side touching the top
shell (at an oil temoerature of 20 0 C and with the bearing in good condition it will take approx . 15 pumD strokes .)
6 . Switch off lubricating oil pur. and watch dial oauge (at an oil temperature of 20 0 C and with bearing in goo d
condition it will take approx. ' D15 seconds for -116 pin to drop through half the distance of the beaHrg clearance
and approx .'l hour more until it will rest on the bottom shell) .
0 7 . Replace and secure pins in joints of the two drive linkages, remove dial gauge .
Note : The strainer element (3) in the oil supply pipe to the lubricators is removed after commissioning of the
.enqins .
0
Arbeitszeit - Stunden Alle Betricbssfunden
036 5610 E
CC)
030 .06-2
Working tirne
Tiempo
Du
- Hours
rie de fravoil - Heures
de trabajo - Horas Ak Every
Toutes les
Cada as necessary
Operating hours
Heurts do mar~(,h0e
Horas do servicio
ic
0
0
KSZ 70/125 B 1 031
A-veitska-le-Nr .
CROSSHEAD PIN Work card No .
0 Corte olrc~oii
. No .
Tar,cl troba ; a No .
031-0 1
applicable work shee .. . . . . . . . 040 .0 6
.TOO'L_S REQUIRED Too l

11 Lifting br2-,ke-, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3" . 3 64
031 .364 I Single-raill Traveliing crab
. . . . . . . . . . . . . . . . . 030 .
I Pir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 030 .371,
I Lifflng icsl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03' .'-23
... .
.1 0T4)
2 I iorcue spanner 750-2000 Nm (75-20 . 005 00-
.
030 .371 1 Feel'er gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9 01. L 5,11
1 Socket wrench 36 x 20 . . . . . . . . . . . . . . . . . . . . . . 001-771
1 Socket wrench 60 x ill . . . . . . . . . . . . . . . . . . . . . . 001 .8ocWz
1 AdaDter 20 x 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . .()nl-Q? A
UJU4Z,l i i+_'~' IN ~I Til I r h .1-LL m g n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UVU .I ;Q
j
1 Dodecagonal slugging wrench, size 60 1
1 Set open-end wrenches and 1 set double-head, open-end . . . en-te s
nr1r) 1 :;JZ1
I !~ _1`11-Y-1<61~1 I I It %
L
I EG 3END I
;C 521/1 '1 Ouide shoe (560 kg) 3 Tackle (11593 kg )
0 1
~T!, 2-, 1 fj~Z pll~, 1 -rint,- 2 Crosshead pin ~525 kg) 4 Te .-kle (2500 kg,1
5 Tackle 1,50021 kg)
Piston witi, piston rod, tslescopic-pi De bracket and bcih crosshead bearino covers are removed .
6uidE shoe with cross~ead L pin L lowered'Lhe
'onto supporting pir, inserted into lower hole, an d
ccnnecting rod
swung ouL as flar as possible towards the exhaust side .
S^K1'H'N.̀'E Or- OPERUION'S " : Removing crcsshead pin iogether with guide sho e
I . Faster lifting bracket on the two diaconally opposed studs with nuis, attach to hoist, ii ;t as-sembly and remove
~upportinc pin in guideway .
2 . Cautiously lower crosshead pin together with guide shoe and slide it out without skewing it .
L141
t Fssembly in crankcase, slew connecting
c rod round n towards enoiner o t 0I s i d e
4 . Lower guide shoe together with -.rosspin and remove assembly towards exhaust side .
SE~IJENCCE OF OPERATO'S 2 : Installin g
For inSt3llirg, revirse sequence of operations Outlined above and securE bolts .
STARTING POSITIO N
Piston and piston rod are pulled, telescopic-pipe bracket and drive rods
of lubricators are removed . Both, bearino covers of crosshead bearincs are
taken off .
0
SEQUENCE 0;7 OPERATIONS 3 : Removing crosshead pin without guide sho e
1 . Remove two lateral fixing screws, unscrew two collar bolts on top in
piston rod supporting surface and the bolts between guide shoe and cross-
pin (1 and 2) .
2 . Lower guide shoe onto supporting pin in upper bore hole o-1 guideway
and secure connecting rod with two tackles .
3 . Cautiously lower connecting rod by turning the engine, taking up slack
of tackles, until crosshead pin is free, paying attention to the four
waisted bolts .
Caution! The crosshead pin must be resting during this operation on the
bearing shells (danger of accident!) .
4 . Mount lifting bracket on two diagonally opposed studs, fasten with nuts
and attach crosshead to hoist, with the rope lowered through the cylinder .
5 . Turn crankgear to move connecting rod to bottom center, lower crosshea d
SEQUENCE OF OPERATIONS 4 : Installing pin and remove it towards exhaust side, using tackle .
To install crosshead, reverse sequence of operations outlined above and secure bolts .
0 D.t. 0.
036 5612 E Aroeitszeit 5:unden Alle Betriebsslunden
031 .01-2 Working time, H urs
Durie ce trcv it Hevres
i iem.Do at irccoic. - "orcs U Every
Taufe$ les
ICCO-- as necessary
CiDerating hours
Heures de morche
Horoi at se . vicoc
:io7,i na l Machinin g Max .
d imn en s i o r al I owan ce cl earanc e
L 06 0
0 .10-0 .14 0.2 0
0.20-0 .27 0 .3 0
64 . 8 "1.- 0 . 01-1 -
36 ~G 466/ 2
Nois : Check clearance between guide shoe and guide rail after installing the guide shoe, if necessary readjust
by re .moving graded-thickness wasmers . Measure clearan .-e with crankgoar in top center and ir. bot-Lor.n. center
pcsition . Then check alignment of piston in liner and . correct
aryas(cf necesswo r k. sheet 049. 061 . Tig~--"en
nollts in guideway and guide rails To recommended torque
40
0
5612 Z/0311-01-2
REMOVING AND INSTALLING KSZ70/1 25 B rO3-5
0
M+Ak+ N PISTON COOLING STUFFING BOX Arbeitskarte.Nr.
Work card No.
Carte tra~aii No . 035 .01
Torieto trcbaio No.
Applicable Work Card . . . . . . . . 000-30
1 Assembly mandrel . . . . . . . . . . . . . . . . . . . . . . . . . 035-371

1 Adjusting sleeve . . . . . . . . . . . . . . . . . . . . . . . . . 035-372
I 1 Torque wrench 270-750 Nm . . . . . . . . . . . . . . . . . 008-004
1 Socket wrench 36x2O . . . . . . . . . . . . . . . . . . . . . . 001-771
1 Double end box wrench SW36x41 . . . . . . . . . . . . 000 .227
1 Set double-head, open-end wrenches
1 Key, size 8, 1 7
1 Adaptor S 53344106, O41x2O
1 Assembly pliers A 85x165
Special greas e
LEGEND
1 Discharge pipe 19 Telescopic-pipe bracket
2 Supply pipe 20 Crossnead bearin g
3 Flow-control flap 21 Guide sho e
4 Stop cock (discharge) 22 Sliding panel
0 5 Stop cock (supply) 23 Guide rai l
6 Thermometer 24 Sealing strip
7 Instrument fitting 25 Leak water pipe
8 Surge tank 26 Water drain pipe
9 Check valve 27 Casin g
10 Stuffing box 28 Sleeve
11 Telescopic pipe 29 Retaining ring
12 Engine frame 30 Pip e
13 Pipe bend 31 Cove r
14 Seal 32 Sealing packet -
15 Slide panel flange 33 Seal rin g
16 Sealing strip 34 Rin g
17 Sliding panel 35 Hexagon screw
18 Guide way 36 Hexagon nut
Note : Erratic operation and thumping sounds ar e
indices of the air pad being too small and low
supply pressure . The piston cooling system must
operate without thumping . The setting of the
check valve in the air supply pipe should not be
0 changed (1/4 to 1/3 turn open) !
MAINTENANCE
1 . The cooling water discharge temperatures and the

temperature differences between the individual
outlets should be checked and compared unless they I
are automatically monitored .

2 . Realign telescopic pipes and check proper fastening of
telescopic pipe brackets, sliding panels and stuffing
boxes in accordance with the Maintenance Schedule and re-
place seal rings, if necessary .
Notice! Tighten hexagon bolts (35) to soecified torque

(cf . work card 000-30) . Tighten hexagon nuts to
snug fit by hand . Tighten two of the nuts that are
more readily accessible with torque wrench t o
C9
p. t. 0.
D36 5612 E Arbeitszeil - Stunden Alle Betriebsslunden
Working time - Hours Every Operating hours
035 .01-2 Dur6e de travail - Heures Toutes let 12 OOD Heures
0 de marche
Tiernpo de trobojo - Horas Coda H ras de servicio
soecified torque (cf . work card 000 .30) while measuring the tightening angle . Tighten the remaining
two nuts by the mean value of the two angles measured before .
3 . Proper functioning of the stuffing boxes qan be checked at the transparent leakwater pipes mounted in the 0
recesses of the frame .
SEOUENCE OF OPERATIONS 1 : Removin g

1 . Close cocks (4 and 5) in cooling water supply and discharge pipes at the bottom of the surge tank and drain
cooling water into collecting tank - pressure in cooling system released .
2 . Turn crankgear to top cente r
Remove retaining ring (29), push sleeve (28) downwards, then push sleeve together with pipe (30)
upwards
to remove them sideways .
4 . Cover up opening in surge tank and disconnect coupling at leak water pipe (25) .
5 . Remove hexagonal screws . and 2 taper pins in flange while supporting the casing (27)
from below at the flange .
b . Remove complete casing downwards, paying attention to the seal ring between casing and frame
.
Disassemble stuffing box on work bench as follows :
7. Clamp* casing (27) in vice, paying attention to the cylindrical sealing surface .
8. Unscrew hexagonal screws and remove cover (31) .
9. Remove complete sealing packet (32) and disasssimble it co,-.Ipletely .
10. Remove seal ring (33) .
. 0
SEQUENCE, 0: OPERATIONS 2 : Instal lin g
l'o reassemble and reinstall stuffing box in frame, reverse sequence of operations outlined above . Renew seal
rings between joints if necessary . Before installation, fill free spaces ol profile seal rings to approx
. 80
vith special grease and also coat surfaces wetted by water with the same grease . This special type grease
(Autor-2tikfett) is sold by Fa . Martin herkel KG, D-2000 Hamburg under the order No 3000-024 .114
. Should the
dbove named special grease not be at hard, the parts may be greased with an equivalent lubricant on mineral
oil bases as per DIN 51 825 thickened -with dry lubricant MoS
2*
Between cover (31) and packing, there should be a clearance, marked x in the drawing, of 0 .1 - 0 .3
rim when
seal ring (33) is removed . Should the clearance be less than that, remachine collar of cover
. Renew seal ring (33)
as necessary . Make sure to reinstall the seal ring after checking the clearance .
To install the siu -ifing box in the frame recess, it must be carefully pushed over the telescopic pipes from below
with the use of the assembly mandrel . The mandrel will widen the seal rin-s slightly and is being pushed out
by
the telescopic pipe as the stuffing box is fitted . Whille pushing the stuffing box in place, see that mandrel is
*il .ays seating against the pipe to prevent seal rings from becoming wedged in between mandrel and pipe .
fhe angular position of the ca ;ing is determined by the taper pins .
Reinstalled telescopic pipes must be carefully aligned . The li,fe of the sLtu ffing boxes depends upon true running 0
of the pipes . For centering the telescopic pipes, use adjusting sleeve which is to be applied from below
. As the
telescopic pipe is being inserted into the stuffing box packing, there will be an appreciable amount of resistance
Lhat must be overcome until the pipe has pierced through the last ring . To prevent sudden slipping and striking
of the pipe aqain~t packing casing, secure telescopic pipe with a soft rope or dampen impact by placing a piece
of wood on the stuffing box casing .
D36 5612 E / 035-01- 2

REMOVING, MAINTENANCE AND KSZ 70/125 B ~_04 0
M *A5V N OVERHAUL OF PISTON Arbeits,,,orte-Nir.
Work card No . .
0
Corte travail N 0
Tcr)eta trOD01o No .
040 .01
applicabiework sneets . . . . . . . .. U-U-
Z
009 .02
009 .03
G40 .0 3
1 Hang-up and pressure testing tool, compl . . 040 .422
040 .446 1 Piston suspension tool, complete . . . . . . . . . . 040 .44 6
4 Nul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040-448/459
4 Sl eeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 .44 9
4 Hydraulic tensioning tool . . . . . . . . . . . . . . . . . 030 .12 9
1 High-pressure pump, pneumatic . . . . . . . . . . . . . 009-302/312
manual . . . . . . . . . . . . . . . . 009 .41 0
1 Tommy bar, dia . 10 . . . . . . . . . . . . . . . . . . . . . . . . 000 .263
4 Hexagon screw M 24x2xS O
4 Hexagon screw M 24x2x13O
8 Hexagon nut M 24x2
2 Hoist with rope
LEGEN D
0
1 Piston crown 3 Piston rod foot
2 High-pressure hose 4 Nu t
5 Sleev e
STARTIN3 POSITIO N
Fuel, cooling water and air pipes are removed, cylinder
cover taken off and placed on adjacent cylinder cover,
piston rod stuffing box prepared for removal together
with piston and rod assembly .
SEQUENCE OF OPERATIONS : Removin g
1 . Mount 4 hydraulic tensioning tools over
nuts on connecting rod foot, connect hp
hoses to hp pump and release bolts .
Note : For releasing bolts, a little clearan .-
030 .129 must be left in the tensioning tools
to enable bolts to be released . Back
4 off nuts by approx . 200 0, using
000 .263 4. U-11111y
1.1 al .
0 2 . Move crankgear to top center and moun t

:~71__ x - 5 suspension tool on niston crown at rinh',
(no angles to engine axis (see illusiration) .
/ , 0U n S on w n s o n
au ous - nu
VU'J . .)U4 3640462 1
009-3112 rod by means of hoist and leave it hanging
on rope .
4 . Attach hang-up tool to piston rod foot making sure it is in the correct position (see illustration overleaf) .
Note : If tool is only used for suspending the piston, only parts 5, 7 and 8 need be mour.ted .(see illustration
overleaf) . No attempt should be made to transport piston by slinging rope round piston skirt .
5 . Invert piston and piston rod 180" with the aid of the second tackle and set assembly down with the piston pointing
downwards . The stuffing box must be secured with a rope and a clamp to prevent it from falling down and getting
damaged during this operation (danger of accident!) .
6 . Fasten feet of suspension tool with hexagonal screws on prepared stand to prevent it from tilting over (danger of
acciden-161) .
7 . Leave piston rod hanging on hoist .
Note : Pistor. and piston rod can be c1ither
6 kept suspended in cleaning vat on gallery or placed on prepared stand
on gallery or in ergine room .
0 D. t. 0 .
D36 5612 E Arceitszeit - Stunden Ahe Betrietossfunden
Working time - Hours Every
040 .01-2 Operating hours
Curie ce travail
TiemDo de frobolo
-
-
H-eure$
Horas AA I
Toutes; lei
Coda
12 000 HeureS oe MarChe
Horas de servicia
M A I NTEN A NC E
Pistons should be pulled and inspected at specified intervals (see Maintenance
Schedule) . The length of the period between overhauls depends on prevailing operating
conditions, i .e . on engine load, fuel used, quality of combustion, lubrication and
cooling . The piston rings should normally not be removed for inspection because the
rings are subjected to severe stresses during removal and fitting . Inspect lubrication
ol, pistons and cylinder liners through inspection holes . Excessive lubrication i's as
harmful as insufficient lubrication . In the first case, carbon deposits may form and
cover pistons and piston rings and gradually clog the exhaust ports, whereas in the
event of insufficient lubrication, piston rings will run dry and wear rapidly . More-
over, cylinder liners will be subjected to increased wear . The condition of the piston
and of the exhaust ports is checked, with the engine at standstill, through the
inspection hole or, the oontrol side after removal of the inspection hole cover . To
check piston top, remove fuel injection valve and insert tubular lamp, supplied with
the tools, through the opsning in the cylinder cover .
OVERHAUL
Before cleaning the piston (in the cleaning vat on gallery) check lubricating effect
on running surfaces of piston and cylinder liner . Check piston rings for carbon
deposits, for free movement, and measure axial clearance of the rings in their grooves
(c' section 1) . Depending on findings, remove rings for closer inspection and thorough
cleaning of ring grooves . For removing and fitting piston rings, use ring expander
supplied with the tools . Ascertain ring face wear and thus loss of inherent tensio n
40
by placing the ring into a new cylinder liner or a ring having the same inner diameter .
Replace ring if the ring gap has reached the admissible max value defined in section 1 .
If the admissible max gap width has not yet been reached, the piston ring may be used
in one of the lower ring grooves .
Note : With every millimetre of liner wear measured across the bore, the ring gap
increases by approx . 3 mr .
In a new engine, the first two piston rings from the top are of the relieved type .
The specially machined ring ends will provide uniform contact pressure over the entire
circumference of the running surface practically from the very first hours of operation .
Relieved piston rings are marked by an "E" stamped on near the ring gap .
In the course of periodic piston overhauls, top rings should be repla .-ed by new,
relieved piston rings . The length of the period between overhauls is determined by the
wear of the top rings, and a partially worr, ring can reduce it considerably . After
fitting new piston rings, the engine output should be increased gradually befor e
rated load is applied . Before reinstalling us6d rings, rework ring ends and sharp ring
edaes .
When, after many service hours, the ring side cle2ranc .- in Lhe ring grooves has
40
reached t~e admi-4sible m2ximum limit (of section 1), rings of greater wid,h may be
fitted . Piston ring MaUf2 .-turers will supply off-size pistc,,- . rincs Of corresponding
width . The upper linit for a stepwise increase of the ring width has been reached
when the width of the groove has been increased by a total of two mrn due to ref-. .I-
ithing On a laths . The piston crown can then be returned to the manufacturer' s
works for deposit welding .
LEGEN D
i Piston suspension tool 5 Hang-up tool

2 Piston (1200 kg) 6 Hexagon screw and nut
3 Piston rod (900 kg) 7 Collar bus h
4 Hoisting rope 8 1301-11., nut, shim
0
D35 561-21/040-01-2
DISASSEMBLING AND KSZ 70/125 B 1 040
M*AVM ASSEMBLING PISTO N ArDeitskarte-Nr.
Work card No.
Corte tra~ail N 040 .02
0 Torleta trobajo No.
applicable work sheets . . . . . . . 000 .20

TOOLS REQUIRED Tool No . 000-30
009 .02
1 Hang-up tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 422 009-03
1 Piston suspension tool . . . . . . . . . . . . . . .. . . . . . . . 040 446 040 .01
2 Lifting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 453 040 .08
1 Trestle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 452
2 Eyebolt M 16000. . . . . . . . . . . . . . . . . . 000 .035
2 Hexagon bolt M 30x2x7 5
12 2 Hexagon bolt M 24x2x5O
2 Hexagon bolt M 24x2x12 0
1 Double-head socket wrench, size 36x41
1 Tommy bar, dia 1 8
1 Double-head box spanner, size 36x41
1 Set double-head open-end wrenches
2 Hoist with rope
1 Feeler gaug e
1 Note pad
0
LEGEND
1 Piston crown (400 kg) 7 Piston rod (900 kg)
2 Piston insert (380 kg) 8 Discharge pip e
3 Drain funnel 9 Collar nut
4 Stud 10 Stu d
5 Nut 11 Collar nut
6 Piston skirt (480 kg) 12 Stu d
STARTING POSITION
Piston with p iston rod placed in inverted position on suspension tool, the
piston rod pointing upwards . Suspension tool is fastened on prepared stand by
bolts (cf work sheet 040 .01) .
SEOUENCE OF OPERATIONS 1 : Disassemblin g
.1 . Loosen and unscrew collar nuts (9) (cf work sheet o4o .08) .
2 . Hang piston skirt (6) with two eye screws and rope on hoist, lift it up over
the piston r9d and place it on wooden support .
40 Note : Watch soft-lead insert in lower rim when lifting off and putting down
the piston skirt .
3 . Measure and note down projection (C) of piston insert ( 2) beyond piston
crown (1) .
4 . Loosen and unscrew nuts (5) then cautiously lift piston rod out of piston
insert with the use of the hoist and place it on wooden support . When ex-:
I
tracting the piston rod, use care not to damage the sleeves (cf work
sheet 040 .08) .
5 . Loosen and unscrew collar nuts (11) (cf work sheet 040 .08) .
6 . Place trestle on prepared stand and fasten it with bolts .
7. Measure and note down projection (C) of piston insert beyond piston crown .
Note : The difference between the Ist and 2nd measurement is the shoulder
040 .453 clearance . The shoulder clearance will normally be 1 .2 to 1 .3 mm
M3Ox2 after a long period of operation of the piston .
Should the measured shoulder clearanc.L exceed 1 .6 mm,_the inner
UX supporting surface of the piston crown must be remachined .

Remachining is to be made in such a way as to obtain a shoulder
clearance of 0 .5 to 0 .6 mm . Restore sleeve support 0 .5 x 450 at tap
holes . Shorten threaded sleeves of inner bolts at the threaded end
0 by the same amount the inner supporting surface has been remachined .
PT O
D36 5612 E Arbei szeii - Stunden Alle BeirieDsSlunden
Workü g tirne Hours Every Operating novrs
C)
Cli 040 .02-2 Durie de trevaii - Heures Toutes leg as necessar y Heure& de morChe
cy, 1 Tiempo de frabojo - Horcs 1 kh 1 Coda Horaq cle serviCio
The admissible maximum amount by which the supporting surface can be
remachined is 1 .5 mm
8. fasten lifting plate with .hexagonal screws~r
on piston in s j
I- FTTI I .
9.
hang it with rope on hoist and lift insert out of piston crown .
Sling two ropes round stud casings, hang ropes on second tackle, slowly
9
take up slack and turn piston insert cautiously .round 1800, remove
iifting plates and set insert on trestle .
10 . heck whetheC seal rings are in good condition, replace if necessary .
Inspect piston rod, discharge funnel (3), discharge pipe (8) with
holder for damaqe .
Note : Only original seal rings should be used . Seal rings must not be
glued on .
SEQUENCE OF OPERATIONS 2 : Assemblin g
oA () A
i . rasten two litting plates with hexagonal screws (M 24x2x5O) to pisto n
1VL4'4XZX .DL V11 WIVII N) A
an&I
ang WILL rope on uols,
2 . Unscrew fixing screws by means of which the suspension tool is fastened
to the floor .
3 . Fasten second rope to suspension tool, slowly take up slack and lift
it up . Slacken rope of lower lifting plate, unhook it and remove
lifting plate - piston crown in about horizontal position . --
4 . Raise piston crown on suspension tool further up while slackening the
rope on the lifting plate, unhook rope and remove-t his lifting plate
too- piston crown suspended from above on hoist, studs pointing
downwards .
0
Note : Use care not to bend the studs during this process! _
5. Lower piston crown (1) slowly onto piston insert (2), paying attention
to centering and to locating pin .
6 . Measure projection (C) of piston insert and compare with measurement
taken before disassembling . If it is greater than before, correct it
by tightening the two lifting plates (next operation)
7 . Fasten piston crown to piston insert by means of two liftirg
* plates
and hexagon screws (M24x2xl2O) and lift assembly by the suspension
'001*.
8 . Use second rope attached to one of the tool lifting plates to lift up
piston crown together with insert, slacken rope fastened to suspension
tool and invert assembly, turn 180 0, detach rope and attach it to
second lifting plate and lift this end too .
9 . Set piston crown with insert down onto suspension.tool and secure it .
with bolts on prepared stand . Remove lifting plates .
10. Cautiously lower piston rod (7) together with packing- and -sl-ee"s -
into piston skirt (2), seeing that it is in the correct angular
position (locating piece) . The 6 sleeves should only be pushed i n
M24x2x72O completely after correct location by means of the screw bolts (packin g
41
should be compressed as firmly as possible) .
11 . Screw on collar nuts (11)-and &6~w_fliem up handtight .
040 .452
12 . Screw 6 nuts (5) on studs (4), tighten by hand and preload to max .
100 bar, with the use of 3 hydraulic tensioning tools, until gap
between Diston rod and piston insert measures _ 0 .03 mm, (check with
feeler gauge) .
13. Screw down 6 nuts and tighten them handtight .-Release pressure, dis-
connect hoses at tensioning tools .
14. Screw on and tighten collar nuts (11) (cf work sheet 040 .08 )
15 . Preload 6 studs (4) with hydraulic tensioning tool (cf work sheet
000.30) .
16. Attach piston skirt with 2 eye screws and rope on hoist-and lower it
cautiously over piston rod .
17. Screw on and tighten collar nuts (9) (cf work sheet 040 .03) .
Note : Jointing surfaces of piston insert (2) to piston crown (1), when
new, have a taper of 0 .27 mm and to the piston rod flange of
0.03 mm, and are trafulated (cf work sheet 000 .20) . Measurements
taken at the outer diameter. Thus, there will be a gap around the
circumference before the bolts are preloaded . is
The two tapered surfaces of the piston insert must not be
machined to obtain a plane surface .
KSZ 70/,125A+8 040
0
M*AL*N PISTON RINGS
Arbelfskarte-ISIr.
Work cord No.
rarjeto trabojo No.
applicable work sheet . . . . . . . . 040 .01

1 Piston ring expander, compl . . . .040 .421
1 Lover . . . . . . . . . . . . . . . . . . . . . . . . . . 040 .421- 1
040 .421-2 2 Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 .421-2
040 421-31 2 Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 .421-3
3 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . 040 .421-4
040 :421-4
040 .421 - LEGEN D
040 .421-1 ;
. 1 Piston ring
. . . ... . 2 Piston crow n
0 1. Grip piston ring ends with the two grips of the ring expandor .
2. Cautiously push lever inwards and hold it in this position .
3. Lift ring clear of the piston crown and deposit it .
4. Cautiously move ]ever outwards.
5. Check piston ring and piston ring groove.
Note : Refit the two top rings (E - relieved type) in the upper ring grooves .
If several pistons are disassembled at the same time, be sure not to mix up the rings of the
individual pistons . The piston rings should be fitted on the same piston as when removed, unless
they are renewed.
Remachining used piston ring s
450
50
A-B
0
036 5612 E i Arbeitszeit - Stunden Alta Betriebssfunden
r- 040.03-1 Working tinne - Hours Every Operating hours
fl: Du rke da Iravall - Heures Touies Its
12000 Heures de marche
4n Tiempo de frabeja - Horas AA Coda Horos de servicio
0
0
KSZ 701125 B 040
PRESSURE-TESTING
M*AL* N PISTON AND PISTON RO D ArbeilSkcrt e-Nr .
Work card No.
Corte travail No.
Torietc trobojo No . 040 .04
applicable work sheets. . . . . . . 009 .02
0 0 9 . 0 .3
040 .01
TOOL3 R70UHRED -100-1 No .

1 Hang-up and pressure testing tool, co .T.,pl . . . . . . . . . 040 .422
1 Piston hang-up tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 .446
1 High pressure pump, pneumatic . . . . . . . . . . . . . . . . . . . . 009 .302
manual . . . . . . . . . . . . . . . . . . . . . . . 009 .41 0
LEGEND
1 Piston (1200 kg) 5 High-pressure hose
2 Piston rod (900 kg) 6 High-pressure pump
3 Pressure gauge 7 Collar bus h
4 Hang-up tool (50 kg) 8 Hexagon bolt with nut and shi m
0
STARTIQ POSITION
Piston n2s beer, pulled with hang-up too', and deposited with the piston
rod pointing upwards .
.SEQUENCE OF OPERATION S
1 . rrill piston (1) and piston rod (2) with water up to the rim .
2 . Mount pressure testing tool in the position shown (see
illustration) .
3 . Connect hp hose (5) of hp pump (6) to pressure testing tool
and build up test pressure with the oil in the hp pump .
4 . Check all joints between piston and piston rod for tightness .
Note : If hang-up tool is used for lifting only, parts (4, 7 and
8) should be mounted so fhat the piston can later also be
inverted (see illustration) .
0
Arceitszeit - Stunden A[ e BeIriebssfuncen
036 5612 E
040 .04-2
Working time
Dur6e de frovoii
Tiernpo de trabojo
- Hours
- Hevres
- Horas kk Every
I
Toules les
Cada as necessary
Ooeraling hours
Heures ce ma~~he
Horcs de servicio
9
0
KSZ 70/125 B 040
M*AL*N INSTALLING PISTON ArDeitskarte-Nr .
V~ork card No .
Carte 1,o,oil No .
0 Torleto Trcbojo No . 040 .05
äppilcaDie work sneeis jüü . j'~~
00-'
040 . OD
04C . 07
C-4Ü . 10
04C . 1 1
TOOLS REQUIRED Tocl No .

1 Piston lifting too, . . . . . . . . . 040 .446
1 Taper ring . . . . . . . . . . . . . . . . . . 0410 .438
1 Hydraulic tensioning tool . . . 030 .129
1 High-pressure pum .p,
pneum . . ' '009 .302

040 .436 1 Hook spanner
0
1 Adaptor B4'lx . 1
I Double-ended b-.x SP2nner size 36x4i
1 Tomm.y bar, dia . 1 8
'I Double-ended ring spanner size 3-.x4i
1 Tackle with rop e
4 Protection c2p for piston rod foc t
LEGEN D
1 Pist on 3 Cylinder line r

2 Piston
- ring 4 Supporting rin g
ST AR7 I N3 POS I T i ON
Pistor. -.ith pistor. rings, piston rod and stuffing box are assembled, piston liberally oiled . Seating surfaces
of piston rod loot and crosshead carefully cls2ne .4. 4 protec t-ion c2ps for screws or, piston rod foot attached.
SEQUENCE OF OPERATIONIS : :
1 . Place three-piece taper ring in the correct position on cylinder liner (3), secured by means of supporting
ring (4),and cil cylinder liner liberally .
0 2 . Hang pistor, (1i with piston lifting device or., hoist, turn it into the correct position - marking on pisto n
.rod foci !
Note : When fitting a ne-, ; piston with piston rod the first time, set both eccentric rings (El and E2) to
position 0 0 / 0 0 .
3 . Set running gear to top center .
I
4 . Lower piston cautiously into cylinder liner in the course of which Piston rings (2) are being pushed into
their grooves by the taper ring . See that stuffing box is in the correct position .
5 . Insert piston rod foot cautiously into eccentric ring while checking alignment of match marks .
6 . Take off four protection caps, screw on nuts and draw them up handtight .
7 . Remove lifting tool and taper ring .
8 . Check and if necessary correct alignment of piston in liner in top center position (cf worksheets 040 .06,
040.07, 040 .10 and 040 .11) .
9 . Mount four tensioning tools on nuts on piston rod foot and connect hoses to hp pump (cf worksheets 000 .32,
009.03 and 040.01) .
10 .Tighten nuts to specified pressure (cf work sheet 000 .30) .
11 .Remove tensioning tools .
0
Arbei szeit Stincen Alle Betrielasslunden
D36 5612 E Work!l,g time H urs E~ery
To Operating hours
040 .05-2 Dvr" de tra~ciil Heures .'es leg 12000 Heures de morche
Tiempo de troboio - Horas Coda Horcs de servic ;o
0
0
KSZ 104 0
0
M*AL*H MEASURING PISTON ALIGNMEN T Arpeitskarle-Nr .
Worktra'
Carle
card.~o. 0 .
IN 040 .06
Tcrieto Irabojo No .
applicable work sheets. . . . . . . 040 .0 7

040.1 0
Exhaust side
TDC
bottom --
CD
0 Z!
4E
U_
GENERAL Control sid e

When the engine is building in the manufacturer's works, alignment of the pistons is measured in the positions
0 actorox . 30 0 and 150 0 crankanole before TOG after encline has been turned in ASTERN DIRECTION which ensures ihat
the guide shoe seats against the guideway and not against the guide rail . To measure piston clearances or the
alignment of the piston in the liner, measurements should be taken in the direction of the piston thrust and
in axial direction,with the piston in top center and in bottom center position,at the upper slide ring of the
guide ring and from below at the slide ring of the piston skirt,with long feeler gauges . It should, however,
be remembered that the piston center is slightly off-set against the control side (cf clearances in section 1) .
These measurements require installation of the piston without rings .
When it is intended to measure the piston aliqnment in a worn cylinder liner, note that measurements taken in top
center position must be taken from the inner edge of the ring groove for the cylinder cover to the piston crown,
because uniform liner wear around the circumference cannot be expected with certainty . The TOG dimension is the
distance from the top edge of the cylinder liner to the top edge of the piston with the crankgear in TOG position .
The measurements taken of piston and of the guide shoe should be entered in a sketch and appended to the Enaine
Records for reference .
Betriebsslunden
Arbeitszei - Stunden Alle Operating hours
036 5610 E Working Iltme - Hours Every Hevres de MarChe
Dvrke de travail - Hevres Touies le s
040 .06-1 Tiernpo de trobojo - Horas kk I Coda 12000 Horas de servicio
0
0
KS Z 040
CORRECTING PISTON ALIGNMEN T
M*A&*M Arbeitskarte-Nr.
Work card No .
Carle travail No. 040 .07
To,leia trabojo No .
0
applicable work sheets . . . . . 009 .02/03
040 .01
040 .05
040 .06
040 .10
040 .11
1 Pin spanner . . . . . . . . . . . . . . . 031 . 362
1 Pin spanner . . . . . . . . . . . . . . . 031 . 363
LEGEN D
1 Piston ro d
2 Eccentric ring (outer)
3 Eccentric ring (inner)
4 Segmental holde r
5 Fixing screw
0 6 Nu t
A Setting mark for eccentric ring El
on piston rod (exhaust side )
B Setting mark for eccentric ring E2
on holding yoke (exhaust side )
START I NG' POSITIO N

Piston installed without piston rings . Piston rod fastened to crosshead (nuts pulled up handtight with tommy bar) .
Measurements of the position of the piston with relation to the liner have been taken and piston alignment must
be corrected .
SEQUENCE 01 OPERATION S
1 . Loosen and unscrew four nuts (6) .

2 . Read angle positions of eccentric rings El and E2 at setting marks, determine point of intersection in
position diagram (cf work card 040 .10), using the two yellow discs, and enter in diagram . (cf relevance is on17
the point of intersection outside the center, see work card 040 .11) .
3 . Starting from this point of intersection, enter new adjusting value, observing the diagran, scale, which will
0 give new points of intersection of the eccentric rings . Apply yellow discs and read off angle degrees for
eccentric rings El and E2 .
4 . Set running gear to top center, mount lifting tool on piston and hang it on hoist (cf work card 040 .01) .
5 . Reset turning gear to bring crosshead into a suitable working position, piston rod will thus be lifted off
the crosshead . I
6 . Loosen fixing screws of eccentric rings .

7 . Make necessary correction of piston position by setting the eccentric rings El and E2 with the use of the pin
spanner to the angle degrees determined (see under 3) .
8 . Reset running gear and thus the crosshead to top center while inserting the piston rod cautiously into the
eccentric ring . Screw on nuts (6) and draw them up handtight with tommy bar .
9 . Measure once more position of piston with relation to cylinder liner, enter measurements and position of
eccentric rings in Engine Log .
10 . When final piston position has been established, drill new taper holes for both fixing screws (5), remove
drillings carefully, tighten screws and secure with lockwire .
11 . Pull piston once more, fit complete set of piston rings and install piston (cf work card 040 .05) .
036 5612 E ArDe, szeil - Sfunden Alle Belrieossivncen

E~ery ODeroiinq hours
040 .07-3 Work~ 'ng I i~e
Dvr6e de tra~oil
- Hours
- Heure s Touies les cis necessary Heures ce morche
I
Tiernpo de ircbojo - Horcs I AA Coda HorG% Ce SerViCiO
0
0
I
RELEASING AND PRELOADING KSZ 70/125 B 040

M *AthL* N PISTON BOLTS Arbeitska rl e-Nr.
Work card No.
Carte travo it No .
Tarieia trobajo No. 040 .08
applicable work sheets . .000 .19 009 .02
000-30 009-03
000-32 040 .02

1 Nut 3 Hydraulic Tandem tensioning tool . . . . . . . . 030 .129
2 Stud 3 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 .443
3 Sleeve 3 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040 .449
4 Piston rod 1 Tommy bar, dia 10 . . . . . . . . . . . . . . . . . . . . . . . 000 .263
030 .129 8 Gap width 1 Torque wrench (80 - 300 Nm) . . . . . . . . . . . . . 008 .00 3
040 .448 1 Socket wrench A 24x12 .5 . . . . . . . . . . . . . . . . . 001 .757
040 .449
1 Ratchet . .
i 000 .2631' 1 Torque wrench (750-2000 Nm) . . . . . . . . . . . . . 008 .005
1 Socket wrench B46x25 . . . . . . . . . . . . . . . . . . . . 001 .802
2 Sheet-metal guide . . . . . . . . . . . . . . . . . . . . . . . 040 .451
1 Double-head socket wrench 46x55 . . . . . . . . . 040 .450
1 High-pressure pump, pneumatic . . . . . . . . . . . 009 .30 2
0 manual . . . . . . . . . . . . . . 009 .410
CR
1 Slugging wrench, box, size 55 . . . . . . . . . . . 000 .786
~0
rl~
1 Slugging wrench, box, size 46 . . . . . . . . . . . 000 .784
1 Feeler gaug e
1 Note pad
STARTING POSITIO N
.Piston and piston rod with attached suspension tool deposited on
stand and secured to floor, piston rod pointing upwards . Piston skirt
is removed, the nuts of the outer studs tightened .
SEQUENCE OF OPERATIONS 1 : Releasing the inner nut s
0
1 . Mount 3 tensioning tools spaced 120 on nuts (1), connect hose s
to pump and release studs (cf work sheet 000.32) . Backing-off angle
of nut (1) is 3200.
2 . Mount 3 tensioning tools spaced 600 on remaining nuts and loosen
\. \ '009 .302 them .
3 . Remove tensioning tools .
SEQUENCE OF OPERATIONS 2 : Preloading innerstuds
N~4- o r 4 . F, . 1 . . 14,
"V v4 a 4. . .4a . V4 . 1
. .0 ~ 1-M I - -
on the pump .
0
1 . Mount 3 tensioning tools with sleeves spaced 120 on nuts, connect hoses to hp pump .
2 . Preload tensioning tool to 30 bar and screw down nuts with tommy bar .
3 . Measure and note down qap width (B) at tightening tools while under pressure,using feeler gauge .
4 . Raise press.ure i .n tgq~ioning .tools to 1000 bair tighten nuts handtight and release pressure .
5 . Raise pressure in tensioning tools once more to 30 bar and .aqain measure and note down width (B) while tool under
pressure, using feeler gauge .
6 . The difference between the two sets of measurements is the permanent bolt elongation which should be 1 .5 mm (but
not s than 1 .3 mm) for each individual bolt .
Note : If the above defined elongation is not attained, repeat operations 3 - 6, raising the pressure accordingly .
7 . Release pressure and detach hoses, unscrew tensioning tools, mount them on remaining 3 studs spaced 600 and re-
connect hoses to pump .
8 . Preload bolts and take measurements as described under 1 - 6 .
Note : If the elongation is not attained in any one of the bolts, the tension is to be released and after removal of
the fault, it must be retightened as specified .
Possible faults : Nut sticking on threads
Tensioning tool defective
High-pressure pump defective p .t .o .
Arbeitszeit - Stu"den elle Betriebssfunden
Co D36 5612 E Working tirne - Hourt tvery Operatirg hours
r-: 040 .08-1 Durie de travoil
Tiempo de trOD0i0
-
-
Heures
Horns kk -. 1
Tou es les
Cado
as necessary Heures de rnarche
Horns de servicio
I -,
M
LEGEND
1 Collar nut 4 Piston insert 7 Collar nut
4 040,450 2 Stud 5 Piston crown 8 Stu d
3 Piston skirt 0
6 Drain funnel A Check-up measur e
71M 00 8 001
'00 .80215
t
'M M 00
A- I 10 0 Nrn +b, 6 SEQUENCE OF OPERATIONS 3- Releasing bolts piston skirt (3) to piston crown (4)
II
1 . Bolt guide plates (040 .451) to piston skirt (3) (cf illustration) .
2 . Apply double end socket wrench to collar nut (1) and back off nut 1800 with the
use of a slugging wrench .
3 . Back off opposite collar nut by 1800 and continue process of crosswise loosening
nuts in clockwise direction .
4 . Completely release and unscrew collar nuts in the same order .
Note : Do not release collar nuts with a torque wrench, but use slugging box
wrench .
SEQUENCE OF OPERATIONS 4, Releasing bolts piston insert (4) to piston crown (5 )
1 . Apply double end socket wrench to collar nut (7) and back off nut 1800 with the
use of a slugging wrench .
2 . Back off opposite collar nut by 1800 and continue process of crosswise loosening
nuts in clockwise direction .
3 . Completely release and unscrew collar nuts in the same order .
Note : Do not release collar nuts with a torque wrench, but use slugging box
wrench . 0
SEQUENCE OF OPERATIONS 5, Tensioning bolts piston insert (4) to piston crown (5)
1 . Coat threads and nut supporting surface with Molykote paste G-n and screw on
nuts (7) .
2 . Tighten collar nuts (7) handtight, using slugging box wrench .
3 . Apply socket wrench and tighten collar nuts crosswise to MA = 600 Nm with the
use of a torque wrench .
4 . Continue to tighter collar nuts crosswise to MA = 1100 Nm and then retighten
them once more applying the same torque .
Note : Check-uo measure (A) must not decrease by more than 0 .1 mm in the course
of final tightening by the specified tightening angle after bolts have
been tightened to specified torque !
5 . Tighten collar nuts crosswise by a tightening anqle of 600 .
SEQUENCE OF OPERATIONS 6, Tensioning bolts piston skirt (3) to piston insert
1 . Coat threads and nut supporting surface with Molykote paste G-n and screw on
nuts (1) .
2 . Bolt guide plates (040 .451) to piston skirt (3) (cf illustration) . 0
3 . A ' pply double end socket wrench to collar nut (1) and tighten nuts handtight, using slugging box wrench .
4 . Apply torque wrench and tighter. collar nuts crosswise to MA ~- 600 N .
5 . Continue to fichten collar nuts crosswise to MA - 1100 Nm and then retighten them once more applying the same
iorque .
6 . Tighten collar nuts crosswise by a tightening angle of 600
Note : Check fixing of drain funnel (6) on piston rod when piston is disassembled (cf illustration) and, if
necessary, tighten to recommended torque MA - 150 Nm .
During operations 3 to 6, piston being supported by lifting device (040 .446) .
SEQUENCE OF OPERATIONS 7, Screwing in stud s
The following should be noted when it becomes necessary to replace a stud in the piston insert or in the piston
crown :
1 . Clean tap hole and threads of the new stud carefully .
2 . Coat tap hole with LOCTITE Type 242 (cf worksheet 000 .19) .
3 . Screw in stud, using two nuts tightened against each other .
4 . Tighten stud to soecified forgue with the use of a torque wrench (cf illustration) .
5 . Unscrew both nuts .
b 51612 E / 040 .08-1

.DH
POSITIONSDIAGRAMM FUR
KORREKTUR DER KOLBENSTELLUN G KSZ
M *Aftk* M POSITION DIAGRAM FOR Arbeifskarte-Nr .
Work card No .
CORRECTING PISTON POSITION Carte travail Noa. 040 .10
Torieta trabojo
Anwendung der Positionsdiagramme For use of position diagrams

siehe Arbeitskarte 040 .11 see work card 040 .11
Exzenter El = unterbrochene Linien Eccentric E 1 - dashed lines

Exzenter 12 - ausgezogene Linien Eccentric E 2 - full lines
STS - Steuerseite STS - control sid e

AS - Auspuffseite AS - exhaust sid e
siehe Rückseite
P .t .0 .
0 Arbeilszeil - Slunden Alle Betriebsstunden
01 D36 5610 0+E Working time - Hours Every Bedarf Operating hours
00 .10- 2
Durie
" de travail
Ti mpo de trabajo
-
-
Heures Toules les
Horas I A I Cado
as necessary Heures de marche
Horas do ser~icio
0
Anwendung der Positionsdiagramme For use of position diagrams

siehe Arbeitskarte 040 .1 1 see work card 040 .1 1
Exzenter E 1 - unterbrochene Linien Eccentric E 1 ' dashed lines
Exzenter E 2 - ausgezogene Linien Eccentric E 2 - full lines
STS - Steuerseit e
AS - Auspuffseite
KSZ 04 0
APPLICATION OF
Arbeitskarte .Nr.
M+AALIOM POSITION DIAGRAM Work card No .
Carte travail No .
0 Toriela trabaio No. 040 .1 1
applicable work cards . . . . . . . . . . . . . . 040 .06
GENERA L 0110 .07
r, ? n -1 M
1 . Any desired piston position, or relocation of the piston with relation to the centr e
of the guide shce can be achieved within a circle of 2 mm radius by turning two eccentric
rings (E2 - outer ring, Ej - inner ring) .
2. If both eccentric rinas are rotated by the same amount relative to the zero
mark (e .g . 00/00, 850/850, 230 0 /2300, etc .), then the intersection will be in
E1=600 . E2=60'
the centre of the diacram .
3 . If the eccentric rings are rotated by different amounts relative to the zero
mark, then the intersection ouiside ~ha centre of the diagram is goolicable .
The second intersection lying in the centre of the diagrar, is irrelevant .
0
4. Any piston position can be established by one of two possible settings of the
eccentric rings, the result being the same .
0
Example : The intersection obtained with E 1 at 90 0 and E 2 at 45 is identical
0
with the setting obtained with the complbmentary angles E 1 - 2
0
and E 2 - 270 0
I----___L__ ___1 Determining the complementary angles (E 1 t 1800 - E 2 or E 2 t 180 - E 1) as
E2=270" E1=225*
well as determining the intersections with settings where the applicable inter-
section is below the centre, is greatly facilitated by the 2 yellow discs
supplied with the manual . These discs are contained in a pocket of the plastics
cover of Work Card 040 .10 . They have a diameter of 100 mm, same as the dis-
placement curves in the diagram, and the procedure is to place them on the
diagram and to move them to the appropriate position .
5 . To find the eccentric angles related to a certain piston rod position, angle readings from the diagram can be
takep at the side of the relevant intersection or at the opposite side . Thus, two different angles are obtained
for each eccentric position which, however, will result in the same corredtive setting (see item 4) . The
practical approach is to use that pai~ of anqles that will reguire the eccentric rinqs to be turned less .
6 . Normally, the diagram on the face side of Work Card 040 .10 is used . If the correction values are less than 0 .2 mm
the enlarged diagram in the back of the sheet is preferable (0 .2 mm eccentric - 10 cm diagram) .
EXAMPLE First installation of a pisto n

STARTING POSITION : Eccentric rings are on 0 0 /00, the specified setting when a piston is installed for the first
time, setting has been checked at marks El and E2 .
Position of piston with relation to liner has been ascertained (see work card 040 P6), relocation of the piston
by 0 .5 mm towards control side (STS)-and 0 .32 mm towardi left-hand side is indicaied . -
1 . Plot position on diagram by following the vertical line upwards from the centre to 0 .5 (STS) and the horizontal .
line towards the left-hand side to 0 .32 (Note : 0 .2 mm on eccentric - 10 mm on the diagram) .
0
2 . Find eccentric angles with the aid of yellow discs, El - 75 and E2 - 400 (complementary a"ngles bein g
0
El - 220 and E2 - 2550) .
is p. t.0.
Betriabssfunden
D36 5610 E Arbeilizeit - Stunden All*
040 .11-1
Working time - Hours
Duriedetravail -Houres
Tiernpo do trabajo - Horns k Every Operating hours
Toules les
Coda
as necessary
Houres do rnarche
Horas do servicio
0
0
INSPECTING AND CLEANING KSZ 70/125 B 105 0
0
M*A&*M CYLINDER LINE R Arbeitskarte-Nr.
Work card No.
Tarieta trcbaio No .
Applicable Work Cards . . . . . . . . . . 050 .06

050-08
1 Tubular lighting fixture, complete . . . . . . . . . . 050-373
1 Tubular lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050-373-1
2 Shell halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050-373-2
2 Hexagonal screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050-373-3
2 Hexagonal nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050-373-4
1 Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050 .452
1 Manual grinder with grinding and polishing whee l
1 Grinding wheel 2 mm thick for oil grooves
1 Hamme r
1 Chise l
LEGEN D
1 Tubular lighting fixture
2 Cylinder bloc k
0 3 Inspection hol e
4 Piston with piston ro d
STARTING POSITIO N
Fuel injector removed, inspection hole on control side opened .
050 .452
..W&
SEOUENCE OF OPERATIONS 1 : Inspectio n

1 . insert tubular lamp (1) into cylinder through the injector housing in the cylinder cover .
2 . Inspect the small visible section of the piston through the inspection hole (3), and, after turning the
piston to BDC, liner ports and the piston top .
3 . Check tightness of seals between liner and cylinder jacket and seals of land cooling at the leak water
discharge .
STARTING POSITIO N
Cylinder cover removed, running gear in BDC or piston removed .
SEOUENCE OF OPERATIONS 2 : Cleaning and Grinding of Wear Edge s
0
i . Clean and check liner wall at the top of piston ring travel . If below this
area a recess has been fornied in the liner, grind iL-L to the larger diame
and round the transition with radius R2 .
0
PT O
036 5612 E Arbe : ~,g
szeit - Stunden Alle Betriebssturcen
C9 050 .01-2
Work, time
Dur6e de travcil
-
-
Hours
Heures
Every 3000 ODerating hours
Heures de mcrche
Toutes les
1 Tiernoo de trctajo - P.orcs I A Cada 12000 Horas de servi-io
Note : After a fracture of the first piston ring, a shoulder may be formed
by the second piston ring in TDC . I II the shoulder is smaller tha n 0
.1 mm, grind to a height of 20 mm and, if shoulders are larger, grind
up to the groove formed by the first piston ring in TDIC .
Imoortant! Oo not grind local depressions . Check liner diamEter, using

touching-up segments or piston ring . If possible, remove cylinder
liner and machine it .
I
2 . Remove carbon deposits from intake and exhaust ports and round sharp edges with
radius R3 . If radial wear is larger than 1 mn, additionally grind horizontal
edges 1 nm with a transition area ol 8 mm, as shown on the sketch .
3 . .Clean inspection hole and check transition area to liner running surface . If
40
3641 399/3 radial wear exceeds 1 mm, round sharp edges with radius R3 .
4. Clean oil grooves and check croove depth . If radial wear exceeds 1 .5 mm in oil
groove area, re-grind grooves to a depth of 3 mm and r=d the edges towards
liner running surface with radius R1 .
0
5 . Check entire running surface of liner for wear edges and other damage . Grind
any shoulders of less than 1 mm to a height oil 20 mm and shoulders of more thai
1 mm to approx . 40 mm height .
Note : Grinding inside cylinder line r
Whenever the liner is to beground, the piston, piston rod and stuffing
box should be removed and the cover of the piston rod stuffing box
installed, in order to make machining and cleaning easier .
If extensive grinding is required, it is recommended to remove the liner
and have it machined at one of our service bases .
20
6 . Clean running surface of cylinder liner carefully and measure the liner in
longitudinal and transverse directions (see Work Card 050 .06) .
0
D36 5612 E/050 .01-2
REMOVING AND INSTALLING KSZ 70/125 B 1 05 0
M*A&*IM CYLINDER LINER FOR INSPECTION
Aroeitskarte-Nr .
Work card No .
Carte travail No.
050 .02
0 Torleto trobajo No .
4 6 7 applicable work sheets 050 .03

1 050 .0 6

3 Jacks 'Stella" complete wit h
connections . . . . . . . . . . . . . . . . . . . . . . 050 .429
1 High-pressure pump
pneumatic . . . . . . 009 .30 2
10 manual . . . . . . . . . 009 .410
11 1 Liner lifting gear . . . . . . . . . . . . . . . . 050.438
1 Set open-end spanners . . . . . . . . . . . . .
12 Set double-ended ring spanner s
13 1
14 LECEN D
1 Drain pipe (residuals )
& 2 Lubricating oil pipe (cylinde r
fs lubrication)
0 16 3 Locating PiGC 8
4 Cooling water ben d
5 Discharge bend (cylinder head)
17 6 Locating pi n
18 7 Supply pipe (flange cooling )
9 8 Supporting ring
-20 9 Lubricating oil pipe (cylinder
lubrication )
10 Cylinder liner
11 Cylinder jacket
12 Packin g
13 Check hole (cylinder cooling)
14 Copper ring
15 Cooling water supply pipe
16 Plug ( inspection hole)
17 Seal rin g
18 Discharge pipe (land cooling)
19 Check hole (land cooling )
20 Seal ring
21 Seal rin g
0 22 Diaphragm casing
. 3640358
1 .1
0 PT O
r- D36 5612 E Arbeitszei! - Stunden rAC_11e
c
Eveo
c d. Betriebsslunden
Co
C, 050 .02-2
Working time
Durie de travail
Tiernpo de trabojo
-
-
-
Hours
Heures
Horcs I Ak Every
T T outes le,
coca
as necessary
Operating hours
Heures de MürChe
Horo; de servicio
STARTING POSITIO N
Cylinderhead removed ind piston pulled, tubular supports between cylinders removed .
SEQUENCE OF OPERATIONS 1 : Removin g 0

1 . Drain cooling water spaces of cylinder completely, closing the cocks in the supply and discharge pipes as
well as in the discharge pipe from land cooling, and drain cooling water into a collecting tank . There are
separate drain pipes on the engine control side .
Note : Do not drain cooling water into bilge .
2 . Remove lubricating pipes . (2) and fittings at lower end of cylinder liner (10) and plug (16) .
3 . Remove pipes (9) and fittings, venting pipe and supply pipe to flange cooling (fittings should be left in
place) as well as temperature sensor, if provided . .
4. Check whether lubricating fittings at lower end and the plug in the cylinder jacket have been removed .
5. Place 3 hydraulic jacks under supporting ring and connect hoses to hp pump . Lift supporting ring together with
cylinder liner by operating the pump .
6 . Hang supporting ring on three hooks and pull it up cautiously together with the cylinder liner .
Note : If liner must be tilted for removing or transport, install liner removing tool as for liner replacement
(cf work sheet 050 .03) .
SEQUENCE OF OPERATIONS 2 : Preparatian for installin g

1 . Hang liner together with supporting ring by means of liner lifting gear on tackle .
2 . Check whether edges on scavenge and exhaust ports are well rounded . 0 0
3 . Check depth of recess at the top of ring travel (cf section 1) .
4 . Clean cooling water space formed by the cylinder jacket and the cilinder liner and apply a thin COat Of
corrosion inhibiting oil .

5. Use air hose to blow out cooling tubes in the lands, annular space in the liner flange and the lubricating
passages and check whether they are completely free .
SEQUENCE OF OPERATIONS 3 : Fitting pa cking and seal ring s
1 . Clean and
, degrease cylinder liner and liner bore in cylinder jacket within the range
12. 3 of the packing (12) ; the surfaces must be bright and smooth !
2 . Lift supporting ring together with cylinder liner slightly so that the seal rings
can be slipped in place from below .
12 . 2 3 . Slip upper square-section ring (12 .1) over the cylinder liner, paying attention to
the position of the rounded edge (see drawing) .
12 . 1 4 . Slip 6 oval rings 12 .2) over liner . The rings must not be rolled over !
Note : The oval rings must be set "on edge" (see drwg .)on the cylinder liner to
10 prevent fthem from getting damaged on installation of the liner .
5. Slip lower square-section ring (12-3) over the liner, again paying attention to the
correct position of the rounded edge .
6. Fit lower round-section seal rings (17, 20,21 and 23) (see drwg . on face page) . 40
Attention! Do not confuse round-section rings with oval rings (12 .2) . Only original
seal rings must be used !
7. Spray-coat packing (8) with Molykote Spray 321 R .
LEGEND
SEOUENCE OF OPERATIONS 4 : Installing cylinder line r
10 Cylinder liner 1 . Having assured that all preparatory work has been duly carried out, lower cylinder
11 Cylinder block
liner into cylinder jacket from above in the correct angular position with the
23 Round-section seal ring cooling water discharge bend (5) pointing towards the exhaust side .
12 Packing 2 . Continue lowering the liner until locating screw enters the locating piece (3) and
12 .1 Square-section ring
(upper ) the supporting ring seats on the cylinder jacket .
12 .2 Oval rin g 3 . Remove liner lifting gear and, if necessary, push liner completely down by the
12 .3 Square-section rin g weight of the cylinder cover .
4 . Lift off cylinder cover, measure liner bore and enter measurements in Engine Log
(lower)
(cf work sheet 050 .06) . Construction of the liner bore should not exceed 0 .02 -
13 Check hole, cylinder cooling
14 Seal ring, coppe r 0 .03 mm, otherwise the liner must again be pulled and checked .
5. Install piston and piston rod, mount cylinder cover, connect all pipes and carry
H = 64 mm (installed)
out water pressure test . Check seals for tightness at check holes .
0
D36 5612 E /050 .02-2
PULLING CYLINDER LINER KSZ 70/125 B
M *Aft* N FOR REPLACEMEN T Arbeitsko rt e-Nr .
Work card No .
0 Corte travcil No .
050 .03
To-leto trcbojo No .

009 .02
009 .03
050 .02

1 Lifting gear. . . . . . . . . . . . . . . . . . 050 .438
3 Lifting jacks c,=pl . . . . . . . . . 050 .429
1 Liner removing too], complete .050 .447
1 Socket size4l . . . . . . . . . . . . . . . . 050-458
1 Centering bracket . . . . . . . . . . . . . 050.4A7-40
050 .429 1 High-pressure pump
4 pne uma-11c--uuJ,Juq312
manual
' . . . . . 009 .41 0
1 Set Double-ended open-end spanners
1 Set double-ended ring spanner s
12
LEGEN D
Nut
Sl eev e
Traverse, upper (120 kg)
Lifting jac k
Wire rop e
Eyebolts for transporting
liner in horizonta l
position
7 Traverse, lower (60 kg)
8 Cylinder liner
9 Supporting ring (440 kg )
STARTING POSITIO N 10 Linkro d
11 Nut
Cylinder cover removed and piston pulled . 12 Screw plug (cooling water
SEQUENCE OF OPERATIONS connection )
1 . Drain cylinder cooling spaces completely, closing the cocks in the supply and discharge pipes and also in the
discharge pipe from land cooling, by draining the cooling water into the collecting tank . The cooling water drai
n
0 pipes are provided on the engine control side .
2 . Remove lubricating connections at the lower end of the cylinder liner (8) and remove plum
3 . Remove lubricating pipes on supporting ring
cooling . (9 ) and venting pipes and cooling water supply pipe for flange
4 . Unscrew fittings for cylinder lubrication in supporting ring, remove all fittings
!
5. Check whether lubricating pipe fittings at the lower end and the plug in the cylinder jackei havebeen removed
.
6 . Mount liner removing tool in cylinder liner . Insert lower traverse (7)
through inspection hole and into the
scavenge hole on the opposite side and tie it to the upper traverse (3) by means of two link'rods (10 and 11) .
7 . Place three hydraulic lifting jacks under the lugs of the supporting ring and connect hoses of
hp pump . Operate
pump until cylinder liner together with supporting ring has been raised by 2 - ? mir . The cylinder liner has thus
been loosened in the cylinder block .
8 . Slip sleeves (2) over three cylinder cover studs and clamp their . down with nuts
(1) to hold down the supporting
ring .
9 . Place two lifting jacks under the projecting ends of the upper traverse, operate
hp pump to lift the cylinder
liner out of the supporting ring .
10.Hang liner removing tool with rope on hoist, pull cylinder liner out completely and set it down cautiously
-
the supporting ring being left on the cylinder jacket . Ropes can be fastened to the eyebolt (6) for horizontal
transport of liner.
0 Note : When it is intended to remove the support .ring from the cyl
.block, remove three sleeves and hang support .rin g
by means OT The 11ittino Qear (050 .438, on hoist, Maximum oil Dressure f . liffinn inck - 1&0 h" r
CoCli
v~
D36 5612 E
050 .03-2
Arbeitszeit Stunden
Working tirn . Hours
Durke ce travoii Heurec
Tiempo cie trcbaja - Horas U
Alle
E~Lry
Touies le s
1 Cada as necessar y
Betricbsslvnoen
Ooerating hours
He res de morche
Horos
" de ser~icio
0
0
INSTALLING KSZ 70/125 B
M+A&+N A NEW CYLINDER LINER Arbeiiskarte-Nr .
Work cord No.
0 Come tro,ctil No .
Tcrjelo trcDaio No . 050 .04
applicable work sheets 050 .02
050 . 06
050 .43 8
LEGEND
1 Cylinder liner 5 Supporting ring
2 Locating screw 6 Locating piece
3 Centering bracket 7 Cylinder jacket
4 Locating groov e
Note : When installing a new liner, check whether
scavenge and exhaust ports as well as the
inspection hole are in line with the respective TOOLS REQUIRED Too! No .
openings in the cylinder jacket . The liner ports
need normally not be reworked . Only original seal if ing gear . . . . . . . . . . . . . . . . . . . . 050 . 438
rings should be used and they must not be twisted 1 Liner removing tool . . . . . . . . . . . . . 050 . 447
in their grooves, but should be evenly tensioned 1 Set open-end spanner s
over tMe entire circumference . 1 Set double-ended open-end SP2nner s
SEOUENCE OF OPERATIONS
1 . Having checked that the preparatory work has beei duly carried out, place supporting ring
(5) on cylinder
jacket (7), paying attention to the locating piece, and screw centering bracket (3)'to ing
t ' ring .
2 . Lower cylinder liner (1) from above, in the correct suppor
angular position, into the bore of the cylinder jacket
so that the-locating screw (2) enters the groove coin the centering bracket . The cooling water discharge fro
m
tne cylinder cover (not to be confused with the oling water bend) should be pointing towards the exhaust side.
3 . Continue to lower cylinder liner until liner flange seats or, the supporting ring
. If the liner has been correctly
installed, no forcing should be needed in screwing in the lubricating fittings .
4 . Remove lifting device and the centering bracket and push liner down onto its seat
by the weight of the cylinder I
cover.
5 . Then remove cylinder cover, measure liner bore and enter dimensions in Engine Log (cf work sheet
050 .06) .
Allowable maximum constriction of liner bore is 0 .02 - 0 .03 mm, otherwise Pull liner once more and check for
the cause .
6.
Install piston and piston rod, mount cylinder cover, connect all pipes aid carry out water pressure test .
Check tightness of seal rings at check holes .
Note : The cooling water connections in the liner flange are sealed
by two screw plugs . Before mounting the
cylinder cover and connecting the cooling water pipes, remove screw plugs and check whether passages
are in alignment .
0
Arbeitszeit - Stunden
C~i
Co
036 5612 E Working tirne - Hours
Alle Betriebssfunden
E~ery Operciting hours
u; 050 .04-2 Durce de trovoil - Heures Toutes le s Heures de morche
Tiempo de trcbo ;o - Horas Ak I Ccdc as necessary Horas ce servicio
0
0
KSZ 70/125 B 1 05 0
MEASURING CYLINDER LINER
0
M*Atk*M Arbeitskarie-Nr .
Work card No .
Corte travail No .
Tcrieto trabolo No.
050 .06
Applicable Work Cards . . . . . . . . . . . . . 040 .01
055-0 1

1 Inside micrometer caliper . . . . . . . . . . 050-381
1 Gauging strip . . . . . . . . . . . . . . . . . . . . . . 050-43 7
LEGEN D
050 .43 7
1 Cylinder liner
050 .38 1 2 Cylinder jacke t
1 STARTING POSITIO N
Cylinder cover removed and placed on adjacent cylinder, crankgear

in BDC (Biston left in place or pulled), engine temperature about or
below 40 C .
0 SQUENCE OF OPERATION S
36 35 191/1 x LV 1 1 . Hook gauging strip into cylinder liner .

2 . Measure liner diameter with inside micrometer caliper through the
drill holes 0, 1, 11, 111, IV, provided in the gauging strip .
Notice! When taking the measurements, the temperature of the inside micrometer caliper should be about the
same as that of the cylinde-r liner .
3 . When the piston has been pulled, measuring point V will be accessible (this dimension is punched into the lower
end of the gauge strip) .
4 . Diametrical liner measurements are to be taken in the direction of the engine axis and at right angles to it .
The measurements should be entered in the engine log .
5 . The drill hole "Oll in the gauging strip is located above the top ring run-out groove . This top section of the
liner is not subjected to wear . In order to eliminate the effect of the temperature in the calculation of
liner wear, the measurements taken in the planes I-IV, and in the plane V if the piston has been pulled, are
to be compared with the measurement taken in the plane 0 but not with the original measurements recorded in
the engine's test certificate as they were taken in the cold engine .
6 . The cylinder liner is to be replaced when the admissible max . wear or admissible max . ovality are exceeded
(cf . Section 1) .
Notice! The condition of the run-out groove at the top of travel of the top piston ring and the conidtion of
0 the scavenge and exhaust ports should be checked every time cylinder liner measurements are taken .
Co D36 5612 1 Arbedszeil - Stunden Alle Betriebsslunden

v~ 050 .06-2 Working lime Hours E~ert, Cperotmg hours
Dur#e de trova it
Tiempo de trabojo
:: Heures
- Horos
0 .51 Ak Toutes les
Cada
as necessary Heures
0 de morche
H ras cle servicio
0
0
GRINDING CYLINDER COVER KSZ 70/125A+B rO5O
M *Atk* N ON CYLINDER LINE R AroellSKcrte-N- .
Work cord No.
Carle iro~oil No . .
0 Tc,,eia i'CDaill No 050 .07

1 Grinding device . . . . . . . . . . . . . . . . . . . 050 .44 1
1 Casing half, upper . . . . . . . . . . . . . . . . 050 .441-1
1 Casing half, lower . . . . . . . . . . . . . . . . 050 .441-2
1 Grinding ring . . . . . . . . . . . . . . . . . . . . . 050 .441-3
3 Eyebolt M 1 2
2 Hexagon screw M 16
2 Hexagon nut M 1 6
1 Grinding compound
1 Hois t
0
~f
050-4~1-1 bis -3
STARTIN,', POSITION LEGEN D
Cylinder cover is removed, suspended from above on hoist . 1 Cylinder cover (2000 kg) 5 Cylinder cover stud
2 Lifting gear 6 Groove in cylinder
14ote : Grinding the jointing surfaces is indicated only i n
3 Handl e line r
the event of the cylinder cover blowing due to un-
4 Cylinder liner 1 Groove in cylinder
evenness of the jointing surface!
cove r
SEQUENCE rp OPERATION' S
1 . Apply grinding compound to grinding ring and place it onto cylinder liner (4) .
2 . Lower cylinder cover (1) onto grinding ring .
Hold cylinder cover suspended from hoist on lifting gear (2) so as to relieve part of the weight .
4 . Move grinding ring by handle (3) back and forth between two cylinder cover studs (5) . Angular movement during
0
grinding will De approx . 23 .
5 . Lift cylinder cover and grinding ring frequently during this process for better distribution of the grinding
compound .
Note : Use coarse grinding compound. Do not remove more material than absolutely necessary and sto when the
contacting surfaces have a dull grey appearance and make full contact over the entire circumference
*D .
A~ter use, screw both handles into t~e inside of the ring and place the ring into the two-piece casing .
Use care not to damage the grinding surfaces .
If, after grinding, the cylinder should still be blowing though the cylinder cover studs have been properly
preloaded, this may be due to distortion of the sealing surfaces .
6 . Before remounting the cylinder cover, place a 1 .5 mm thick copper ring between cover and cylinder liner .
7 . Local erosion that cannot be removed by grinding should be filled with a self-hardening filler having a high
metal content (compressive strength approx . 1500 bar, temperature resistance from - 50 to + 200 0 C) .
Note : If this does not stop the cylinder from blowing, have liner flange groove and sho'ulder on cylinder cover
remachined on a lathe by one of our service basis.
THE GRINDIN3-DEVICEE IS AVAILABLE
ON SPECIAL ORDE R
0
D36 5612 E ArtmOtzeit - 51-,ncer, Alle Betriens-undei
Warking irne - Hou's E~ery
050 . 07-1 Ooercting nours
Durie :Ja' tru~Gil - Heures
Tiempo de trobejo - Horas U
Toutes le s
1 Codo
as necessary Heures ce rnerche
Floras ce ser~ici
0
0
0
SEALING CYLINDER SPACE KSZ 70/125 B
P4 +A&+ kllbsl~~ FOP, EMERGENCY OPERATIO N ArbeiiSK-arte-N_
Work card No .
0 Car!e travail I
No ,.
050 .08
Tc-iefo t-coa .~ ;,io .
I aprlicable wcrk shset 040 .0 1
T OOLS RED "Ll' i RED' Tocl No .
1 Blanking device, complete . . . . . . . . . . . . . . . . . . 050 .43 6

2 Tightening screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-0 . 436-1
2 Hexagonal nit (P. 20x2) . . . . . . . . . . . . . . . . . . . . . 050 .436-2
2 Hexagonal nut (I'-20x2 lefthandi. . . . . . . . . . . . . . 050 .436-3
1 Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or~n
- . 4-52
1 Seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050 .452-1
4 Castellated nut (M16) . . . . . . . . . . . . . . . . . . . . . . 050.452-2
1 Set double-ended cpen-end spanner s
LEGEN9
1 Cylinder line r
2 Scavenge and exhaust Dcrts
3 Diaphragm casin g
STARTING POSITIO N
Piston, piston rod and stuffing box are removed . Engine operation is to be resumed .
1 . Insert blanking device into cylinder liner (1) and press it against the Scavenge and exhaust ports(2) by
-means of the tightening screws .
2 . Fasten cover with screws on diaphragm casing (3) .
0 Note : Use care not to damage the seals and the cylinder liner when mounting the device .
D36 5612 E Arbeitszeit - Stunden Alle Betriebssionoen

05C .08-2 Duree de iravoil - Heures Toutes les
ODeratin ; hours
Tiernpa de traboin - Horas Coda as necessary Heures de marche
Horos de servicio
0
0
KSZ 70/125 B
M#Ak*N REMOVING CYLINDER COVE R Aroeitskarte-N-.
Work card No.
0 Corte travail No . .
055 .01
Tcrielc frcbajo N "
applicable work sheets. . . . 000.30

009 .02
009 .03
1 Tension tool, complete . . . . . . . . . 055 .38 1
1 Cylinder cover support . . . . . . . . . 055 .388
1 Stella jack . . . . . . . . . . . . . . . . . . . . 050 .42 9
1 hp pump, pneumatic . . . . . . . . . . . . . 009 .302/312

manual . . . . . . . . . . . . . . . . 009 .41 0
1 Lifting gear. . . . . . . . . . . . . . . . . . . 050.438
1 Impact ring spanner size 60
1 Adaptor B 50x1', B60x1"
0 1 Box spanner size 46x5O
1 Tommy bar, dia . 12
LEGEN D
1 Cylinder cover 3 Connecting hos e
009-302 2 Tommy bar 4 Screw plug
009-31 2
oog .41 o
START ING Pffffl O N

Cooling w2ter has been drained into collecting tank and*all pipe connections (starting air, fuel delivery pipe)
and, if necessary, all valves are removed . Connections on cooling water bend and water discharge should b e
left in place.

SEQUENCE OF 6PERATION S
1 .Remove protection sleeves from cylinder cover studs, mount hydraulic tensioning tool, connect hoses of hp pum p
to tensioning tool, open relief valve on pump and screw all hydraulic nuts down to stop by means of the hand wheel s
then back off each nut by one half turn (cf work sheet 009 .01 or GO9 .03) .
0 2 .Swit on pump, raise pressure in device (cf work sheet 000 .30) until all nuts can be loosened
'0 by means ~f the
tommy bar . Back Off 211 nuts by aDcrox . .
3 .Release pressure, unscrew all hydraulic nuts by means of the handwheels, disconnect hoses and lift off tensioning
tool .
4 .Unscrew all nuts from cylinder cover studs .
5 .Lift off cylinder cover by means of lifting gear and lower it onto the supporting device placed on the adjacent
cylinder .
Note : Should a cylinder cover be carboned in place, use hydraulic jack to loosen it cautiously - do not tear it
loose by -means of the lifting gear . To loosen cover in these conditions, mount jack on engine control side
(cf illustration overl .eaf) .
Should one of the tensioning elements be defective (nut cannot be loosened etc), disconnect branch pipe
and seal outlet in T-piece with screw plug (4) .
To drain cooling water from cylinder cover, when it is intended to remove the cover o~ to screw out the
indicator socket (5), at first close cocks in cooling water supply and discharge pipes as well as in the
discharge pipe from the land cooling system, then open drain cock of respective cylinder and loosen screw
plug (6) to ad-nit air . Then, to drain the remaining water into receptacle (7), unscrew screw plug completely
(see overleaf) . Cooling water must be drained below the cylinder head level to prevent water from flowin g
into the cylinder when unscrewing the indicator socket or removing the cylinder cover
D36 5612 E . P .t .o .
Arbeitszeit - Stunden 1 Alle
a 055 .01-3 Working tirne - Hours Every
BetrieDSSfunden
Operating hours
c)~
Dur6e da trawül - Heures
Tiernpo de trübc10 - Horas
3 Toules las 12000 Heures de marche
Floras de servicio
Lifting cylinder c-.ver Lowering the cylinder cover or, adjacent cylinder
1 0
055 .38 8
36 35 499
Jack for prying 'loose a cylinder cover Carboned in place Drawing cylinder cove r
364036 5
LEGEND
5 Indicator socket
6 Screw plu g
7 Receptacle
D36 5612 E/055-01-3

KSZ 701125 B 05 5
M *Atk+ N MOUNTING CYLINDER COVER Arbeitskarte-Nr.
Work card No.
Carle t ra'a il No .
0 Tarieta ircbajo No. 055 .02
applicable work sheets . . . . . . 000 .30
009.02
009 .03
1 Tensioning tool, compl . . . . . . . . . . . . 055 .381
1 Torque wrench . . . . . . . . . . . . . . . . . . . . . 008 .00 5
1 High-pressure pump, pneumatic . . . . . 009 .302/312
manual . . . . . . . . 009 .41 0
1 Lifting gear . . . . . . . . . . . . . . . . . . . . . . 050 .438
1 Slugging wrench, box-type, size 55
1 Adaptor B 5501, B46x1 "
1 Socket wrench, size 46x5O
1 Tommy bar, dia . 1 2
LEGEN D
0 1 Cylinder head 3 Connecting hose

2 Tommy bar 4 Screw plug
STARTING POSITIO N
Annular groove in liner flange has been checked
and found to be spotlessly clean and in good
condition, same as the seal rings of the cooling
water bend and the discharge pipe .
The supporting surfaces of cylinder cover upper
and lower part and also the seal rings have been
checked and found to be in good condition (if
cylinder cover was disassembled) .
1 . Lower cylinder cover onto liner, paying attention to the locating
piece and the position of the cooling water bend and the discharge .
Screw down nuts and tighten -Lh6m to snug fit by hand with the use
of the tommy bar .
2 . Lower tensioning tool with hoist onto nuts, connect hoses of hP pump
0 to tensioning tool (cf work sheets 009 .02 and 009 .03) and open
relief valve on pump . Screw hydraulic nuts down to stop by turning
the hand wheels .
3 . Switch on motor pump until recommended pressure (cf work sheet
000.30) has been reached .
4 . Tighten nuts with tommy bar inserted through the slots in the sleeves .
I
5 . Relieve pressure in hp pump and remove connecting hoses .
6 . Screw off hydraulic nuts by turning the hand wheels and lift off
hydraulic tensioning tool .
7 . Screw protection sleeves onto threads and connect all pipes to
36 35 498
cylinder cover.
Ao-t L. Correct tightening of cylinder cover bolts requires a reliable pressure gauge .
Remember that screwed connections, i .e . threads of bolts and nuts, will settle slightly . In the case of new
engines, the following procedure is therefore recommended after a short period of operation . Retighten all
cylinder head bolts to the defined pressure, then loosen bolts in the middle of the cylinder cover and
again retighten them to the defined torque .
Should one of the tensioning elements be defective (nut cannot be loosened etc), disconnect branch pipe
and seal outlet in T-piece with screw plug (4) .
0
D36 5612 E Arbei szeit - Slunden Alle Betriebssfunden
Work!ng time Hour , 5
055 .02-2 Duri'e' Ce Ira,cif - Heu!e 3 E~ery
ToWes les
Operaling hours
I Tiernpo de frocio - Horas AAA Coda 12000 Heures de Mcrche

Horcs de servicio
0
0
DISASSEMBLING AND ASSEMBLING KSZ 70/125 B
M *AGk* N CYLINDER COVER Aroeits,arte-Nr.
Work card No .
Come tro,oil No . .
0 Tcr)etc Iroba, a No 055 .03

055 .02
055 .04
000 .32
009 .02
009 .03
221 .0 2
4 Hydraulic tensioning tool . . . . . . 030 .4,29/009-346
4 sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 055 . 399/423
4 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 055-400/055 .420
2 Tommy bar, dia . 10. . . . . . . . . . . . . . . . . . . 000 .26 3
1 High-pressure pump, pneumatic . . 000-302/009-312
manual . . . . . . . . . . . 009 .41 0
1 Torque spanner 80-300 Nm . . . . . . . . . . . . . 008 .003
1 Spanner socket size 24 x 12 .5 . . . . . . 001 .757
0 1 Spanher socket size-46 x 20 . . . . . . . 001-773
1 Torque spanner 280- 760 Nm. . . . . . . . . 008 .004
1 Spanner socket size 55 x 20 . . . . . . . . . 001-775
1 Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . 055 .411
1 Set double-ended open-end spannar s
LEGEN D
11 Cylinder cover, upper part 6 Seal ring
2 Cylinder cover, bottom part 7 Seal ring
3 Cylinder cover center bolt 8 Seal rin g
2 3 5 6 4 Cylinder cover bolt, lower 9 Nut
36 40 c15/X par t
5 Fuel injecto r
STARTING POSITIO N
Cylinder cover removed and set down .
SEQUENCE OF OPERATIONS 1 : Releasing and Disassemblin g
0 1 . Unscrew fixing nuts of fuel injector (5) and remove fuEl injector (cf
work sheet 221 .02) .
2 . Unscrew nuts of center bolts (3) .
3 . Remove protection cap of cylinder cover bolts for fastening the lower
part (4) .
4 . Mount four tensioning tools, evenly spaced (cf illustration), on nut s I
of bolts (4) connecting the lower part, connect hoses to pump, relieve
bolt I*oad and loosen nuts (cf work sheet 009 .02'or 009 .03) .
5 . Release bolt load of remaining bolts in the same way, using the tensioning
tool, loosen and unscrew nuts .
Note : For releasing the bolt load, leave a little clearance in the tensioning tools, otherwise bolt load :2nn9t be
0
removed . Nuts (9) must be backed off approx .270
6 . Lift up cylinder cover upper part with the use of the lifting gear .
7 . Check and if necessary replace seal rings (6, 7 and 8) .
0 c .J
co
PA .o .
LA D36 5612 E Arbeitszeil Stunden Alle Betriebsslunden
055 .03-1 Work ing t i me Hours E~ery Ooerating hours
[)urit at fro~ il Hevres
Tiernoo ce tr=CiO Horcs
Toutes Its as necessary Heures at marche
AA Coda Horas de serv~clo
SEQUENCE ff OPERATIONS 2 : Assembling and Preloading Bolt s
Note : Correct preloading of cylinder cover bolts for fastening the lower part requires a reliable pressure gauge . 0
1 . Lower upper part of cylinder cover, suspended by hoist, onto lower part, paying attention to the seal rings .
Note : If it becomes necessary to replace the studs (4) extending into the lower part of the cylinder cover,
the new studs must be torqued up to M, - 250 Nm 25 mkD )
L
2. Screw on 10 nuts (9) and tighten them to snug fit by hand with the use of the tommy bar .
3 . Mount four'tensioning tools (see illustration), connect hoses of hp pump to tensioning tools and open relief
valve on pump .
4 . Switch on hp pump -and raise pressure in tensioning tools to 1000 b a
5 . Draw nuts (9) quite tight, inserting the tommy bar through the slots in the sleeves .
6 . Release pressure in hp pump .
7 . Reset tensioning fools to remaining bolts and tighten them in the same manner .
8 . Slip protection caps over bolt thread .
9. Torque up cylinder cover center bolts to M . 650 Nm (- 65 mko) .
10. Install fuel injector, cf work sheet 221 .6r.
MA - 120 NM
SEOUENCE OF OPERATIONS 3 : Tightening bolts in flange of starting and
relief valve after replacing packing and
seal ring s
1 . Cap width must be 0 .01 mm before tightening of bolts .
2 . Torque up bolts (11)
to I"A = 120 Nm ( ;-- 12 mkp) . Gap y .should then
be closed up . If it is not, increase -tightening torque t o
V.A = 140 Nm .( -_ 14 mkp) .
Note : If then the gap is still not closed, check connecting paris
for accuracy to size .
.5 . Screw in press screws (12-) the same amount x and lock with nuts
.
Note : Press screws must be retightened after a short operating perio~
of the engine .
SIOUENCE OF OPERATIONS 4 : Removing and installing press ring and seal

ring in starting and relief valve sea t
1 . Mount extractor (13) on press ring (14) and screw in two puller
screws (17) iD .diagonally opposite position .
2. Extract press ring by tightening the two puller screws uniformly
3. Mount extractor on seal ring (15)
and extract seal ring together *with packing (16) by tightening the puller 0
screws uniformly .
4 . Clean tapered metallic sealing surface and the packing space and check both for damage
.
Note : For refacing tapered seat of starting
.and relief valve, if required, see work card 055-04 .
5 . Renew packing (16) and round-section seal ring (18), if Lequired .
6 . For installing seal rings, reverse procedure-of removal .
LEGEN D
13 10 Starting or relief valve

.17 11 Scre w
12 Press screw (packing )
~R- 14 13 Extractor
is 14 Press ring
16 15 Seall rin g
16 Packin g
17 Press _,cre w
18 Round-section seal rin ;
18 x Reference dimensio n
y Gap width
D36 5612 E/055-03-1

REFACING TAPERED SEAT KSZ-B fV_
055 -
M*AL* IN CYLINDER HEAD FOR
STARTING AND RELIEF VALVE
Aroeitskarie.Nr.
Work card No.
Carte travail No.
0 Torieto trooctio No. 055 . 04
applicable work sheet . . . . . . . . 055 .03
055 .401 TOOLS REQUIRED Tool No .
055 .412
Engine type 70/125 B 78/155 B 1 90/160Ol B
055 .417r- ~
FLZLo 1 Hand grinding too l
1 Grinding paste .
055 .412 055 .417 "0551.401 B
i I I ~
.
=fl I Note : A special electric grinder is available at M.A .N . service

points for repairing extensive damage of tapered seats . This
electric grinder is also available on special order .
LEGEND
Li 1 Sealing surface
ri 2 PaLking space
L . -)
3 Valve flange
STARTING POSITION
Starting or relief valve removed, press ring and seal ring in
cylinder head removed.
0
3640278/5
SEQUENCE OF OPERATION . 1 : Refacing with hand grinding too l

1 . Clean tapered sealing surface in cylinder cover and valve flange and the packing space .
2 . Fasten guide sleeve to'cylinder cover (or-valve flange) without tightening the bolts yet . Then align sleeve
to tapered sealing suriace and tighten bolts . 1
3 . Applygrinding paste to tapered annular surface of__qrindi .ng ~leeve and oil cylindrical outer surface .
4 . Insert grinding sleev'e'*'into guide sleeve and turn it back and forth .
5. The grinding sleeve should be frequently retracted slightly s3 as to allow the grinding paste to spread on the
tapered annular surface .
Note : When grinding valve seats, d'o not remove more material than absolutely necessary to obtain a perfect seat
which is indicated by a dull grey continuous annular surface .
6 . Withdraw grinding sleeve and remove guide sleeve .

7 . Carefully clean tapered seat in cylinder head or valve fl ange .
Note : Clean and oil grinding tool and keep it in such a way that the tapered grinding surface will not be da .mageJ.
0 TOOLS REQUIRED Tool No .*
LEGEND
1 Grinding notor (grinder) 11 Measuring device Engine type 701125 B 78/155 B 90/160 B
2 Switch (on/off) '12 Conu s
3 Electric socket 1 Pilot . . . . . . . . . . . . . . . . * 1 055.414 055 .415 055 .416
13 Truing devic e
4 Cable plu g 14 Diamond cutting 1 Hunger special grinder I
5 Electric cable poin t complete with accessories 055 .413 055 .413 0,55.41 3
6 Clamp rin g 15 Clamp rin g 1 Truing device with
7 Grinding wheel 16 Gear wheel handle 1 Connecting cable
8 Pil o t 17 Knurled screw 1 Measuring devic e
9 Hexagon screw 18 Set screw 5 Grinding wheels dia .
10 Set ring 19 Knurled ring 30/600 of various
20 Pilot spindl e hardnes s
1 Fair spare carbon
brushes (for grind .
motor )
1 Alu rod
TECHNICAL DAT A p .t .o .
Speed of grinding ~otor. . . . . . . . . . . . . . . . . . . . 26 000 rpm
0 Operating voltage. . . . . . . . . . . . . . . . . . . . . . . . . . = 110 V or
50iM VC D. s
036 5610 E Arbeitszeit - 51 .,.dem Alie Betriebssfunden
Working time - Hoirs E~ery Operating hours
C)
9 0 5*5~ .-04-1 Duree de ircvail - Heures
i I Coda le s
Toutes if necessary Heures cle marche
Tiempo cle trcibo ;o - Horas Horas de ser~icict
C, a
12 11 STARTING POSITIO N
Starting or relief valve removed, press ring and seal ring is'
cylinder htad taken out and 2 stud screws removed . 0
SEQUENCE OF OPERATIONS 2 : Refacing with HUNGER special grinder
Caution! Use goggles during grinding !
1. Clean bore holes for fitting the pilot (8),deburr if necessary .
2. Insert pilot so that face edge is flush with conus (12) .
3. Draw up hexagon screws (9) lightly handtight .
4. Oil pilot sparingly, screw on set ring (10) and slide measuring
device (11) in position .
5 . Determine plane of reference surface with relation to the conus
to be ground at 4 points with the use of the _measuring, devi.ce
(cf illustriTion) .
6 . Adjust position of pilot until it seats squarely with relation
to the reference surface by light tapping on the conus disc
using the Alu rod .
Tolerance - + 0 .0 5
7. Tighten screws crosswise and evenly, correct if necessary .
8 . Feel conus, tolerance should be = 0 .03 mm .
9 . Remove measuring device .
10. Set truing device (13) for grinding wheel (7) to 300 (adjustable
.
40
to + 1 0)
Lote- Grinding wheel should be carefully trued whenever th e

grinder is clamped into position and as necessary .
11 . Insert grinder into'clamp ring (15) and clamp it down lightly .
12 . Insert diamond coupling point (14) .
13 . Switch on grinder and move diamond cutting point evenly back
and forth by means of the gearwheel handle (16), adjust diamond,
if necessary, until grind- .ng wheel is running true (cf
12 illustration) .
14. Apply grinder to pilot .
15. For coarse adjusting of grinding depth, move grinder about
pilot spindle (20) seating on the pilot until distance of
grinding wheel to surface to be ground is approx . 1 mm, then
tighten set screw (18) .
16 . Fine adjustment of grinding depth is by turning the knurled
ring which is arrested in position by means of the knurled
screw (17) .
.LoLe . Direction of rotation is marked on top face side of 0
knurled ring by (+) . The grinder with the grinding wheel
is thus moved towards the conus (12) . Fine adjustment
should be made in such a way that grinding is effected
by as large a diameter as possible .
17 . Carefully apply grinder and move it slo0y by hand repeatO y
in both directions until an even grinding pattern is achieved
over the entire circumference .
18 . Remove grinder .
19. Sharp edges produced at the conus ihould be rounded off .
0
D36 5610 E / 055 .04-1
I
KSZ 70/125 B
TESTING, DISASSEMBLING AND KSZ 78/155 057
M *Atk* N ASSEMBLING RELIEF VALVE Arbeitskcrte-Nr .
Work card No.
Cart" travail No.
Tarjela trabojo No. 057 .01
I The testing device is available on special orde r

1 Hand lover. . . . . . . . . . . . . . . . . . . . . . . 057.3611356
1 Testing device . . . . . . . . . . . . . . . . . . . 057.362
LEGENO
1 Relief valve 6 Suction pipe
2 Delivery pipe 7 Filte r
3 Fuel injector 8 Hand pump
4 Pressure gauge 9 Distributor valve
5 Strainer
SEQUENCE OF OPERATIONS 1 : Checking valve opening pressur e

0 I
1 . Mount relief valve (1) on testing device .
2 . Swing valve into testing position, connect delivery pive (2) and provide connection with distributor valve (9) .
3 . Open relief valve and operate pump until liquid escape$ from the valve opening without air bubbles .
4 . Close valve and continue to pump until valve opens .
5 . Read valve opening pressure indicated on pressure gauge, and, if necessary correct opening pressure to 1 .1 x
firing pressure.
(Example : suppose firing pressure WOO barthe corresponding valve opening pressure will be w, 110-bar) .
Note : Adjusting the- opening pressure by one bar requires a change in ring thickness of approx . 0 .7 mm of
the buter spring
LEGEN D
1 Hand lover 5 Pressure springs
2 Cap nut 6 Valv e
3 Valve spindle 7 Cylinder cover
4 Valve casing 8 Rin g
Is

1 . Remove relief valve from cylinder cover.
2. Remove hand lever .
3. Unscrew cap nut, using tommy bar (is spring-loaded) .
4. Remove valys spindle together with valve and the two springs . If necessary, dis;_ssemble completely .
Note : If only the valve head need be chocked, the assembly as a whole, comprising the valve spindle, springs,
nut and lover, can be removed by unscrewing the cap nut with the use of the tommy bar.
SEQUENCE OF OPERATIONS 3 : Assembling
To assemble valve, reverse sequence of operations outlined above . The valve head and the seat in the casing should
be in good condition . All moving parts should be coated with lithius-soap multipurpose grease . After mounting relieill
valve in the cylinder cover, check free movement of valve by actuating the hand lever (057.361) . 1
0
D36 5612 E p .t .o.
r Arbeitszeit - Slunden Alle Betricbsstunden
057 .01-2 Working firne - Houri
Durie de troycil - Heures
Tiempo de trobajo - Horas A 1-Y
T"'. 1*5
Coda
12000 Operating hours
Heures do marche
Horas de servido
PNEUMATICALLY OPERATED RELIEF VALVE
LEGEN D
I Hand lover
057 .356 2 Cap nu t
3 Valve spindle
4 Valve casing
5 Pressure springs
I 8 Rin g
9 Air piston
10 Arresting pin
36 40 522/2
irl
"7
5 4
SEQUENCE OF OPERATIONS 2 : Disassembling
5. Unscrew four nuts on cover of air cylinder .

6. Pull out cover together with air piston (9) and piston rod . -
7. Unscrew spring-loaded screw and extract it together with the arresting pin'(10) .
8. Disassemble completely, if necessary.

When assembling the air~ cylinder, use care not to damage the seal rings of the air piston (9) and check that
piston and arresting pin move freely . After complete assembly, check whether arresting pin will arrest the
valve in opened position and check pipe fitting of air pipe for tightness . For operating the valve, use hand-
lever (057 .356) . 0
0
KSZ 70/125 B
TESTING, DISASSEMBLING
KSZ 78/155 B
AND ASSEMBLIN G
M+Aak*N RELIEF VALVE
Arbeitskarle-Nr.
Work cord No .
0 Caric travail No .
057 .01
Toriela trobnjo No.

1 Hand lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057 .361/356
1 Testing device, complete . . . . . . . . . . . . . . . 057 .35 5
1 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057 .355 .1
4 Stud M 27x2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057 .355 .2
4 Hexagonal nut M 27x2 . . . . . . . . . . . . . . . . . . . 057.355 .3
2 Hexagonal screw M 20x2 . . . . . . . . . . . . . . . . . 057 .355 .4
1 Seal 91 x 104 . . . . . . . . . . . . . . . . . . . . . . . . . . 057 .355-5
1 Hand pump (special tool) . . . . . . . . . . . . . . . 008 .03 2
accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 003 .057
LEGEN D
1 Relief valve
0 2 Testing console
3 Pressure gaug e
4 Hand pump (special tool )
36 30 674/1
SEQUENCE OF OPERATIONS 1 : Checking opening pressur e
1 . Remove relief valve (1) .from cylinder cover .

2 . Mount relief valve on testing console (2) and connectit to hand pump fastened by screws . -
3 . Open relief valve and operate pump until liquid flows out of valve opening without air bubbles .
4 . Close' valve and continue pumping until valve opens .
5 . Read opening pressure at pressure gauge and correct, if necessary, to 1 .1 x the firing pressure .
(Example, Suppose firing pressure is 100 bar,opening pressure of relief valve will be 110 bar) .
Note : Changing the opening pressure by 1 bar will require a change in ring thickness of oluter spring by approx .
0 .7 mm .

0
1. Remove relief valve from cylinder cover.
2. Remove hand lever .
3. Unscrew cap nut using the tommy bar (is spring-loaded!) .
4. Remove valve spindle together with valve and 2 springs . If necessary disassemble completely .
I
Note : If only the valve head need be checked, the assembly as a whole, comprising the valve spindle, springs,
nut and lover, can be removed by unscrewing the cap nut with the use of the tommy bar .
To assemble valve, reverse sequence of operations outlined above . The valve head and the seat in the casin g
should be in good condition . All moving parts should be coated with lithium-soap multipurpose grease . After mounting
'
the relief valve in the cylinder cover, check free movement of valve by actuating the hand lover (057 .361 ) .
THE TESTING DEVICE IS

AVAILABLE ON SPECIAL ORDE R
p.t .o .
D36 5612 E Arbeilszeil - Slunden Alle 110ricbsslunden
Working time - Hours Every Opcroling hours
057 .01-3 Durke de travail - Heurcs Toutcs les 12000 Heures de rnurche
Tiempo de lroboio - Horas Cada Hares de scrvicio
057 .361
0
LEGEN D
1 Hand lover 5 Pressure springs
2 Cap nut 6 Valve hea d
4 Valve casing 8 Rin g
36 40 46 9
5 4 3 2
PNEUMATICALLY OPERATED RELIEF VALV E
0
LEGEN D
1 Hand lover
2 Cap nu t
3 Valve spindle
4 Valve casin g
36 40 522/2 5 Pressure spring
8 Rin g
9 8
9 Air piston
10 Arresting pi n
10
r~4,~P-, 0~ 5j,
mml~m 522/3
1 0
5. Unscrew four nu ts on cover of air cylinder .

6. Pull out cover 'together with air piston (9) and piston rod .
7. Unscrew spring-loaded screw and extract it together with the arresting pin (10) .
8. Disassemble completely, if necessary .
When assembling the air cylinder, use care not to damage the seal rings of the air piston (9) and check that
piston and arresting pin move freely . After complete assembly, check whether arresting pin will arrest the
valve in opened position and check pipe fitting of air pipe for tightness . For operating the valve, use
handlever (057 .356) . -
0
KSZ 70/125 B 057
TESTING, DISASSEMBLING AND
M+AL*N ASSEMBLING RELIEF VALVE Aroeiisitorle-Nr .
Work card No .
Come travail No .
0 Torieta trcoato No . 057 .0 1

1 Hand lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057.3611356
1 Testing device, complete . . . . . . . . . . . . . . . . 057. K 5
1 Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057.35E-1
4 Stud M 27x2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057.355-2
'4 Hexagonal nut M 27x2 . . . . . . . . . . . . . . . . . . . . 057.355-3
2 Hexagonal screw M 20x2 . . . . . . . . . . . . . . . . . . 057.355-4
1 Seal 91 x 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . 057.355- 5
1 Connection fitting . . . . . . . . . . . . . . . . . . . . . . 057.3E3/364
1 Hand pump . .' . . . . . . . . . . . . . . . . . . . . . . . . . . . . 009 .41 0
1 High pressure hose . . . . . . . . . . . . . . . . . . . . . . 009.321
LEGEN D
1 Relief valv e
2 Testing consol e
0 3 Pressure gauge (0-400 bar)
4 Hand pump
SEOUENCE OF OPERATIONS 1 : Checking opening pressure
1. Remove relief valve (1) from cylinder cover .

2. Mount relief valve on testing console (2) and connect'it to hand pump fastened by screws .
3. Open relief valve and operate pump until liquid flows out of valve opening without air bubbles .
4. Close val've and continue pumping until valve opens .
5. Read opening pressure at pressure gauge and correct, if necessary, to 1 .1 x the firing pressure .
(Example : -Suppose firing pressure is 100 bar,opening pressure of relief valve will be 110 bar) .
Note : Changing the opening pressure by 1 bar will require a change in ring thickness of outer spring by approx .
O .,7'mm . ..
0 SEQUENCE OF OPERATIONS 2 : Disassemblin g

1 . Remove relief valve from cylinder cover .
2. Remove hand lever.
3 . Unscrew cap nut using the tommy bar (is spring-loaded!) .
4 . Remove valve spindle together with valve and 2 springs . If necessary disassemble completely .
Note : If only the valve head need be checked, the assembly as a whole, comprising the valve spindle, springs,
nut and lever, can be removed by unscrewing the cap nut with the use of the tomm ; ba r* .
To as sembl e. valve, reverse sequence of operations outl in ed above. The valve head and the . seat in the casing
should be in good condition . All moving parts should be coated with lithium-soap multipurpose grease . After mounting
the relief valve in the cylinder cover, check free movement of valve by actuating the hand liver (057 .-361) .
p . t .0 .
Co
CD
D36 5612 E ArDeilSZeit - Stunden I . U . ~) Alle Beiriebssluncen
Working lime - Hour s E~ery Operating hours
j 057 .01-4 Duriedetrovail -Heures 2+3 . 4 Toutes les 12000 Heures ce marcne
Tiernpo de trabojo - Horos Cccla Horcis de servicio
LEGEND
0
1 Hand lever 5 Pressure springs
2 Cap nu t 6 Valve hea d
4 Valve casin g 8 Rin g
PNEUMATICALLY OPERATED RELIEF VALV E
057-35 6 LEGEN D
0
1 Hand lever
2 Cap nu t
3 Valve spindle
4 Valve casin g
5 Pressure spring
-W
8 Rin g
9 Air piston
10 Arresting pi n
. rr~ r-. .m n;
W%Vul l
~_aH,
5 1 is
SEQUENCE OF OPERATIONS 4 : Disassembling
5. Unscrew four nuts on cover of air cylinder .

6. Pull out cover together with air piston (9) and piston rod .
7. Unscrew spring-loaded screw and extract it together with the arresting pin (10) .
8. Disassemble completely, if necessary .
SEQUENCE OF OPERAT IoNs 5 : Assembling
When assembling the air c0inder, use care not to damage the seal rings of the air piston (9) and check that
piston and arresting pin move freely . After complete assembly, check whether arresting pin will arrest .the
valve in opened position and check pipe fitting of air pipe for tightness . For operating the valve, use hand-
lever (057 .356) . Fill grease cup on air cylinder with lithium-soap multipurpose grease and give it a few turns .
06 5612 E/057 .01-4

CHECKING AND RECONDITIONING K7-10SZ70/1 5B 1 100
*
ArDeitskarte-Nr.
TIMING GEAR DRIVE Work card No. .
0 Corte travail N a
Torieto trabojo No .
100 .0 1
applicable work sheets . . . 000 .19
1& . 2
see illustration 100.02 TOOLS REQUIRED Tool No .

SEQUENCE OF OPERATIONS 1 : Checking 1 Wheel pivoting tool . . . . . . . . . . . . . . . . . . 100 .36 1
1 Disc.0 . . . . . . . . . . . . . . . . . . . . . 0 .0 . . . . . . . 100 . 36 0
Check gearwheels and wheel bearings at intervals 1 Torque wrench 280-760 . . . . . . . . . . . . . . . . 008 .00 4
specified in maintenance =edule . Measure gear 1 Socket wrench, size 36 x 20 . . . . . . . . . . 001 .77 1
backlash and bearing clearance in hubs of gearw ee s
2 Eyebolt M 24 x 2 . . . . . . . . . . . . . . . . . . . . . 000 .145
and enter in Engine Log . Tooth flanks and proper Eyebolt M 30 x 2. . . . . . . . . . . . . . . . . . . . . 000 .146
1
functioning of spray nozzles should however be
1 Ja~k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050 .429
checked at shorter intervals. Secure all screwed
1 Feeler gauge . . . . . . . . . . . . . . . . . . . . . . . . . 000 .451
connections carefully in the course 6f assembl y 1 Set slugging box wrericbe s
and blow out spray nozzles and lubricating pipes 1 Note pa d
with pressure air. 2 Come-along s
For gear backlash of gearwheels see wo-rksheet 100 .02 1 Lifting gear ;with rop e
When admissible maximum values are exceeded, adjust gear backlash by means of set screws (27) and the eccentric
0 axle (5), then check bearing pattern of gear teeth . Then secure all screwed connections carefully, drill new
holes for~ taper pins .
Note : If parts of the timing gear have been removed during reconditioning work, obs2rve match marks (19) when
reinstalling them. . The match mark on the camshaft wheel (7) should line up with the split-joint of the
casing with the crankgear of cylinder No 1 in TDC. Apply a thin coat of Mos 2 -based lubricant to toot h
flanks when reassembling tcf work sheet 000 .20) .
~SEQUENCE OF OPERATIONS 2 : Adjusting gear backlash
1 . Line up marking (34) on flange of eccentric axle (5) and on locating piece (6) with marking 1 (33) on the
surface of the brace block . Fixing screws are loosened .
2 . Adjust intermediate Wheel (3) by means of the set screws (27) until defined gear backlash is achieved at the
meshing points of the gear wheel on the crankshaft (1) and the gearwheel on the camshaft (7) . For ascertaining
gear backlash, at least four of the bolts (31) must have been tightened . Enter measurements in Engine Log .
3 . Then tighten all fixing bolts (31) in the flange .
Note : If available adjusting range should be too small to achieve the desired gear backlash, turn axle (5) and
locating piece (6) through 180 0 until match mark A (34) lines up with match mark 2 (32) on surface of
brace block .
SEQUEN CCE OF OPERATIONS 3 : Adjusting bearing pattern

10
1 . Adjust axle (5) by means of set screws (27) on locating piece (6) until satisfactory bearing patterns are
obtained at the meshing gearwheel on the crankshaft (1) and on the camshaft (7) .
2 . Draw all fixing screws quite tight, locate axle and locating piece in their position with taper pins and
secure all screws, nuts and taper pins .
SEQUENCE OF OPERATIONS 4 : Mounting two-piece gearwheel on crankshaft-
1 . Turn crankshaft until fitted feather key is at the top, mount -the gearwheel half with the milled groove and
mount second wheel hal f wi th bol ts f rom bel ow, wi th bol t threads coated wi th Mol ykote. paste G-n .
2 . Tighten nuts (29) to recommended for ue (cf work sheet 000 .30) .
3 . Check gap width between the two wheel halves with feeler gauge 0 .03 mm .
4 . Tighten nuts further by soecified fichtening anole (cf work sheet 000 .30) using slugging box wrench .
5 . Secure nuts with cotter pins (30) .
Note : When replacing studs in the wheel half, coat tap holes with LOCTITE Type 270 (cf work sheet 000 .19)
and screw in studs with the use of two nuts which are to be tightened against each other .
SEQUENCE OF OPERATIONS 5 : Removing intermediate wheel
1 . .Remove gear casing (21) .
2 . Bolt wheel pivoting tool to lower box frame (cf illustration) .
0 P .t .o .
036 56112 E Arbeitszeit - Slvnden Alle Beiriebsstunden
Working time
Co 100-01-2 - Hours s Coerating hours
r- Dor6e de travoll
Tiempo de trobojo
-
-
Heures
Horcs
TIve ry
Cada
. .t
leg 6000 Hevres de Marche
Horcs de serAcio
Section A-B 3 . Turn intermediate wheel (3) into suitable position by means
of turning gear and bolt down slide piece (32) of tool .
4 . Remove clamp ring (4) and shift intermediate wheel in axial 0
direction into pivotting position (use Stella jack if
necessary) .
5 . Secure intermediate wheel in the direction of engine control
side and exhaust side by means of come-alongs .
6 . Remove fixing screws of eccentric axle and brace block s
24 on the engine control side (if necessary lower intermediate
/ / " ou ~' I kY means 01 Lhe set screwsi .
27 25 36 40 470/6 7 . Swing intermediate wheel out of lower engine frame with th e
aid of the come-;alongs .
Section C-D B . Mark off position of tool axle to make sure it will be re-
installed from the same side and then extract axle from the
tool .
31
lote : Screw down disc on eccentric axle and secure axl e
to prevent it from slipping out (see illustration) when
34 intermediate wheel (1200 kg) is lifted up by means of
33 rope and tackle and set down on prepared stand (wooden
supports) .
~6, Lin 470/2

SEQUENCE OF OPERATIONS 6 : Mounting intermediate whee l 40
lo mount intermediate wheel, reverse sequence of operations
24 25 27 2 6
outlined above .
Move crankgear of cylinder No 1 to TOC and line up match-mark
(19) of gearwheel (7) with the split-joint of the casing .
Tighten flange bolts of intermediate wheel axle to recomnendpd
torque (cf work sheet 000 .30) .
~ote : Before resuming operation,coat flanks of gear teeth with

Mos2 -based lubricant (cf work sheet 000.20), then run
gear train for a short period without oil lubrication b y
- means of, the .t6rning gear . Upon final installation o f
the gear train, check gear backlash and bearing pattern of
gear teeth and enter backlash in Engine Log .
36 40 470/4
0
3640502
100 .361 3 2 3
TIGHTENING BOLTS OF SPLIT MUFF COUPLING ON INSTALLATION Or' CAM-
SHAFT WHEEL
SEQUENCE OF OPERATION3 7 : Tightening with torque wrench
36 34 930 TOOLS REQUIRED Tool No .
1 Torque wrench 750-2000 Nm . . . . . . . . . . . . . . . . 008 .005
1 Socket wrench, size 55x25 . . . . . . . . . . . . . . . . 001 .804
1 Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001 .916
1 Slugging box wrenc h
Tighten coupling bolts crosswise from the center to the ends i n
three steps, applying the recommended torques (cf work shee t
000 .30) .
40
i , 11 e--N For releasing bolts, proceed in the reverse order in one ooeration
1 `6 5612 E / 100 .01-2 using slugging box wrench .
CHECKING AND RECONDITIONING K4-6SZ70/125 B 1 10 0
M*A&+M TIMING GEAR DRIVE Arbeitskarte-Nr .
Work card !~o
Carte travail ~o. 100 .0 1
Tarjeta trcbaio No.
0
applicable work sheets 000 .19 000-30
000 .20 100 .0 2
Ls ee illustration 100.0 2
SEQUENCE OF OPERATIONS 1 : Checkin g 1 Wheel pivoting tool . . . . . . . . . . . . . . . . . . . . . 100 .361
1 Torque wrench 280-760 Nm . . . . . . . . . . . . . . . . 008 .004
Check gearAeels and wheel bearings at intervals 1 Socket wrench,,siz6 36x2O . . . . . . . . . . . . . . . 001 .771
specified in Maintenance Schedule . Measure gear 1 Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050 .429
backlash and bearing clearance in hubs of gearwheels 1 Feeler gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .451
and enter in Engine Log . Tooth flanks and proper 2 Hexagon screw size 16x7O Ig . . . . . . . . . . . . .
functioning of spray nozzles should however be
1 Set slugging box wrenches
checked at shorter intervals . Secure all screwed
1 Note pad
connections carefully in the course of assembl y
2 Come-alon g
and blow out spray nozzles and lubricating pipes
with pressure air . 1 Lifting gear with rop e
For gear backlash of gearwheels see worksheet 100.02

When admissible maximum values are exceeded, idjust gear backlash by means of set screws (27) and the eccentric
axle (5), then check bearing pattern of gear teeth . Then secure all screwed connections carefully, drill new
0 holes for taper pins .
Note : If parts of the timing gear have been removed during reconditioning work, obs*rve match marks (19) when
reinstalling them . The match mark on the camshaft wheel (7) should line up with the split-joint of the
casing with the crankgear of cylinder No 1 in TDC. Apply a thin coat of MoS 2- based lubricant to tooth
flanks when reassembling (cf work sheet 000 .20) .
SEQUENCE OF OPERATION'S 2 : Adjusting gear backlas h
1 . Line up marking (34) on flange of eccentric axle (5) and on locating piece (6) with marking 1 (33) on the
surface of the brace block . Fixing screws are loosened .
2 . Adjust intermediate wheel (3) by means of the set screws (27) until defined gear backlash is achieved at the
meshing points of the gear wheel on the crankshaft (1) and the gearwheel
' on the camshaft (7) . For ascertaining
gear backlash, at least four of the bolts (31) must have been tightened . Enter measurements in Engine Log .
3 . Then tighten all fixing bolts (31) in the flange .
Note : If available adjusting range should be too small to achieve the desired gear backlash, turn axle (5) and
locating piece (6) through 180 0 until match mark /\(34) lines up with match mark 2 (32) on surface of
brace block .
SEQUENCE OF OPERATIONS 3 : Adjusting bearing patter n

1 . Adjust axle (5) by means of set screws (27) on locating piece (6) until satisfactory bearing patterns are
0 obtained at the meshing gearwheel on the crankshaft (1) and on the camshaft (7) .
2 . Draw all fixing screws quite tight, locate axle and locating piece in their position with taper pins and
secure all screws, nuts and taper pins .
SEQUENCE OF OPERATION'S 4 : Mounting two-piece gearwheel on crankshaf t
1 . Turn crankshaft until fitted feather key is at the top, mount the gearwheel half with the milled groove and
mount second wheel half with bolts from below, with bolt threads coated with Molykote paste G-n .
2 . Tighten nuts (29) to recommended forgue (cf work sheet 000 .30) .
3 . Check gap width between the two wheel halves with feeler gauge 0 .03 mm .
4 . Tighten nuts further by specified tightening angle (cf work sheet 000 .30) using slugging box wrench .
5 . Secure nuts with cotter pins (30) .
Note : When replacing studs in the wheel half, coat tap holes with LOCTITE Type 270 (cf work sheet 000 .19)
and screw in studs with the use of two nuts which are to be tightened against each other .
SEQUENCE OF OPERATIONS 5 : Removing intermediate wheel
1 . Remove gear casing (21) .
2 . Bolt wheel pivoting tool to lower box frame (cf illustration) .
3 . Turn intermediate wheel (3) into suitable position by means of turning gear and bolt down slide piece (23)
of tool .
4 . Screw two hexagon screws M16 into rest 1 1 ent-mounted gearwheel (18) and attach rope to gearwheel .
5 . Unscrew connecting bblts (22) . P .t .o .
0
Arbeit it Stunde Alle Betriebssfunden
co D36 5612 E
r_
C4 100.01-3
W."lilnzg
e finIL Hours r'
Durie de troVoil - Heures
Tternpo de trobajo - Horas I Ak . Every
Toutes les
Coda
6000
Operating hours
Heures de rnarche
Horas de servicio
6 . Remove clamp ring (4), locating piece (6) with brace blocks (25 and 26)
and set screw (27) and shift intermediate wheal in axial direction
into pivoting position (use Stella jack if necessary)-
7 . Secure intermediate wheel in both directions, towards engine control 0
and exhaust side, using come-alongs .
8 . Remove cover (35) of insert hole for eccentric axle (5) and disconnect
oil supply pipe .
9 . Remove fixing screws of eccentric axle, shift it sideways and take it
over with lifting gear and rope (use clamp ring groove for securing
24 hemp rope) .
10 . Swing suspended intermediate wheel out of engine frame with the aid of
26 the come-alongs .
25 27 3640753/ 2 11 . Mark off position of axle to make sure it will be reinstalled from
the same side and then extract axle from the tool .
12 . Lower intermediate wheel (appr . 1000 kg) by means of lifting gear and
rope onto wooden supports .
SEQUENCE OF OPERATION'S 6 : Mounting intermediate whee l

Section C - D
To mount intermediate wheel, reverse sequence of operations
outlined above .
Move crankgear of cylinder No 1 to TOC and line up match-mark
31 . (19) of g .arwheel (7) with the split-joint of the casing .
Tighten flange bolts of intermediate wheel axle to recommended forou e 0
34 32 : (cf work sheet'000 .30) .'
Note : before resuming operation,coat flanks of gear teeth with

33 Mos 2 -based lubricant (cf work sheet 000 .20), then run
gear train for a short period without oil lubrication by
means c-.' the turning gear . Upon final installation o f
~he gear train, check gear backlash and bearing pattern o f
3640753/3 gear teeth and enter backlash in Engine Log .
(D
0
3640753 A 100.363 23 3
TIGHTENING BOLTS OF SPLIT MUFF COUPLING ON INSTALLATION OF CAM-

SHAFT WHEEL
SEQUENC7 OF OPERATIONS -7 :Tightening with torque wrench
1 Torque wrench 750-2000 Nm . . . . . . . . . . . . . . . . 008 .005
1 Socket wrench, size 55x25 . . . . . . . . . . . . . . . . 001 .804
1 Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001 .916
1 Sl .ugging box wrenc h
Tighten coupling bolts crosswise from the center to the ends in
thfte steps, applying the recommended torques (cf work sheet
000 .30) .
For releasing bolts, proceed in the reverse order iin one operation
using slugging box wrench .
0
D36 5512 E / 100 .01-3

K 7-10 SZ70/1250 10 0
CHECKING AND RECONDITION-
M *A&* N ING TIMING GEAR DRIV E Arbeitskarte-Nr.
Work card No. .
0 Carte travail N 0 100 .02
applic6ble work sheet . . . . . . . 100.01
LEGE14 D
1 Gear on crankshaft (two-piece) 13 Shi m 24 Plexagon screw (cf work sheet 100 .01)
2 Crankshaf t 14 Couplin g 25 Brace bloc k
3 Intermediate wheel 15 Flange bearin g 26 Brace block
4 Clamp rin g 16 Gearwheel (governor) 27 Set scre w
5 Eccentric axle 17 Spray nozzl e 28 Casing cover
6 Locating piec e 18 Spray nozzl e 29 Nu t
7 Gearwheel on camshaft 19 Mar1king (TDC-cylinder No 1) 30 Grub scre w
8 Bearing shel l 20 Spray nozzl e 31 Plexagon screw
9 Bearing shell 21 Gear casing 32 Mark 2
10 Bearing bush 22 Spray nozzle 33 Mark 1
11 Shi m 23 Slide piece 34 Mark
12 Cheese-headed bol t
0 0. t. 0.
Aroeaszeit - Stuncien Alit eetriebssfunden
D35 5612 E Opercling hours
100 .02-2 rie ce travail - Heure s Toute s les 6000 Fievres de marche
00
Tientoo de Irabo;o - Horas Coda Horcs de servi .io
I
Number of aear teeth and weiaht s
0
D
Gearwheel Numbe'r of teeth Weight kg E
Drive wheel (1 and 22) 118 120 0

Intermediate wheel (3) 111 120 0
Gearwheel on camshaft (7) 118 90 0
Clearance s
Nominal dimensio r
Measuring point New limit , -~ -M
mm
A 280 .1 H6 -
B - 0.156-0 .240 0 .3 5
C 280 f 7 -
D 200 .4 H7
E - 0.400-0 .475 - 0
0 .6
F 200 h6 - 36 40 340/1
U T S
G 150 K -
H - 0 .043-0.123 0.2 0
1 150 f7 0
K 0 .16 - 0 .27 0 .40
-
200 h6 - -
M 120 H7 -
N - 0 .06 - 0 .10 0 .2 0
0 200 H7 - -
P - 0 .100-0 .192 0 .3 0
R 200 e7 - -
.65 -
S 370 + 0 -
+0 .4 5
T - 0 .45 - 0 .85 1 .2 0
U 370 - 0 .2 -
V - 0 .25 - 0 .3 5
W - 0 .20 - M O
x - 0 .15 - 0 .2 0
* gear backlash (with tierods preloaded)

0
0
KSZ 70/125 B 1 103
M *AtL* N FUEL CAM Arbeitskarte-Nr .
Work card No . .
0 Corte travo :1 N a 103 .0 1
Tarleia trcbo~o No.
applicable work sheets . . . . . . . . 200 .02

200.06
TOOLS REQUIRED . Tool No .
1 Torque wrench 750-2000 Nm . . . . . . . . . . . . . . . . . . . . . . . 008 .005
1I Socket wrench, size 46x25 . . . . . . . . . . . . . . . . . . . . . . . 001 .802
1 Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001 .91 6
1 Box wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .835
1 Extension tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .863
2 Link plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 .367
2 Shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 002.451
2 Hexagon bolt M 1 6
2 Rop e
1 Working platform, approx . 800 mm high from ship's own means
1 Sheet of cardboar d
LEGEND
1 Cam (50 kg) 4 Camshaf t
2 Cam holder 5 Sheet of cardboard
3 Fixing bol t
STARTING POSITIO N
Lateral and bottom covers of injection pump drive are removed . In-
jection punp shut-off (cf work sheet 200 .06) .
SEQUE_NCE OF OPERATIONS 1 : Removing

1 . Screo two link plates on cam (1) .
2 . Turn camshaft (5) so that fixing bolts (3) can be released with
the box spanner . Bolts should not be screwed out completely .
3 . Attach ropes to two link plates and turn cam downwards .
4 . Screw out fixing bolts, lower cam onto cardboard sheet, then lift
it Out through the opening in the drive gear casing and deposit
it on wooden supports .
SEOUENCE OF OPERATIONS 2 : Installin g
1 . Hang cam with link plates and rope up on tackle and lift it throug h
the opening into the drive gear casing .
2 . Fasten cam with two fixing bolts handtight on carp . holder and
remove link plates .
Note : After fitting new cams or after loosening a cam, the TO .^
lift must be newly adjusted in accordance with the marking .
Any adjustments are made by turning the cam on he camshaft .
(for clearance between tappet roller and cam see work sheet I
200 .02) .
3 . Torque up first fixing bolt to MA - 600 Nm, using torque wrench .
4 . Tension second fixing bolt to final torcue M, .1200 Nm .
5. Then tension first fixing bolt to final tiahlening torque
M - 1200 N m
Note : Preloading of fixing bolts in two steps is necessary because

of the difference in friction between the cam and the cam-
shaft, which may be considerable depending on the state o f
I ubri cation .
0
D36 5612 E A r Coe it szei I - Stunden Alle Betriebssfunden
.
Working time - Hours Every Ooerol ng hours
Heures de marche
103 .01-2 Durke de travail
Tiempo ce trcbaio
- Heures
- Horas
Toutes le s
A Coda
as necessary Horcs ce servicso
0
0
CHECKING 120
DISASSEMBLING AND ASSEMBLIN G KSZ 70/125 B
M *Afk* N REVERSING GEAR
Arbeitskarte-Nr.
Work card No.
0 Corte travail No.
120.0 1
= 300 N m
LEGEN D 13 1
1 Pisto n 14 Reversing hand lever
2 Piston ring 15 Extensio n
3 Cylinder 16 Bol t
4 Cove r 17 Seal ring
5 Oil tank (ahead) 18 Seal ring
6 Oil tank (astern) 19 Seal ring 1 Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 .359
7 Camshaft 20 Bol t 1 Torque wrench 80-300 Nm . . . . . . . . . . . . . . . . . . . . 003 .003
8 Slip ring 21 Bol t 1 Socketwrench, size 30x12 .5 . . . . . . . . . . . . . . . . . 001 .759
9 Slip ring 22 Locating pin 1 Extension, size 12 .5025 . . . . . . . . . . . . . . . . . . . 001 .911
10 Locating pin 23 Casin g 1 Feeler gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .451
11 Flang e 24 Bolt 1 Eyebolt M~M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .146
12 Lockrin g 25 Bol t 2 Eyebolt MID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 .141
13 Oil drain screw 1 Set open-end wrenche s
0 SEQUENCE OF OPERATIONS 1 : Checking 1 Tackle with rop e
1 . Check to see that all pressure air gauges are on zero (exception : shut-off pressure air receiver) .
2 . Screw out dipstick in "asterh" oil tank and check oil level (level marks on dipstick) .
Note : With the reversing piston in mid-position, the oil level in the two tanks should be at the same
I
height (length of travel from end position is 82.5 mill - 1/2 stroke) .
3 . Screw out screw plug in 'ahead' 'Lank, check oil level and top up oil filling in both tanks if necessary .
4 . Fill grease nipple-in casing with lithium-soap multipurpose grease .
STARTING POSITION
Reversing gear is in end position AHEAD, control air lines are vented .
1 . Disconnect pressure-air lines at oil tanks for Ahead and Astern (5 and 6) (mark lines, if necessary) .
2 . Unscrew both oil drain screws (13) in cylinder (3) and tanks' and drain oil completely .
3 . Hang cylinder together with oil tanks on hoist .
4 . Unscrew bolts (16) in cylinder .
5 Extract cylinder caqtiously in axial direction with the aid of the hoist and place it on wooden supports .
0 p .t .o .
D36 5612 E Arbeitszeil - Stunden Alle 3000 Betriebssfunden
120 .01-2 Working time - Hours
Dur6edetravoil -Heures
Tiempo de trobojo - Horas kk I
Every
Toutes les
Cod a
-
24000
Operating hours
Heures de morche
Hares de servicio
6. Remove cover (4), check and if necessary replace seal ring .
7. Remove covers on both sides of the casing (23) to gain access to the slip rings (8 and 9) .
8. Unscrew bolts (20) in piston rod foot .
9. Locsen 1ccating pin (22) with the use of the extension (15) and push piston rod into Astern position until 0
arrest is tripped, and remove slip ring (9) .
1C .L ., .-ser.. bolts (21), remove entrainer and slip ring (8) .
ll .As .-ertair, slip ring clearance by taking measurements of the individual parts and replace rings if necessary .
12 .0's .-c.nnect control-air pipes (mark pipes), hang casing with rope on hoist and unscrew fixing bolts (24 and
2z) .
. .R ;%ve cas- ng with piston cautiously in axial direction and place it or, wooden supportsi use eyebolts
.
, .Uns .-rew piston' and piston rod.
15 Lccser fixing pins (10 and 22) of piston rod and extract rod .
li :check all seal rings of casing and replace as necessary .
Ncte- The reversing gear need not be disassembled completely unless it is for general overhaul . For an
4Interim inspection the moving parts need not be removed . The axial clearance of the slip rings can
al~ : be ascertained without disassembling the reversing gear, simply by measuring the axial movement
cf the piston with relation to the camshaft .
SEOUENHP 0" OPERATION'S 3 : Assemblin g
To asse .mble reversing gear, reverse sequence of operations outlined above . Before inserting the piston into
.he cylinder, push piston rings with the use of the clamp (120 .359) into their grooves . After replacement of
slip rings, piston rod and seal rings, chack .length of reversing travel . All important screwed connections
0
must be tightened to the specified torque (see illustration) . Lubricate moving parts with lithium-soap grease
.
After mounting the reversing gear on the engine, check proper functioning of the valve holding the reversing
gear In its e~d positioh .
For 'Lank filling see under sequence of operations 1, checking .
Measurin g Nomina l New Limi t

point dimension
.
A 165 U
0.1 0
B 350 H 7
C - 0 .500-0 .60 7
0 349,5-0 .0 5
E 8 f7 -
F 0.038-0 .075 0 .1 5
G 8 ES - - 0
H 4 E8 - -
i - 0 .03 - 0 .06 0 .1 0
K 4 f7 - -
L 160 H7 -
M 0 .30 - 0 .44 -
.3 - -
N 160 -0
0. 4
0 50 H7 -
P - 0 .025-0.075 0-.1 5
R 50 V - -
S 35 -
T 33 + 0 . 13 - -
U 0 .20 - 0.38 0.5 0
0.20 - -
V 33 -
- 0.2 5
W 120 E7 - -
X - 0.072-0 .129 0 .2 0
Y 120 h6 -
0
D36 5612E / 120 .01-2

M.A .N.-DIESEL 125
0
M*AL*N ' PRECISI'Cj~ REGULATI.NG V~WE Arbeftkarle-W.
Work c*rd No.
CWM 1MVW1 No. 125 .02
Tarloo trabojo No.
PRECISION REGULATING
VALVE 105, 1291
LEGEND
1 Air suppl y
2 Controlled flow
3 Vent
4 Hexagon bolt
5 Throttle screw
--4w- Air connections
V Wsarinf parts
1 . Unscrew 4 hexagon bolts and remove wiaring parts M downwards .

2. Cl son all parts and dry vith an air boss.
3. Check wearing parts for signs of wear or hardening (seal rings),#
Replace parts as necssswi .
0 4. Before reassembling, check All moving parts for free movement .
For assembling reverse sequence of operations.
The valve can be lubricated through an .external lubricating nipple with
a grease gun .
PRECISION REGULATING
VALVE 128, W
LEGEND
1 Screw cap 6 Snap ring
2 Grub screw 7 Supply air valve
3 Piston A Ontrolled flow
4 Venting valve P Supply ai r
5 Munger R Vent
0 SEQUEICE OF OPERATIONS
1 . Back out grub screw (2) slightly and unscrew screw cap (1), thus
relaxing the pressure spring .
2. Take out piston (3), vent valve (4) with spring and plunger (5) . I
3. Take off snap ring (6) and remove venting valve (7) .
4. Clean parts and dry with an air hose.
5. Inspect wearing parts (V) for signs of wear or hardening (seal rings) ;
replace parts, if necessary .
6. On assembling, check to see that all moving parts move freely .
'4W, R Assembly is the reverse of disassembly .
D365600 E
125.02-2
0
0
DISMANTLING AND CLEANING M .A .N .-DIESE L 125
0 M *AgL* FOUR-WAY VALVE 215 Arboil'karte-Ne.
Work card No .
125 .031 *
Carte travail No.
Tarieta trabajo No .
3 2 1
7'~ ZZV1
Z71 I'm 731W,-M/J1%A=
11 77q ' rf777777A~7/, V/1*
F__ -
18
V
OPERATING METHOD
4 5 6 2 3
Ai r admi tte d Ai r admi ti7
e 777 admi tte( vented closed vente d
valve jammed or vented or vented
vented air admitted vented vented connecte d
I vented lair admitted l connected I vente d
vented -
KEY TO SYMBOLS TOOLS REQU I RED

V Wearing parts (set of wearing parts see Spare parts catalogue 1 Set of double head fork spanners
assembly 125 )
1 Hexagon screw 5 Spring plate
2 Cover 6 Bush
3 Piston Pneumatic connections
4 Pressure sprin g
NOTE When opening the control or starting air system it is necessary to ensure that no dirt whatsoever can enter
the valves and pipes . Open pipe ends are to be closed with plastic caps or adhesive tape . The place of work
0 must be perfectly clean when valves are to be dismantled . A grease solvent compound or compressed air i s
to be used for cleaning .
When several valves are being dismantled at the same time it is necessary to ensure that parts do not got
mixed up .
When the valves-are to be assembled the place of work must be Perfectly c1lan because even the smallest I
particles of dirt are likely to cause trouble in the valves .
All sliding faces, O-rings and flat seals are to be lubricated with the 'West 11 grease from Westinghouse,
included in the spares supplied . "Alvania No . 21 from Shell or another grease that contains lithium can be
used as a substitute . Normal greases are unsuitable for this purpose .
1 . Disconnect pipes, remove fixing bolts and valve .
2 . Close open pipe ends to prevent entry of dirt .
3 . Loosen hexagon screws (1), remove cover (2) and pull piston (3) .
4 . Remove pressure spring (4) and spring plate (5) .
5. Pull out bush (6) .
6 . Clean component parts and blast them with compressed air .
7. Check wearing parts for wear or solidification (sealing rings), and replace parts if necessary .
0 8. Before assembly, check all moving parts for smooth movement .
Assemblv is t ra ip rawar-ta ordsi r
036 5600 E
~kb!LitE~t -Stunden
All
as required
Betriabigfunden
Operating hours
Ln Dur6o do travail - Houres . too Houres do inarch e
r-
w; 125 .03-1 I rimpo do frobalo - Horas I I "a

TE-1-11,111y
C" . .5 Horas do servicio
0
0
1:
DISMANTLING AND CLEANING M .A .N,-DIESEL 12 5

M *Aftk* M THREE-WAY VALVE 301 Arbeitskarte-Isir.
Work card No,
Carlo travail N 125 .05
Tarieto trabajo No .
TOOLS REQJIRED -
1 Set of double head fork spanners
1 Hexagon screwdriver SV. 4
1 Screwdrive r
1 Pair of pointed pliers for locking rings, clamping
from outside .
KEY TO SYMBOLS
V Wearing parts (set of wearing part s see Spare part s
rn+An uo teeamhl bq) '. -
-OP-Pneumatic connections
NOTE
When opening the control or starting air system it is ,-
necessary to ensure that no dirt whatsoever can enter the
valves and pipes . Open pipe ends are to' be closed with
plastic caps or adhesive tape .- The place of work must be
perf actl y cl ean when val vas are to be di smantl ad . A grease
solvent compound or compressed air is to be used fo r
cl eani ng .
When several valves are being dismantled at the same tire,
it is necessary to ensure that parts do not got mi xed up .
When the valves are to be assembled the place of work must
- 5 1 1 2 4 be Perfectly clean because even the smallest particles of
vented connected close d dirt are likely to cause trouble in the valves .
kiradmitt closedl connected All sliding faces, 0-rings and flat seals are to be lubricat-
ed with the 'West 11 grease from Westinghouse, included in'
the spares supplied . 'Alvania No . 21 from Shell or another
grease that contains lithium can be used as a substitute .
Normal greases are unsuitable for this purpose .
0 SEQUENCE OF OPERATIONS
.1 . Disconnect pipes, remo~va fixing bolts and valve
2 . Close open pipe ends to prevent entry of di~t .
3 . Turn out 3 hexagonal socket screws (SW 4) and remove top part-watch component parts .-
4 . Screw vilve guide out of bottom part .
5 . Clean component parts-and blast them with compressed air . .
6 . Check wearing parts for wear .or solidification (sealing rings), and replace parts if necessary .
7 . Before . assembly, check all moving parts for smooth movement .
.
Assembly is to take place in reverse order.
Arbeitszeit - Stunden . Alto fletriabistunden

036 5600 E Working time - Hours -- Every Operating hours
-j IZU .U :~-l Duriedetrovoll -Heur«
Ti4mpodeirckbalo-Horat -
- Toutes; les
Coda
as required Houres do morche
Horas do servici*
0
0
DISMANTLING AND CLEANING FOUR- M .A .N .-DIESEL 125
WAY CHANGEOVER COCK WITH BUILT- Arbeitskarte-Hr.
0
M *Atk* M UP SWITCH 303 Work card No .
Carlo travail No. 125 .06
Tarieta trabolo No.
0 KEY TO SYMBOLS TOOLS REQUIRED

V Wearing parts (set of wearing 1 Set of double head fork
parts, see Spare parts catalogue spanners
assembly 125) 1 Screwdrive r
1 Pair of pointed pliers
1 Grooved nut 5 Bal l
for locking rings,
2 Piston 6 Switching el ement
clamping from outsid e
3 Cover plate 7 Protective sheath
4 Cylindrical screw
OPERATING METHOD
Position I Position
q
,
Pas sage
1-5 1-9
2 -6 2 - 10
3-7 3 - 11
4 -8 4 - 12
12 - E 8- E
NOT E
When opening the control or starting system, it is necessary to ensure that no dirt whatsoever can enter the valves
and pipes . Open pipe ends are to be closed with plastic caps or adhesive tape . The place of work must be perfectly
clean when valves are to be dismantled . A grease solvent compound or compressed air is to be used for cleaning .
-When several valves are being dismantled at the same time, it is necessary to ensure that parts do not got mixed up .
When the valves are to be assembled the place of work must be perfectly clean because even the smallest particles of
0 dirt are likely to cause trouble in the,valves .
All sliding faces, O-rings and flat seals are to be lubricated with the 'West 11 grease from Westinghouse, included
in the spares supplied . 'Alvania No . 21 from Shell or another grease that contains lithium can be used as a sub-
stitute . Normal greases are unsuitable for this purpose .
1 . Disconnect pipes, remove,fixing bolts and changeover cock .
3 . Remove protective sheath (7) and switching element (6) .
4 . Screw out cylindrical screw (4), remove coverplato (3) (make sure that ball (5) does not get lost) .
5 . Remove grooved nut (1), take piston (2) out of bore .
7 . Check wearing parts for wear or solidification (sealing rings) and replace parts if necessary .
8 . Before assembly, check all moving parts for smooth movement .
AssemblY is to take place in reverse order.
Arbeitsmall Stunden All* Beirieb2stunden

036 5600 E Working ti Hours Every Operating hours
125 .06-1 Dur6e do travail
Tlernpo do
trabalo - Heures
- Horas
T-ut-ws as required
Houres do marche
Cada Horas de tervkio
0
0
DISMANTLING AND CLEANING M .A .N .-DIESEL 125
M *A'OL* M THREE-WAY VALVE 31 7 Arb*ifskarf*-Nr.
Work cord No.
125 .07
Carte travall No .
Tariela trabojo No.
0 TOOLS REURED
1 Hexagon screwdriver SW 6
1 Hock spanner
KEY TO SYMBOLS
V Wearing parts (set of wearing parts, see Spare parts
catalogue, assembly 125)
1 Hexagonal socket screw 5 Valve guide
2 Top part of casing 6 Valve seat
3 piston 7 Valv e
4 Vaive tappet _00 . Pneumatic connection s
NOTE
is When opening the control or starting air

system it is necessary to ensure that no
dirt whatsoever can enter the valves and
pipes . Open pipe ends are to be closed with
plastic caps or adhesive tape . The place
of work must be perfectly clean when valves
OPERATING METHOD
are to be dismantled . A grease solvent
5 2 4 compound or compressed air is to be'used for
ai r admi tted connected close d cleaning .
vented closed I connected When several valves are being dismantled at
the same time, it is necessary to ensure
that parts do not get mixed up .
When the valves are to be assembled the place of work must be Perfectly clean because even the smallest particles
of dirt are likely to cause trouble in the valves .
All sliding faces, O-rings and flat seals are to be'lubricated with 'West 11 grease froin Westinghouse, included in
the spares supplied . 'Alvania No . 21 from Shell or another grease that contains lithium can be used as a substitute
Normal greases are unsuitable for this purpose .
0 1 . Disconnect pipes, remove fixing bolts and.valve .
3 . Loosen hexagonal socket screws (1) remove top part of casing (2) .
4 . Turn out valve guide (5) with piston (3) and valve tappet (4) by means of hook spanner .
5 . Take out valve seat (6) and remove valve (7) .
6 . Clean component parts and blast them with compressed air.
7 . Check wearing parts for wear or solidification (sealing rings), and replace parts if necessary .
Assembly is to take place in reverse order .
0
Arbsitszoit - Stund*n Ails BelriebsitunJon
D36 5600 E Working #I me - Hours Ev
125 .07-1 clur6odetravall -Houres
Tlompo do frobolo - Mores
T.261
Code
as required
. y .6 operati
H .ures no
49 ho
merrclhs
Hares do serviclo
0
0
DISMANTLING AND CLEANING M .A .N .-DIESEL 12 5
0
M *AgL* M TH~EE-WAY VALVE 331 Arbeitskarte-Nr.
Work cord ~o.
Carlo travail No .
Tarleto tral:4110 No .
125 .08
0 TOOLS REQUIRED
2 1 Hexagon screwdriver
3 1 Fair of pointed pliers for locking rings, clamping from
outsid e
4
KEY TO SYMBOL S
V Wearing parts (set of wearing parts see Spare parts
catalogue, assembly 125 )
1 Roller lover
2 Valve tappet
3 Valve guide
4 Locking ring
0 5 Valve seat
--im-Pneumatic connection s
OPERATING KETHOD
Connection 1 1 2
Position I conRected
Position 11 shut I connected
NOTE
When opening the control or starting air system it is necessary to ensure that no dirt whatsoever can enter the
val'ves and pipes . Open pipe ends are to be closed with plastic caps or adhesive tape . The place of work Must be
perfectly clean when valves are to be dismantled . A grea38 solvent compound or compressed air is to be used for
cleaning .
0 When several valves are being dismantled at the same time it is necessary to ensure that parts do not got mixed up .
When the valves are to be assembled the place of work Must be perfectly clean because even the smallest particles
All sliding faces, 0-rings and flat seals are to be lubricated with the 'West 11 grease from Westinghouse, in-
cluded in the spares supplied . 'Alvania No . 2' from Shell or another grease that contains lithium can be used as
a substitute . hormal greases are unsuitable for this purpose .
2. Close open pipe ends to prevent entry of dirt .
3 . Unscrew roller lover (1), remove valve guide (3) with valve tappet (2) and spring .
4. Remove locking ring (4) and valve seat (5) .
5 . Remove wearing parts (V), clean all component parts and blast them with compressed air .
6. Check wearing parts for wear or solidification (sealing rings), and replace parts if necessary .
7. Before assembly, check all moving parts for smooth movement .
Assemblv is to take place in reverse order .
Arbeitszeit - Stunden All* Betriebtstunden

Ln D36 5600- E Working finte :: H uUrs
Dur6# OtrtiVoil Fi : .
Every
Toules Igs as required
Operating hours
Houras do fnarche
I-
W~
1125 .08-1 Tiern :tdde irobeie - Morat Code Horas do servicio
0
0
0 M *Atk* M THREE-WAY VALVES 366-349 and 377 Arbeitl karlo-Nr.
Work card No.
Carts travail N
TariWatrabujo No . 125 .09
0 TOOLS REQUIRE D
1 Hexagon screwdriver SW 4
1 Fair of pointed pliers for locking rings, for clamping
outside-
KEY TO SYMBOLS
catalogue, assembly 125 )
1 Bottom part of casing 5 Top part of casing
2 Locking ring' 6 Hexagonal socket screw
3 Hexagonal socket screw --ow-Pneumatic connections
4 Intermediate piec e
is NOTE
When opening the control or starting air system it is
valves and pipes . Open pipe ends are to be closed with
plastic caps or adhesive tape . The place of work must be
perfectly clean when valves are to be dismantled . A grease
solvent compound or compressed air is to be used fo r
cl eani ng .
When several ylves are being dismantled at
at the same time, it is necessary to ensure
.Connections . 1 2 4 that parts do not got mixed up .
TTnFalmi tted connected close d
!1
When the valves are to be assembled the place
5 vented close connecte d
f.~r,,adililtted . of work must be Perfectly clean because even
closed connected . the smallest particles of dirt ,are likely to
13 vented I connected I .- close d cause trouble in the valves .
All sliding faces, O-rings and flat seals are
to be lubricated with the 'West 11 greas e
from Westinghouse, included in the spares supplied . 'Alvania No . 21 from Shell or another grease that contains
0 lithium can be used as . a substitute . Normal greases are unsuitable for this purpose .
SEWENCE OF OPERATIONS

3 . Turn out hexagonal socket screws (6), lift off top part of casing (5) .
4 . Turn out hexagonal socket screw (3), lift off intermediate piece (4) .
5 . Remove locking ring (2) from bottom part of casing .
6 . Remove all wearing parts (V) .
8 . Check wearing parts for wear and solidification (sealing rings), and replace parts if necessary .
Arbeituoil , - Stundon All* Betriebostunden

D36 5600 E Working time - Hours Every
as required Operating hours
Dur6o do travail - Houres Toults lag Houres do rnarcho
Lr;
125 .09-1 Tiompo cle trabalo - Horas Cada Hares 4a servicio
0
0
M *Atk* M THREE-WAY VALVE 353 Arbeitskerte-Hr.
Work card No .
Carte travail No. 125 .1 0
Toristo trab4io No.
0
TOOLS RECUIREO
1 Set of double-h6ad fork spanners
KEY TO SYKBOLS
V Wearing parts (set of wearing parts see Spare
parts catalogue, assembly 125 )
--w- Pneumatic connection s
Connection 1 2 1 4
Position I closed connected
Position 11 connected I blosed
NOTE
When opening the control or starting air system,it is necessary to ensure that dirt whatsoever can enter the
ivalves and pipes . Open pipe ends are to be closed with plastic caps or adhesive tape . The place of work must be
perfectly clean when ValV83 are to be dismantled . A grease-solvent compound or compressed air Is to be used
for cleaning .
When several valvbs are being dismantled at the same time, it is necessary to ensure that parts do not get mixed up .
0 When the valves are to be assembled, the place of work must be perfectly clean because even the smallest particles
All sliding faces, O-rings and flat seals are to be lubricated with the 'West 11 grease from Westinghouse, in-
cluded in the spares supplied . 'Alvania No . 21 from Shell or another grease that contains lithium can be used as
a substitute . Normal greases are unsuitable for this purpose .
SEQJENCE OF OPERATION S
3 . Screw out valve guide .
4 . Dismantle valve further .
6 . Check wearihg parts for wear or solidification (sealing rings) and replace parts if necessary .
AssemblX is to take place in reverse order .
Arb*ituall -Stunden Alle Betriebsstundon

Ln D36 5600 E Workin: 4time - Hours as required Operating
do hours
Durfie 4, trovall - Moures To
"V'j'y
"V l« loß Hour" marche
.125.10-1 Tiompo do trabolo - Hares Cada Horas do servicio
0
0
M .A .N .-DIESEL 12 5
DISMANTLING AND CLEANING
0 M *A&* k 3/2-WAY VALVE 370 Arboitskarte-Isir.
Work card 1
Carlo trava
Tarjeta trabaia No.
125 .1 1
0 TOOLS RECUIRED -
1 Set of double-head fork spanners
1 Hexagon screw driver SW 4
from outsid e
KEY TO SYMBOL S
catalogue,-assembly 125 )
1 Bottom part of casing 6 Valve cone
2 Locking rings 7 Pisto n
3 Intermediate piece 8 Hexagonal socket screw
4 Top part of casing 9 Hexagonal socket screw
5 Piston -es- Pneumatic connection s
Is
NOT E
When opening the control or starting air system, it is
valves and pipes . Open pipe ends are to be closed with
plastic caps or adhesiVe tape . The place of work must be
perfectly clean when valves are to be dismantled . A grease-
solvent compound or compressed air is to be used for
cleaning .
When several ralves are to be dismantled at the same time,
it is necessary to ensure that parts do not got mixed up .
OPERATING METHOD
2 4
air admitted connected shu t
vented shut connecte d
When the valves are to be assembled, the place of work must be perfectly clean because even the smallest particles
All sliding faces, 0-rings and flat seals are to be lubricated with the 'West 11 grease from Westinghouse, in-
cluded in the spares supplied . 'Alvunia No . 21 from Shell or another grease that Contains lithium can be used
as a substitute . Normal greases are unsuitable for this purpose .
1. Disconnect pipes, remove fixing bolts and valve .
3. Screw out hexagonal socket screws (8), lift off top part of casing (4) and pull out piston (7) .
4. Screw out hexagonal socket screws (9) and pull out intermediate piece (3) .
5. Remove locking ring (2) from bot tom part of casing .
6. Remove all component parts from casing .
7. Clean component parts and blast then with compressed air .
8. Check wearing parts for wear or solidification (sealing rings) and repliCe parts if necessary .
9. Before assembly, check all moving parts for smooth movement .
Arbeilszoit - Stunden AU* Betrisbistunden

Ul)
036 5600 E
rl~ 125 .11- 1
Lr)
Workinietime
Dur6e
- Hours
travail -Houres
Tiompa do lrobalo - Horas k. Cada
lea as required rrallog
. hours
0 rev do marchis
Hares do sarviclo
0
0
DISMANTLING THREE-WAY M .A .N .-DIESEL 12 5
M *AIIL* M SOLENOID VALVE 371 Arbeit karte-Nr.
Work card N
0 Cart* Irooll 125 .12
Tarial . trobalo No .
0 TOOLS REQUIRE D
1 Screwdrive r
1 Pair of pointed pliers for locking rings, clamping from
outsid e
KEY TO SYMBOL S
5 Socket s
--imo- Pneumatic connection s
NOTE
0 When opening the control or starting air system, it is

valves and pipes . Open pipe ends are to be closed with plastic
caps or adhesive tape. The place of work must be perfectly
clean when valves are to be dismantled. A grease solvent com-
pound or compressed air is to be used for cleaning .
When several valves are being dismantled at the same time, it
is necessary to ensure that parts do not get mixed up .
When the valves are to be assembled the place of work must be
perfectly clean because even the smallest particles of dirt
are likely to CaU30 trouble in the valves .
All sliding faces, O-rings and flat seals are to be lubricated
with the 'West 11 grease from Westinghouse, included in the
spares supplied . 'Alvania No . 211 from Shell or another grease
that contains lithium can be used as a substitute . Normal
greases are unsuitable for this purpose .
OPERATING METHOD
0 Connection
Solenoi d
2 1 3
efiergised
Solenoid no t
1
closed
Ftonnecte d
energised 'I connected

T closed
3 . Screw out socket (5) and remove wearing parts .
4. Clean component parts and blast them with compressed air.
5 . Check wearing parts for wear or solidification (sealing rings), and replace the parts, If necessary .
0
Arbeltsisit ~ -stundo" Ail s
k
Estriebtstundan
D36 56DO E Workini 4, time -Hours H&UPras 4 hours
Oporating
1125 .12-1
Durds travail - Hourn
Tiomoo do firabojo ~ Horas
Tpossies cis required
'"r I- March*
Coda Horas do servicio
0
0
M *AOL* M THREE-WAY VALVE 380 Arbeitlkarte .Nr.
Work card No . .
Cwto ravoil No
11
Terjet. trabajo No.
125 .14
TOOLS REQUIRED
1 Screwdrive r
1 Pair of pointed pliers for locking rings,
clamping from outsid e
KEY TO SYMBOLS
V Wearing parts (set of wearing parts see
Spare parts catalogue, assembly 125)
Pneumati c connection s
OPERATING METHOD
Connecti ons 1 1 2 4
Position I COnRected shu t
Position 11 shut I connecte d
NOTE
When opening the control or starting air system it is necessary to ensure that no dirt whatsoever can enter,the
valves and pipes . Open pipe ends are to be closed with plastic caps or adhesive tape . The place of work must be
perfectly clean when valves are to be dismantled . A grease solvent compound or compressed air is to be used for
cl eani ng .
0 When several valves are being dismantled at the same time, it is necessary to ensure that parts do not get mixed up .
When the valves are to be assembled the place of work must be perfectly clean because even the smallest particles
All sliding faces, O~-rings and flat seals are to be lubricated with the 'West 11 grease from Westinghouse, in-
cluded in the spares supplied . 'Alvania No . 21 from She]] or another grease that contains lithium can be used as
a substitute . Normal greases are unsuitable for this purpose .
SEQUENCE OF OPERATIDNS
3 . Screw 3 countersunk screws out of cover of casing .
4 . Dismantle valve further .
6 . Check wearing parts for wear or solidification (sealing rings), and replace parts, if necessary .
Assembly is to take place in reverse order.
0
Arbeitnelf = Stunden All@ Betriebtstunden
Le )D36 5600 E Working fline Ho ors E-* Operating hours
rl: 125 .14-1 Dur6o do Iravall
Tempo do trabajo=
Ho,ros
No,r,
. My. W as required S*urol do inarch*
Coda Moral do servicia,
0
0
ZERLEGEN UND REINIGEN DES M .A .N .-DIESEL 125
0 M +Atk* M DOPPELRÜCKSCHLAGVENTILS 405
Arbeitzkorte-Nr.
Work card No.
125 .15
Carlo travail No .
Torieto frobojo No .
BENÖTIGTES WERKZEUG
1 Satz Doppel maul schl Ussel

1 Spitzzange fOr auBonspannende Sicherungsring e
ZEICHENERKLÄRUNG
V Verschleißteile (VerschleiSpäckchen siehe Ersatzteil-

katalog Gruppe 125 )
1 Schiebor
2 Sie b
3 Sicherungsring
--bo-Pneumatische Anschlüsse
0 WIRKUNGSWEIS E
Luftdurchgang wenn eine Zuleitu7 belüftet ist .
Ni nwei s
Bein Öffnen des Steuer- bzw . Anlaßluftsystems besonders darauf achten, daß in Ventile und Rohrleitungen keiner-
lei Schmutz eindringen kann . Offene Rohrenden mit Kunststoffkappen oder Klebeband verschließen . Ventile nur an
sauberem Arbeitsplatz zerlegen, ~um Reinigen fettlösende Mittel und Druckluft verwenden ,
Wenn gleichzeitig mehrere Ventile zerlegt werden, ist darauf zu achten, daß die Teile nicht untereinander
vertauscht worden .
Beim Zusammenbau ist auf Peinliche Sauberkeit am Arbeitsplatz zu achten, bereits kleinste Schmutzteile können
Störungen im Ventil verursachen .
Alle Gleitflächen, O-Ringe und Flachdichtungen sind mit dem loi Res'ervateilumfang enthaltenen Fett 'West Ie der
Firma Westinghouse binzufetten . Ersatzweise kann auch 'Alvania Nr . 21 der Firma Sholl oder ein anderes Lithium-
fett verwendet werden . Normale Schmierfette sind hierfür ungeeignet .
0
ARBEITSFOLGE
1 . Rohranschlüsse lösen, Befestigungsschrauben entfernen und Ventil abbauen .
2 . Offene Rohrenden gegen Eindringen von Schmutz verschließen .
3 . Siebe (2) vorsichtig ausschrauben .
4 . Sicherungsringe (3), Dichtelemente und Schieber (1) ausbauen .
5 . Einzelteile reinigen und mit Druckluft abblasen .
6 . Verschleißteile auf Abnutzung biv .Verhärtung (bei Dichtringen) kontrollieren ; wenn erforderlich,leile
erneuern .
7 . Schieber auf Leichtgängigkeit kontrollieren .
Der Zusammenbau wird in umgekehrter Reihenfolge vorgenommen .
Arbeitszoit - Stundon AU Befrisbistunden

D36 5600 Working time - Hours Every rating hours
125 .15-1 Dur6ed4travail -Houres Tout" log Bedarf OH .P .Or., do march*
liernpodetrabolo-Hores Cadck Horas do servicio
0
0
DISMANTLING AND CLEANING .A .N .-DIESEL][12 5
FM-
M +Atk* M DOUBLE SHUT-OFF VALVE 407 Arbsit3korts-Mr.
0 Work card No .
C.rl .travall No. - 125 .1 6
Terjeta trobala No.
0
TOOLS REQU IRED
1 Set od fouble head fork spanner s
from Outsid e
KEY TO SYMBOLS
jog parts catalogue, assembly 125 )
1 Slide
2 Straine r
3 Locking ring
--@I- Pneumatic connection s
OPERATING METHOD
Air flows through when air is admitted to both inlet Pipes simultaneously .
NOTE
valves and pipes . Open pipe ends are to be closed With Plastic Caps Or adhesive tape . The place of work must be
cleaning .
When several valves are being dismantled at the same time it is necessary to ensure that parts do not get mixed up .
When the valves are to be assembled the place of work must be oerfectly clean because even the smallest particles
All sliding faces, O-rings and flat seals are to be lubricated with the 'West 11 grease from Westinghouse, included
in the spares supplied . OAlvania No . 21 from Shell or another grease that contains lithium can be used as a
substitute . Normal greases are unsuitable for this purpose .
0
1. Disconnect pipes, remove fixin .g bolts and valve .
3. Carefully screw Out strainers (2) .
4. Remove locking ring (3) and slide (1) .
5. Clean component parts and blast them with compressed air .
6. Check wearing parts for wear or solidification (sealing rings), and replace partsI if necessary .
7. Check slide for smooth movement .
0
Arbtitszoit _51unden All* Botriobsslund*n
036 5600 E Working time -Hours Eve Operating hours
Ln
r-: 125 .16-1 Duriledetrovell -Houres T.2. 1. as requIred Houma do morche

Timpa do trobsio - Mores Code Horas do serviclo
0
0
DISMANTLING ANC CLEANING M .A .N .-DIESEL 112 5
0 M*Ak*Pd PRESSURE RECUCING VALVE 409 Arbsit5karts-ISIr.
Work card No. .
carts travail No 125 .17
Toristatrabola No.
TOOLS REQUIRE D
1 Screwdri ver .
KEY TO SYMBOLS
V Wearing parts (set of wearing parts see Spare paos
1 Cylindrical screw
2 Top part of casin g
3 Bottom part of casing
4 Knurled scre w
-am- Pneumati c connections
NOTE
0
When opening the control or starting air system, it is neces-
sary to ensure that no dirt whatsoever can enter the valves
and pipes . Open pipe ends are to be closed with plastic caps
or adhesive tape . The place of work must be perfectly clean
when valves are to be dismantled . A grease-solvent compound
or compressed air is to be used for cleaning .
When several valves are being dismantled at the same time, it
is necessary to ensure that parts do not got mixed up .
When the valves are to be assembled, the place of work must be
perfectly clean because even the smallest particles of dirt
are likely to cause trouble in the valves .
All sliding faces, O-rings and flat seals are to be lubricated
with the 'West 11 grease from Westinghouse, included in the
spares supplied . 'Alvania No . 21 from Shell or another grease
I that contains lithium can be used as a substitute . Normal
I greases are unsuitable for this purpose .
1 . Disconnect pipes, remove fixing screws and valve .
3 . Turn out 6 cylindrical screws (1) and knurled screw (4) .
4. Separate top part of casing (2) from bottom part (3) and remove wearing parts
I
6 . Check wearing parts for wear or solidification (sealing rings) and replace parts if necessary .
0
Arbsifneit -stunde" Alto Betriebestunden
036 5600 E Working time -Hours Eve tiAg hours
LO
Durtle de travel[ - Houres Two$ 1 .6 as require d Ho'ur-es do rnarche
0
125 .17-1 Timpo do trobajo - Horas Cada Horas do ssrvlcio
0
0
DISMANTLING AND CLEANING M .A .N .-DIESEL 1 12 5
M *AOL* P4 RAPID RELEASE VALVES 435 and 442 Arbeits karle .Nr.
Work card No.
125 .18
CCU-tofrovall No.
Tarlota traWo No.
TOOLS REQJIRED
1 Set of dou , ble head fork spanner3
1 Flat steel 2-thic k
KEY TO SYMBOLS
parts catalogue, assembly 125 )
1 Thrust pad 3 Plu g
2 Check nut --w- Pneumatic connections
NOTE
When opening the control or starting air system it
is necessary to ensure that nii dirt whatsoever can
0 enter the valves and pipes . Open pipe ends are to
be closed with plastic caps or adhesive tape . The
place of work Must be perfectly clean when valves
are to be dismantled . A grease solvent compound
or compressed air is to be used for cleaning .
When several plves are being dismantled at the
SaMO time it is necessary to ensure that parts do
not get mixed up .
When the valves are to be assembled the place of
work must be Derfectlv clean because even the
smallest particles of dirt are likely to cause
trouble in the valves .
All sliding faces, D-rings and flat seals are to be
lubricated with the 'West IN grease from Westing-
house, included in the spares supplied . 'Alvania
No . 20 from Shell or another grease that contains
lithium can be used as a substitute . Normal greases
-;a are unsuitable for this purpose .
0
1 . Disconnect pipes, remove fixing bolts and valive .
3 . Release check nut (2), screw out thrust pad (1) with flat steel and plug (3) . I
5 . Check wearing parts for wear or solidification (sealing rings), and replace the parts if necessary .
6 . During assembly, Only screw in thrust pad (1) to such an extent that the diaphragin is slightly pressed together .
Ails Betriebsstunden
k
Arbeitatelf -Stunden
D36 5600 E Working firno -Hours 0 Wing hour s
Ln
rl; 125 .184 Dur6tdolravall -H4ures T.Uly
Ever. . In as required H::res do marche
Ln rjornpa do Irabalo - Maras Cada Horas do sarviclo
0
0
DISMANTLING AND CLEANING M.A.N .-DIESELI 125
CONTROL VALVE 125 Arbeitskarte-Nr .
Work card No.
Carl@ travail No.
Taristatrabaia No. 125 .20
TOOLS REQUIRE D
I Double-ended open-end
spanne r
2 1 Socket screw spanner,
0
angle-type, size 5
lSocket screw spanner
1 Hook spanner, dia.
40
Sch,iitt "
LEGEND
V - Wear parts (wear parts kit see spare parts catalogue
group 125 )
1 Slot screw
2 Hexagonal nu t
3 Valve for presetting fuel admission or presetting
speed'.
4 Valve for starting an d
5 Valve for releasing interlocked control lover when
camshaft has reached its end position after reversin g
(AHEAD or ASTERN)
0
6 Starting valv e
7 Pawl (swivable )
8 Setting Cal for presetting fuel admission or speed
9 Reversing valve AHEAD
10 Reversing valve ASTERN (behind the former )
Schnitt 04
Section U
Schnitt P-P
Section-, M
ccmzz~~]q
me 0
r! t_x"~~ ~ ~_A
Pat.0 ,
0 Arb*ilszoit
,ns, . ::Stuu
nden Alls, BetriabsOunden
Working I! Ho rs Evrs operating hours
Durdedstravail -Houres To to Us Houres; do marche
Tlempa do trabojo - Home A Coda as necessary Horas do serviclo
0
0
Schnitt ~_E
Section E-E
Ansicht Y
View Y
40
Note : When breaking connections of the control-air or starting air system, special care should be used to
prevent dirt from entering valves and pipes . Seal open pipe ends with plastic caps or adhesive tape .
Clean conditions must be maintained at the work site when disassembling the valves, for cleaning use
degreasing solvents and pressure air .
When disassembling more than 1 valve, make sure not to confuse the parts .
When assembling,the work place should be -spotlessly cleaa because even the smallest dirt particles may
cause valve trouble .
The sliding surfaces, 0-rings and gaskets should be coated with grease 'West 11 from Westinghouse,
included with the spare parts . "Alvania III from Shell or any other grease on Lithium basis may be used
in view of the former . Normal grease is unsuitable for this purpose .
1 . Separate pipe connections, remove fixing sc~ews and switch gear (mark pipe connections if necessary) .
2 . Seal open pipe ends to prevent dirt from entering . 0
3 . Remove slot screw (1) and hexagonal nuts (2), remove individual valves and disassemble switch gear .
Note : Disassemble valves individually and store parts separately or disassemble and reassemble one valve after
the other (do not confuse the parts of the various valves) .
4 . Clean parts and blow dry with an air hose .

5. Check wear parts (V) for wear and seals whether they have become hardened ; replace parts (V) if necessary .
6. Before reassembling, check all moving parts for free movement .
7. For reassembling, reverse sequence of operations . Be sure that the pawl (7) can be moved freely in the
direction of the arrow when the cam is in the position shown in the drawing .
Note : The pawl prevents the starting valve (6) from opening when the engine control lever is moved from FUEL to
ST OP.
0
DISASSEMBLING AND CLEANING M .A.N .!-D1'ESdL 12 5
M *Atk* M THREE-WAY VALVE 323 Arbeilskerlo-Hr.
Work Card 4o .
Carlo tr*va!l 146
Twice frabajo No.
125 .27'."
TOOLS REQUIRE D
1 Set double-pdod open-end spanners
1 Screw driver
1 Pointed pliers for expanding retaining rin g
LEGEND
V* Wear parts (for wear parts kit see spare Part s
catalogue component 125)
1 Valve guide -
2 Valve tappet
3 Retaining rin g
--w- pneumatic connection s
1 2 4
Position I connected close d
0 Position 11 closed connected
1 . Separate pipes, unscrew fixing screws and remove valve .

2 . Seal pipe ends to prevent dirt from entering .
3 . Unscrew valve guide (1), withdraw valve tappet (2) and spring .
4. Remove retaining ring (3) and wear parts M .
5. Clean parts and blow dry with an air hose .
6. Check wear parts for wear and if seal rings are hardened, replace parts as necessary,
7. Before assembling, check all parts for free movement .
For assemblinq . reverse sequence of operations outlined above .
036 5600 E it rn , = Stu.nden Ails 114triebutunden
CO
125.27-1 TDAW
Ti_r.b,*kiPti"n
Dur&4
Orn 4 1i ae
urds tr
'aI,
Hov
- rs
Hour"
nio rmn po d a trabolo - Hores k T%O:ly. Iss as
Cade
necenary rating hours
OH.P.r
0 dds inerche
Hors, a ssr,,klo
i . , 444
0
0
DISASSEMBLING AND CLEANING M.A .N .-DIESEL 12 5
*Atk* 5/2-WAY VALVE 393 Arbeitskarta-W.
Work card No
Carlo Irovall ;io.
Tarieta Irabojo No .
125 .28
TOOLS REQUIRE D
1 Set doubl e-ended open-end spanners
1 Phillips screw driver
LEGEND
V Wear parts (for wear parts kit see spare parts catalogue
components 125 )
1 Linseed head screw
2 Cover
3 Uve r
4 Linseed head screw
--m-pneumatic connections
Note :
When separating control-air or starting air pipes,great care
should be used to prevent dirt from entering the valves and
0 pipes. Pipe ends should be sealed with plastics caps or adhesive
tape . Clean conditions must be maintained at the work bench
when disassembling the valves . For cleaning use degreasant s
and an air hose.
If several valves are disassembled at the same time, care must
be taken to prevent that the various parts of the different
valves are not confused.
RP S When assemblinq clean conditions must be maintained at th e

work bench because dust and dirt in any form are liable to cause
valve failure s
Sliding surfac ;s, O-rings and flange seals should be greased
with Westinghouse 'West I' grease contained in the spare parts
kit. If the former is not available, 'Alvania No 21 fro m
Shell or another lithium-soap grease can be used instead . The
commonly used grease types are unsuitable for this purpose .
1 . Separate pipes, unscrew fixing screws and remove valve.

2. Seal pipe ends to prevent dirt from entering .
3 . Loosen linseed head screws (1 and 4), remove covers (2 and 3) and remove wear parts (V) .
4. Clean parts and blow dry with an air hose .
5. Check wear parts for wear and if seal rings have hardened, replace parts as necessary .
6 . Before assembling, check all parts for free movement .
For assembling . reverse siqupnce of operations outlined above .
9
E Arbeitszoll Stunden Ails Betriobutunden
125.28-1 Workinj 4 time
, - Hours Every Operating hours
Dur4o 41 travall -Houres
rlsmo,o
do trabola - Maras
Toutes In
Code
(is necewary Moures de marchs,
Maras do servicla
0
0
DISASSEMBLING AND CLEANING M .A.N .-DIESEL 12 5
2/2-WAY MAGNET VALVE 386 Arbeitskarle-Hr.
Work card ~o.
Carts travail No .
Tariete frobsio No . 125 .29
TOOLS REQUIREO
1 Screw drive r
1 Hook spanner
LEGEN O
V Wear parts (for wear parts kit 308 spare parts
catalogue component 125 )
1 Hexagonal screw
2 Electric portion
3 Cove r
4 Slotted screw
5 Scre w
6 Casin g
A, P pneumatic connections
Note :
When separating control-air or starting air pipes,great
care should be used to prevent dirt from entering the
valves and pipes. Pipe ends should be sealed with
plastics caps or adhesive tape. Clean conditions must
be maintained at the work bench when disassemblin g
the ValV83 . For cleaning use degreasants and an air hose .
If several valves are disassembled at the same time,

care must be taken to prevent that the various parts of
the different valves are not confused .
When assembling clean conditions must be maintained at
the work bench because dust and dirt in any form are
liable fo cause valve failures.
Sliding surfaces, O-rings and flange seals should be
Magnet energized - passage P-A closed
greased with Westinghouse 'West 11 grOa3O contained in
Magnet de-energized - passage P-A opened
the spare parts kit. If the former is not available,
'Alvania No 21 from Shell or another lithium-soap grease
can be used instead. The commonly used grOaSS types are
unsuitable for this purpose .
0 SEQUENCE OF OPERATION S
1 . Switch off current in .current supply cables, loosen slotted screw (4) to disconnect cable, and remove cover (3) .
2 . Discdnnect pipes, unscrew fixing screws and remove valve .
3 . Seal pipe ends to prevent dirt from entering .
I
4 . Loosen hexagonal screw (1) and remove electric portion (2) .
5 . Unscrew screw (5) in casing (6) and remove wear parts (V) .
6 . Clean all parts and blow dry with low pressure air ,
7 . Check wear parts for wear and if gaskets are hardened, replace parts as necessary .
8 . Before reassembling check moving parts for free movement .
For reassambl inii, reverse sequence of operations outlined above .
036 5600 E Arbeilszoit ' -Stunden Alle betrieb,stunden

Working time, =Hours orati
r--
pl: 125.29-1 Ourio do vay 11 Houres T..tY
",er .o lett (n necessar y 2 dn ! ho
Tiampo do tralmlo-Horas A Coda Horas de servicie
CX>
I
0
0
DISMANTLING AND CLEANING . M .A .N .-DIESE L 125
M *Atk* M POSITIONER 21 3 Arbeitskarle-ISIr.
Work card No .
Cart. travail No . 125 .30
Tarieta trobalo No .
I=
KEY TO SYMBOL S .TOOLS RECUIRED

V Wearing parts (set of wearing parts see Spare 1 Set of double head fork spanners
sparts catalogue, assembly 125 ) 1 Hexagon screwdriver SW 6
1 Cap 4 Hole for punch 1 Punch 5 dia . .
2 Hexagon nut 5 Hexagon nut -
3 Hexagon nut 6 Bol t
NOTE 0
When opening the control or starting air system it is necessary to ensure that no dirt whatsoever can enter thq
valves and pipes . Open pipe ends are to be closed with plastic caps or adhesive tape . The place of work must Ve
cleaning .
When several valves are being dismantled at the same time it is necessary to ensure that parts do not get mixed up .
When the valves are to be assembled the place of work must be perfectly clean because even the smallest particles of
dirt are likely to cause trouble in the valves .
All sliding faces, G-rings and flat seals are to be- lubricated with the "West 11 grease from Westinghouse, included
in the spares supplied . 'Alvqnia No . 21 from Shell or another grease that contains lithium can be used as a sub-
3 . Remove cap (1) and bolt (6), screw off hexagon nuts (2, 3 and 5) and dismantle positioner .
5 . Check wearing parts for wear or solidification (sealing rings),
.1 ~
D36 5600 E Arbeitszeit -Stunden

Working time - Hourg
Alt o . getritbsstunden
N:.,,r ling hours
Ul)
11"; 125 .30- 1 Durlie de travall - Heuros T'ZZ . i. .. as required 0 res a do Marche
L0 Tiernpo da trobalo - Horas Cada Horas do servicio
0
0
M .A .N .-DIESEL F125
0 DISMANTLING AND CLEANING Arbeitskarte-Nr.
POSITIONER 226 Work card ~o.
Carts travail No.
Tarieto trabolo No.
125 .31
KEY TO SYMBOLS TOOLS REQJ1REO

parts catalogue, assembly 125 ) 1 Punch 5 dia .
3 Hexagon nut
4 Hole for punch
5 Hexagon nu t
6 Bolt
NOTE
When opening the control or starting air system It is necessary to ensure that no dirt whatsoever can enter the
cl eani ng .
When several valves are being dismantled at the same time it is necessary to ensure that parts do not got mixed up .
When the valves are to be assembled the place of work must be Derfectly clean because even the smallest particles Of
dirt are likely to Cause trouble in the valves .
All sliding faces, O-rings and flat seals are to be lubricated with the 'West 11 grease from Westiqhouse, included
in the spares supplied . 'Alwania No . 29 from Shell or another grease that contains lithium can be used as a sub-
p.t .o. ,
Arbeitszeit -Stunden Aft Betriebssfunden
036 56M E
125,31 .1
Working time -Hours
Dur6*dotrcwoll -Haut«
Tjempo da trobalo - Horts k to.Z.,
Cade
as required Op4roflng hours
Houres do marchs
Hares do servicio
SEMENCE OF OPERATION S 0
1 . Disconnect pipes, remove fixing bolts and positioner .
3 . Remove bolt (6), screw off hexagon nuts (3 and 5) and dismantle positioner .
4 . Clean all component parts and blast them with compressed air .
5 . Check wearing parts for wear or solidification (sealing rings), and replace if ne~essary .
Assembly s to take place in reverse order .
0
DISMANTLING AND CLEANING M .A .N .-DIESE L 125
0 *Atk* M PRESSURE REDUCING STATION 61 5 Arbeiftkorte-Nr
Work card N
Corte travail ;6.
Torieta trabala No.
125 .32
KEY TO SYMBOLS TOOLS REQJIRED

parts catalogue, assembly 125) 1 Screwdrive r
1 Hexagon screw 6 Plug screw 1 Pr. pointed pliers
0 2 Casing 7 Setscrew 1 Book spanner, 22 dia .
3 Hexagon screw 8 Hexagon screw
4 Casing 9 Control lever unit
5 Cylindrical screw 10 Drain valve
-00- Pipe connection or vent
NOTE
perfectly clean when valves are to be dismantled. A grease solvent compound or compressed air is to be used for
cleaning.
When several valves are being dismantled at the same time, it is necessary to ensure that parts do not got mixed up .
When the valves are to be assembled the place of work must be Perfectly clean because even the Smallest particles
of dirt are likely to cause trouble in the Valves .
p .t .o .
0
036 5600 E Arbeiltzeit - Stundon
Working time -Hours
Alto
Ever,
Betriebsitunden
t,
Operating
L"
rl: 125 .32-1 Dur6o do travail - Houres Tout., 1. as requiredHeures do Zurrshe
Tempo do trobaia - Horas Coda Horas do sorvicio
LC31
0
1 . Disconnect pipes, release fixing screws and remove valve .
3 . Release hexagon screw (3) and remove wearing parts M .
4 . Loosen hexagon screw (1), separate casing (2) from casing (4) and remove wearing parts (V) .
5 . Loosen 5 cylindrical Screw$ (5) and remove wearing parts .
6 . Loosen 2 plug screws (6) and remove wearing parts M .
7 . Loosen 2 setscrews (7) and remove wearing parts M .
8 . Loosen 4 hexagon screws (8) and pull out control lover unit (9) .
9 . Screw out drain valve (10) .
10 . Clean all component parts and blast them with compressed air .
11 . Check wearing parts for wear or solidification (sealing rings), and replace parts if necessary .
is
036 5600 E / 125-32-1

CLEANING FILTERS IN KSZ
HYDRAULIC POSITIONER Arbeitskarte .Nr .
Work card No .
TOOLS REQUIRE D
1 Open-end spanner, size 32 Cleaning fluid
1 Ring spanner, size 1 3
1 Ring spanner, size 2 7
LEGEND
1 Cover x 6 Filter to p
2 Cover x 7 Contamination indicator
x 3 Hexagonal head 8 Screw connection
x 4 Filter casing 9 Screw connection
x 5 Holding clamp 10 Oil drain plug
SEQUENCE OF OPERATIONS 1- Cleaning fine filte r

Clean fine filter before admissible maximum contamination
is reached (cneck indicator(7) .
0 1 . Release 2 hexagonal screws in holding clamp (5) .

2 . Apply ring spanner to hexagonal head (3) and unscrew
filter casing (4) while holding the filter top (6) .
3 . Clean filter element, magnet filter and filter casing .,
4 . When assembling, tighten filter casing (4) and clamp
holder (5) only moderately, paying attention to seal
ring .
SEQUENCE OF OPERATIONS 2 : Cleaning suction filter of
left-hand pum p
1 . Remove cover (2) .
2 . Separate screw connection (8) and take out pipe
section with suction filter .
3 . Wash suction filter in diesel oil or TN Trilen e
and blow out cautiously with low-pressure air . Do not
allow dirt to enter filter .
4 . Reinstall suction filter, tighten screw connection (8)
carefully and mount cover (2), paying attention to
seal .
SEQUENCE OF OPERATION 3 : Cleaning suction filter of
0 ri'ght-hand pum p
2 . Separate screw connection (9) and withdraw pipe
section with suction filter .
3 . and 4 . as under sequence of operations 2 . I
SEQUENCE OF OPERATIONS 4 : Oil chang e

1 . Unscrew oil drain plug (10) and drain oil completely .
2 . Remove covers (1 and 2) and check inside for con-
tamination and oil residues, flush out with fresh
oil if necessary .
3 . Replace oil drain plug (10) paying attention to seal .
4 . Fill in fresh oil through opening (1 or 2) and replace
covers .
OIL QUALITY : Same oil as for crankgear lubrication of

9 353SO92
engine (cf section 1) .
Oil volume : approx. 50 1
x Note : These parts are only fitted with electro-automatic plants .
0 1
036 5600 E Arbeitszeit - Stunden All* Betriebsstunde n
Working time - Hours Every Operating hou
125.40-1 Dur6e de travail - Heures Toules les as necessary
Heures de .,r,.ih
'a.
Tiompo do trabojo - Horas Coda Horas de servicio
0
0
M .A .N .-DIESEL 125
0 M *Atk* M CLEANING PIPE FILTER 451 Arbeitzkorte-Mr.
Work card No .
Carts travail No . 125 .41
Tarista trobajo No .
TOOLS REW I RED

1 Double head fork spanner
Cleaning flui d
NOTE
When opening the control or starting air system, it is necessary
0 to ensure that no dirt whatsoever can enter the filters, valves
and pipes . Open pipe ends are to be closed with plastic caps or
adhesive tape . A grease solvent compound or compressed air is to
be used to clean the filters .
When installing the filters, it is necessary to ensure that

everything is perfectly clean because even the smallest particles
of dirt are likely to cause trouble in the controls .
1 . Check to make sure that no pressure is in filter .
2 . Screw out screw with strainer .
3 . Blast strainer with compressed air from outside to inside and slo on the inside . Clean strainer in cleaning
fluid and blast it .
4 . When installing the strainer make sure that no foreign particles can enter the pipe system .
5 . On completion of installation, check filter for tightness .
0
ArbAitszait -stunden Alls 1106*1pstfunden
D36 5600 E Working time Hours Every Operating hours
125 .41-1 travail :: Nsures
Plu=0dodo trabojo - Horao
To ., . Ids
Cada
as required Houres do marcho
Horas do servicso
LA
0
0
DISASSEMBLING AND CLEANING M .A.N .-DIESEL 12 5
'M *Atk* M PRESSURE AIR FILTER 444 Arbeitskarts.Nr.
Work card Ao .
0 Carlo travall No . 125 .42
Tarjetatrobajo No .
TOOLS REQUIRED '

1 Spare filter-cylinde r
1 Open-end spanner, size 17
1 Vat with cleaning flui d
LEGEN D
1 Casing 5 Seal
2 Filter cylinder (cer ;mic) 6 Casing cover
3 Sealing disc 7 Nut
4 Cover 8 Condensate drain valve
Note : When opening control-air or starting air systems make
sure to prevent dirt from entering valves or pipes . Seal
pipe openings of separated pipes with plastics caps or
adhesive tape. Work bench must be spotlessly clean for
disassembling filter . For cleaning use degreasants and air
hose.
0
Clean conditions must be maintained when assembling as
minute dirt particles can cause troubles .
Seals (5) must be greased with lWast 11 grease from
km Westinghouse which is included with the spares ."Alvania
No 21 from Shell or any other grease on Lithium bass
1
MV1711)~c may be used in lieu of the former . Standard grease is
unsuitable for this purpose .
_rrm-T-T-~
CHECKING
Open drain valve (8) and drain condensate at intervals specified in the Maintenance Schedule . With new engines,
check and, if necessary, clean filter cilinder at same intervals . '
SEQUENCE OF OPERATIONS : Disassembling and cleaning

0 1 . Release pressure in pipe.
2 . Open condensate drain valve and drain water .
3 . Unscrew and remove four nuts (7) on casing cover (6) using open~end spanner, size 17 .
4 . Withdraw casing cover together with casing (1) downwards (paying attention to Seals) .
5. Unscrew cover (4) and remove filter cylinder (2) downwards .
6. Soak filter cylinder in solvent (patrol, TH Trilene, or similar) for several hours, then blow out with low
pressure air from the inside and allow it to dry . Be careful when using inflammable solvents, danger of
explosion.
To assemble filter, reverse sequence of operations outlined above, paying attention to the seals .
Note* It is good practice to have a second filter insert ready for installation so that the dirty insert can be
exchanged by a clean one and the dirty filter can be cleaned at leisure. After assembly, close drain valve
and check tightness of filter at split-joint& .
036 5600 E Arbeitizall -Stunden Alto Salriebtstundea

125 .42-1 Workingfinwo =Hours
Dur6t do trav it Mourn
0
T.
6-ry
. ... In as necessary ~ 4ruras
re ti"dog mhoaurrcsho
C6 riampo do lrabaio - Morn A Coda Maras do servicio
0
0
M .A .N .-DIESE L 12 5
M *A&k+ M TESTING PRESSURE SWITCHES Arbeitskarte-Nr .
Work card No .
0 Tariela trabojo No .
008 .1074 008 .107-7

008 .107- 8
A
008 .107-4
8
008-107-9 008 .107- 5
C

1 Three-way cock on pressure A Operatio n 1 Testing device for pressure switch . . . . . . . . 008 .107
switch B Testing Consisting of :
2 Screw cap C Venting 1 Union nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 008 .17-1
3 Receptacle D Close d 1 olive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 008 .107-2
E Testing 1 Straight, threaded pipe socket . . . . . . . . . . . . 008 .107-3
0 2 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 008 .107-4
SEQUENCE OF OPERATIONS 1 Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 003 .107-5
1 Scaling disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 008 .107-6
1 . Unscrew screw cap (2) . 1 Pressure gauge (0 - 6 bar) . . . . . . . . . . . . . . . . 008 .107-7
2. Screw testing device onto connecting or I
socket . 1 Pressure gauge (0 - 40 bar) . . . . . . . . . . . . . . . 008 .107-8
3 . Set three-way cock (1) to position TESTING . 1 Stop cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 008 .107-9
4 . Place receptacle (3) under testing device 1 Open end wrench, size 1 9
and open cock of testing device only so far 1 Test lam p
that the pressure in the pipe is dropping
sl owl Y .
5 . Determine exact switching point at respective
alarm device (signal lamp or similar) or directly
on the pressure contactor by means of a test
lamp .
6 . Readjust switch point on pressure contactor, if necessary .
7. Reset three-way cock (1) to operating position, remove testing device and replace screw cap (2) .
0 -, 1. D365600 E Arbeitszeit - Stunden Alle Betriebssi unden

i- Working tirne Hours TE~ery
'.t Operating hours
C'; 125 .45-1 Duree cle travOil - Heure s ou es les Heures de Marche
1 Tiempo de trobojo - Horos I A Cada Horas de ser~icio
0
0
M .A .N .-DIESE L 125
TESTING MINI VALVES
M *Aak* M Arbeitskorte-Nr .
Work card
tr .,a~I o~i . .
0 Carte
Tarieta trabajo No.
125 .46
008 .108
LEGEND TOOLS REQUIRE D Tool No .
1 Plate 1 Tester for mini valves . . . . . . . . . . . . . . . . . 008 .108

2 Mounting plate 1 Set open-end spanner s
1 Angular screw driver SW 3
1 Note pa d
Note : ',he mini valve tester permits observation of switching actions of mini valves connected in a closed control
circuit . The tester together with the valve to be checked is then to be connected to the control circuit .
8
01
to
C:)
10
1 . Remove mini valve to be checked (defective) and screw it to the mounting plate (2) of the tester . Care should
be taken to prevent foreign matter from entering the pipes .
2 . Bolt plate (1) of tester in the position previously assumed by the mini valve and draw pipe connections quite
tight in order to close the control circuit .
3 . Carry out respective manoeuvres from the control stand while observing the pressure gauges .
4 . Note down read-outs of pressure gauges .
Note : Whether or not the valve under test is s~itching properly can be determined by comparing the gauge
readings indicating the pressures at the different ports of the mini valves at the various switch I
positions of the control gear .
Attention : No attempt should be made to repair defective mini valves . Replace complete valve (see spare parts
catalogue group 125) .
0 ~ 036 5600 E
125 .46-1
W
Arobrking
'its"it
ti
L- Stunden
rne Hours
Alle Betriebsstunden
Every Operating hours
Durie de Ira ail - Heures Toutes les cis necessary
Heures do marche
Tiernpo de trabajo - Horns AA Coda Horns de servicio
0
0
MAINTENANCE OF M .A .N .-DIESEL
M*AL*N WOODWARD LIG GOVERNO R Aroeitskorte-Nr .
Work card No. .
Corte travail J N 0 140 .01
Tarieto ircba a No .
applicable work sheet . . . . . . . . . . . . 140.02

TOOLS REQUIRED Tool No
1 Set of tools, complete . . . . . . . . . . . . 140.110
1 Screw drive r
LEGEN D
1 Speed setting motor
2 Gea r
3 Oil filler cu p
4 Compensating adjusting pointer
5 Needle valv e
6 Drain plu g
7 Oil level gauge glas s
Note : A new governor, before going into service
0 must be filled with oil . The following
should be noted :
With enqine runninq the oil level should
be within the low and high marks on the oil
level gauge glass (7) .
With stopped enoine, at first the governor should only be filled up to about the lower mark and then, with the
engine running, to the level stated above . With the engine running, the oil level will rise slightly and some oil
may escape from the venting hole in the oil level glass gauge .
The oil spaces sho0d be vented after initial operation, after a long period of standstill and after remounting
the goverior on the engine .
STARTING POSITION : Engine running

SEQUENCE OF OPERATIONS 1 : Ventin g
1 . Back off needle valve (5) on front face side of governor by about three turns and set compensating adjustment .
pointer (4) to maximum . - The governor begins to hunt and will thus expell air from the oil spaces .
2 . Reset compensating adjusting pointer and needle valve to original position after approx . 30 sec.
0 Instructions for Adjusting : see section 3, Wooward Bulletin .
Note : No guarantee claims will be entertained once the seals have been broken and the governor opened .
SEQUENCE OF OPERATIONS 2 : Oil change with governor remove d
1 . Disconnect fuel control linkage, separate pipes from Servomotor and electric leads to speed setting motor (if
provided) .
2 . Unscrew four hexagonal bolts in the foot of the casing, lift governor vertically up and set it cautiously down
onto wooden supports
3 . Remove casing top cover
* (with speed setting motor), turn governor upside down to drain oil charge .
4 . Fill governor with light grade diesel fuel, turn drive shaft repeatedly, move terminal shift back and forth,
tilt governor a few times, then drain fuel oil .
5 . Mount governor on engine and refill with clean oi l
6 . Close needle valve (5) by turning it clockwise wit~ a screw driver (noting the number of turns) then back needle
valve off by about three turns and run engine for a short time .
7 . Drain the oil by unscrewing the drain plug (6) and refill with clean oil up to the lower mark on the oil level
glass gauge (7) .
8 . Run engine with needle valve in open position (this will expell air from the oil spaces) then reset needle valve
to the original position (governor muit not hunt) .
9 . Check oil level and fill up as necessary (oil level should be between the upper and lower marks) . p .t .o .
Belriebsstunden
D36 5610 E Arbeitszeit - Stunden Alle
Working firne - Hourt E~ery 6000 Operating hours
140 .01-1 Dur6e de tra~ail - Heures Toutes les Heures Ge marche
Harps de ser~icio
Tiempo de trobajo - Horas Coda
SEQUENCE OF OPERATIONS 3 : Oil change without removing governo r
For changing the oil, the governor should, if possible, be removed . 0

1 . Unscrew oil drain plug at the bottom of the casing and drain the oil .
2 . Fill governor with light grade diesel fuel through the oil filler cup (3) .
3. Close needle valve (5) by turning the screw clockwise with the use of a screw driver (noting the number of
turns between open and closed position), then back off by about three turns and run engine 1/2 to 1 minute .
4 . Stop engine and drain fuel oil completely .
5 . Refill governor with clean oil and run engine for a short time .
6 . Drain oil once more and refill with clean oil up to the lower mark on the oil level gauge glass
.
7 . Run engine with opened needle valve (this will expell the air from the oil spaces) and reset needle valve to
the original position (governor must not hunt) .
8 . Check oil level and eefill as necessary (oil level should be between the upper and the lower marks)
.
jote- When changing the oil in the governor, the oil in the booster servomotor (if provided) should be drained
too .
-GOVERNOR OIL SPECIFICATION S
The use of a suitable oil is an essential requirement for trouble-free operation of the governor . The oil t o
be used should not foam nor have a tendency to entrain air or form sludge or deposits . The oil serves at the same
time as a corrosion inhibitor, protecting the internal parts against corrosion . The same oil grade is used for is
lubrication of the engine crankgear (see section 1) .
SPEED SETTING MOTOR (if provided )
The gear of twe speed setting motor is filled with grease which should be renewed after approx . 1 000 operating
hours . Note that the gear casing should only be filled 3/4 full with new grease .
The bearing bushes of the motor are self-lubricating . When changing the oil in the governor, fill in a few drops
of oil through be oil cup at the top of the casing .
CHECKING GOVERNOR DRIVE GEA R

Remove cover (14) and check parts of the drive
gear, especially gear and bevel wheels, ball bear-
ings and the coupling sleeve on the governor drive
shaft at specified intervals . After replacement of
individual parts, check gear backlash and contact
pattern of gear teeth and, if indicated, make ne-
cessary corrections by reworking the shims.
Note : When working on the drive gear, be sure to
secure all screw connections within the
drive gear casing . Lubricating oil pipes
should be blown out with low-pressure air
and the drive gear casing washed out with
light-grade fuel .
LEGEN D
1 Woodward governor 8 Drive shaft
2 Coupling sleeve 9 Drive whee l
3 Casing 10 Drive gear casing
4 Ball bearing 11 Ball bearin g
5 Spacer sleeve 12 Bevel wheel
6 Shaf t 13 Drain plug
7 Bevel wheel 14 Cove r
15 Lubricating oil pipe
13 12 11 10 0
MAINTENANCE OF M.A .N .-DIESEL ~14 0
Arbeilskarte-Nr.
BOOSTER SERVOMOTO R Work card No .
Carte travail No. 140.02
0 Tcrieto trobojo No .
applicable work sheet . . . . . . . . . 140 .0 1
TOOLS REQUIRE D
1 Set double-end open-end spanner s
LEGEN D
1 Oil delivery port to governor 10 Air inlet, norma l connectio n

(port No . 1, unthrottled ) (unthrottled)
2 Oil inlet port from governo r 11 Set screw for adjusting the pisto n
3 Cover with valves lif t
4 Oil delivery port to special 12 Air inlet fo r special appliance s
appliances (port No . 2, throttled) (throttled )
5 Suction and delivery valves 13 Vent port
6 Pressure sprin g
7 Pisto n
8 Seal ring
9 Cover
0
Notice Drain oil from Booster Servomotor when changing oil charge of
~,Jloodward governor .
SEQUENCE OF OPERATIONS 1, Dismantlin g

1 . Disconnect oil delivery and return pipes as well as compressed a ;r pipes
(match-mark pipes and associated connecting fittings, if necessary) and
remove servomotor .
2 . Unscrew four nuts, remove valve cover and pour out oil .
3 . Remove pressure spring and piston or separate complete cylinder together
with piston from cover .
4 . Clean all parts in light-grade fuel, check seal rings, replace if
necessary and check suction .and delivery valves in cover for tightness
and free movement .
SEOUENCE OF OPERATIONS 2, Assembling and Mlountin g
1 . To assemble Servomotor, reverse sequence of operations outlined above and check to see that the piston and the
valve balls move freely . Check setting of set screw (see drawing) .
2 . Mount Servomotor on engine and reconnect the two oil pipes connecting the governor .
0
3 .. Reconnect pressure air pipe .
Notice 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 pockets to flow to the governor and have Servomotor filled with oil .
6 . Fill oil level to lower mark on sight glass and check all connections for tightness .
141
0 I D36 5617 E Arbed 'eit - Sturden Alle Befrieo!stunden

140 .02-1 Working time - HourS Every Operchrg hours
10 Tiemoo
Durie de travail - Heures 1+2 . 2 Toules les 5000 Heures de marche
de IrCoOjO - HOMS Cado Hora ; ce servicio
0
0
KSZ 1 1160_
M *Af3k* N STARTING AIR PILOT VALV E Arbeitskarte-Nr .
Work card No .
Tarjeta troba,o No .

1 Pin spanner. . . . . . . . . . . . . . . . . . . . . . . . . . . 160 .351
1 Set double-enoed open-end spanner s
1 Wrench key with hexagon head 0 .8 x 5 . 5
Lithium-soap multipurpose grease and Molykote sliding lacquer 3402
Lift of pilot valve plunger - 22 .5 mm
Roller clearance - 2 .5 mm
IEGEN D
1 Starting cam 10 Pressure spring
2 Camshaft 11 Rolle r
3 Drain pipe 12 Dowel pin
4 Air pipe 13 Pi n
5 Control-air pipe 14 Tappet
6 Drive gear casing 15 Plunge r
7 Bush 16 Collar screw
0 8
9
Valve casing
Bus h
17 Casing cover
Note : Performance of starting air pilot valve and starting valves in

conjunction with the main starting valve and the engine controls in
the control console is most conveniently checked during test
manoeuvres which should be carried out every time before the ship
reaches a port or estuary after a long voyage .
CHECKING FOR FREE MOVEMEN T
Turn engine so that the flattened portion of the starting cam comes to stop
under the pilot valve to be checked . Then, either remove air pipe and push
valve plunger downwards with a suitable tool or remove camshaft cover in
which case all plungers become accessible and everyone can be pushed down
by hand . When being released, the plunger-should immediately move outwards
without sticking or jamming . Sticking plungers must be removed, cleaned
and coated with lithium-soap grease before reassembly .
SEQUENCE OF OPERATIONS 1 : Removing and disassembling
1 . Disconnect air pipe (4) and control-air pipe (5) .
0 2 . Unscrew four nuts and extract valve casing (8) upwards .

3 . Remove roller (11) after knocking out dowel pin (12) and pushing out
pin (13), Check roller for fissures and replace it, if necessary .
4 . Unscrew four nuts on casing cover (17) and remove cover .

Caution! Cover is under spring-load ! I
5. Withdraw tappet (14) and plunger (15) in upward direction, remove pressure spring (10) .
6. Screw out collar screw (16), using pin spanner, and pull plunger out of tappet .
7. Remove and disassemble the other pilot valves, making sure not to interchange the parts of the different units .
8. Clean all parts in light-grade fuel and check for wear.
1 . When assembling, lubricate all moving parts with lithium-soap multipurpose grease . The running surface of
the tappet (14) should be coated with Molykote sliding lacquer 3402 .
2 . To mount casing cover, compress pressure spring .
3 . The spring preload (100 N) enables the plunger to be easily moved in assembled condition .
4 . Upon assembly, check roller clearance and, if necessary, correct it by reworking either the tappet or the cover .
5 . Check operation of valves in test manoeuvres and inspect pipe connections for tightness .
0
Co1
r- ,
C~
D36 5610 E
160 .01-1 Arbeitszeit
Working time
Dur6e de travail
Tiernpo de trabojo
-
-
-
-
Slunden
Hours
Heures
Horas 1
Alle
Every
Toules le s
Cada
6000
24000
Betriebsslunden
CDeraling hours
Hevres de morche
Horcs de servicio
k
4- I
0
0
REMOVING AND INSTALLING KSZ 70/125 B 161
0
M *Atk* N STARTING VALV E Arbeilsk rte-Nr.
Work grnd No.
Carts travoil No . 161 .01
To6eta trobaio No.
6 7 8 9 10 11 12 13 14 15 is

1 Flat iron lover. . . . . . . . . . 161 .354
1 Washer. . . . . . . . . . . . . . . . . . . 161 .354-1
1 Hexagon screw M 12x25 . . . . 161 .354-2
2 Hexagon screw with spigot M 20x2
0 1 Set open-end wrenches
1 Screw drive r
1 Slide gaug e
LEGEN D 1 Grinding compound
1 Tackle with rop e
1 Cylinder cover 7 Guide piston 13 Thrust bolt
2 Valve casing 8 SeAl rin g 14 Air piston
3 Valv e 9 Piessure spring 15 Stop screw
4 Grub screw 10 Stu d 16 Control-air pipe
5 Grease cup 11 Castellated nut 17 Grease cu p
6 Bush 12 Control-air cylinder 18 Starting air pipe
19 Flame trap
Note : If the temperature of the starting air pipe of a cylinder rises unduly after engine start-up, it is an
indication of a leaky starting valve with exhaust gases entering the starting air pipe .
The valve should be removed and reconditioned as soon as possible as otherwise the valve seat will be
destroyed quickly.
The grease cups should be filled with lithium-soap grease and the moving parts lubricated by giving the grease
cups a few turns before engine manoeuvres .
SEQUENCE OF OPERATIONS 1 : Removing and Disassemblin g
1 . Remove pipe connections to starting air pipe, paying attention
to the seals and the flime trap .
2 . Disconnect control'-air pipe .
161 .354-2 e-1
3 . Unscrew 4 hexagonal nuts on studs in cylinder cover, hang
complete starting valve on tackle, extract it and put it down .
4 . Remoye two hexagon nuts on air cylinder (12) and remov e
cylinder together with air piston (14) .
161.354- 1 I'll"""",% \r- 11 5 . Remove cotter pin and unscrew castellated nut (11) while
holding the guide piston (7) .
36 40 504/1
161 .354 Caution! Piston is spring-loaded .
6 . Pull piston (7) completely off the valve (3) and take off
spring (9).
7 . Pull valve (3) out of valve casing (2).
B . Pull air piston (14) out of control-air cylinder (12) and check condition of pistbn rings .
0
p- t.-O-
D36 5612 E Arbeitszeit - Stunden Alto Betriebsstunden
161 .01-2
Working time
Dur6e da trovoll
Tiefnpo de trobajo
- Hours
- Heures
- Horas kk Every
Toutes Its
Cada 12000
Oparating hours
Heures da %rche
Horos de servicio
SEQUENCE OF OPERATIONS 2 : Refacing valve hea d
1 . Fasten fl at-iron lever together with washer to valve head with hexagonal screw . 0
2. Grind valve seat with fine or coarse emery .
Note : During refacing,lift valve head frequently to allow emery to distribute evenly. Cease grinding wheq
valve seating surface forms a ring of even width and a dull-gray finish .
SEQUENCE OF OPERATIONS 3 : Reassembly and installatio n
For reassembling reverse operations outlined above, observing the following points :
1 . Before reassembling, lubricate air piston and guide piston with lithium-soap multipurpose grease .
2. After reassembling, check to see that there is a clearance of 1 mm between air piston (14) and stop screw (15),
and if clearance is less than that, shorten screw by grinding after having unscrewed it from the air cylinder
(12) and measured with a slide gauge .
3. When reinstalling the valve, check to see that seal in cylinder cover is in good condition (if necessary, soften
seal by annealing and subsequent quenching .) and be sure to install the valve in the correct position (grub
screw 4) .
4. Check satisfactory operation by test manoeuvres and check at the same time all line connections for tightness .
40
KSZ 162
MAINTENANCE OF MAIN STARTING
M *AGL+ M VALVE
Arbeitskarte-Nr.
Work card No. .
0 Carte travail No 162 .0 1
TOOLS REQUIRED TOOL NO .

1 Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 .353
1 Vice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001 .641
1 Single head fork spanner SW 46
1 Double head fork spanner SW 19x22
24x2 7
KEY TO SYMBOL S
1 Compressed air pipe (from receiver)
2 Valve casin g
3 Cove r
4 Control air pipe (from control console)
5 Pressure sprin g
6 Bush
7 Valve pisto n
8 Starting pipe (to starting valves )
9 Pressure gauge pipe (after main starting valve)
10 Leve r
NOTE To monitor the air pressure before and after the main 11 Vent pipe
starting valve,"pressure gauge pipes (16 and 9) are 12 Spring
branched off . 13 Casing
14 Valve cone
If there is any trouble in the controls, the main 15 Valve sea t
starting valve can be opened manually by means of
16 Pressure gauge pipe (before main starting valve )
lever (10) .
Valve lift 30 mm
Venting valve 5 mm
1 . Main starting valve should be checked for tightness and both valve
00' .641
cones, for smooth movement at regular intervals .
2 . Before manoeuvres, open stop cock and give grease cup a few turns,
refill with lithium-soap multi-purpose grease if necessary, and
close cock afterwards .
is NOTE During lubrication, compressed air must be shut off at air
receiver and valve cone must be moved with layer (10) .
3 . Valve seats that are not tight must be ground with fine emery (see
sketch) and valve cone must be perfectly clean before installation .
Ui
0 s -Stunden . Betriebsstunde n
D36 5600 E
162 .01-1
W rkinzo
Arob ei' et'ime
i
D rie de travail
Ti'empo d* trahajo
- Hour,
- H*ure s
- Horas I H EE
[All"
Y i,) nr)ri
Operating hour s
Tou es les Heures de rnurche
TC0*u 0 Horas de servicio
0
0
K5Z 70/125 B 200
M *AeL* N INJECTiON PUMP MAINTENANCE Aroeilskorle-Nr .
Work card No .
Carle travail No . 200 .01
0 Tcrieto lrabojo No .
TOOLS REQUIRE D
1 Set open-end wrenches
MAINTENANCE 1 Feeler gaug e
For reliable and economical engine operation it is very important that the injection pumps be in good oondition .
Injection pumps should, therefore, be checked at the intervals specified in the Maintenance Schedule . With the
moving parts being connected to the central lubricating system and the pump plunger and barrel lubricated by the
fuel supplied, they require but little maintenance .
SEQUENCE OF OPERATIONS : Checkin g

1 . Remove covers of drive gear casing alid check condition of fuel cams, drive rollers and tappets (visual inspection,
tightness of fuel cams, clearances) .
2 . Switch on lubricating oil pump and check lubrication of tappet and oil supply through spray nozzles for cam.
tracks . -
3 . Remove link pin in link joint between pump rack and fuel control linkage and check pump rack and control sleeve
for binding and sticking .
Note : Hard moving or sticking control sleeves can be made movable with light-grade Diesel fuel .
0
4 . Replace link pin in pump rack and tighten nut (link must be freely movable) .
5 . Replace cover in drive gear casing .
6 . Check that fuel system is pressureless and shut off supply pipe to injection pump .
7 . Unscrew both baffle screws in each pump, paying attention to seals, check screws for wear and replace as
8.: necessary .
Check leak fuel discharge at larger intervals . Replace pump element (plunger together with barrel) when leak
fuel losses become excessive .
Note : Pump wear is caused, above all, by foreign particles suspended in the fuel . Fuel filter~s and separators
should therefore be cleaned in good time .
Should a plunger have become stuck during operation, an attempt should be made, after removal of the pump
element,to pull the plunger out of the barrel (by moving it cautiously back and forth in fuel oil) and
to 'make it again movable by grinding the plunger in the barrel with lubricating oil and polishing p2ste
(do not use emery) .
A spring-loaded member provided on each pump rack permits the engine to be shut down by giving way in the
case of a pump plunger having become stuck . Injection pumps can be shut off individually in the even t
of disturbances by lifting the tappet* roller out of the operating range of the fuel car. .
MEASURES AND CLEARANCES (mr. )
0 Meas .point Nor. . dim . New Limi t

A 50 H7*
B 0 .023 0 .02 5
C 50 *
D 104 D G
E 0 .120 0 .164 0 .3 0
F 104 h6 -
G 91 D6 -
H 0 .120 0 .164 0 .3 0 L
J 91 h6 -
0 .1 2
K 15 *
+ 0 .1 0
L 0 .10 0 .15 0 .2 0
Ill 15 - 0 .03 -
N 4. 6
0 15H7 (14,9+0 .1 )
P 8 + 0 .01 r")
R 45 H 7
S 0 .05 0 .10 0 .2 0
the two parts are
T 45 e7 I -
0 lapped to mat e P .t .0 .
D36 5612 E Aroettszeil - Stunden Alle Betrieossluncen
Working time - Hours Every Operating hours
r-
200 . 0 1 -2 Durie ce travail -
Tiempo de lrcbojo -
Heures
Hares
Touies let
Ccdc 3000 Heures oe mor he
cp
Horcs ce servi CIO
Measurin g Nominal dimen - Machinin g Max .
point sion allowance clearan c
.00 9 0
A 195 ' 0,10
0 4
B - 0,196 - 0 .321
.3 0
C 195 - 0
0 .3 3
0 .2 4
0 75' *
+ 0 .2 1
E 0 .18 0 .22 0 .3 0
F 75 n5- -
G 0 .4 - 0. 9
H 14 * -
j 85 + 0 .1 -
K 0 .4 - 0 .6 1 .0
L 84 .6 - 0 .1 -
• MeBbereic h
• range of measure
36 40 473/6
29 30 31 3 2 33 34 35
LEGEN D
1100 NM
I Drive gear casing 10 Fixing screw 19 Seal 27 Stud 35 Pump rack
2 O-rin g 11 Sea l 20 Sea l 28 Hexagonal nut 40 Valv e
Supporting plate 12 Plat e 21 Angle flange 29 Lockwire 41 .Valv e
4 Spring plat e 13 Pump plunger 22 Hexagonal screw 30 Set ring 42 Stop piston
5 Retaining ring 14 O-ring 23 Pump caiin g 31 Cheese-headed scre w
6 Clamp sleev e 15 Fixing screw 24 Valve casing, compl . 32 Grub screw
7 Pressure spring 16 Seal 25 O-rin g 33 Seal
8 Control sleeve 17 Pump barrel 26 Cover 34 Fixing screw
9 Spring plate 18 Baffle screw
KSZ 701125 B I 200
0 M*Ak*N INJECTION PUMP
Arbeitskarte-Nr.
Work card No
Corte travail i~o. 200 .02
Torieta trabojo No .
applicable work sheets . . . . . . . . . 000 .30

200 .01
200 .0 6
1 Gauge mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 .352
1 Torque wrench 80 - 300 Nm . . . . . . . . . . . . . . . 008 .003
1 Torque wrench 750 - 2000 Nm . . . . . . . . . . . . . 008 .005
1 Socket wrench, size 30 x 12 .5 . . . . . . . . . . . 001 .759
1 Socket wrench, size 50 x 25 . . . . . . . . . . . . . 001 .803
1 Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001 .916
1 Mill cutter (spccial tool) . . . . . . . . . . . . . . 434 .003
1 Lifting eye R 1 1/811
1 Ke y
1 Feeler gaug e
1 Slide gauge or micrometer
1 Tackl e
0
LEGEND
21 Angle flange (fuel)
36 Roller tappe t
37 Rolle r
40 Delivery pip e
41 Lubricating oil pipe
42 Fuel control linkage
43 Bol t
44 Air pip e
45 Leak fuel pipe
46 Nu t
G Roller clearance
H. Measuring rang e
1 . Close cocks in fuel supply and in excess fuel pipe .

2 . Disconnect angle flange (21) of fuel supply pipe, fuel injection
pipe (40), lubricating oil pipe (41), air pipe (44) and leak fuel
pipe (45) . Screw lifting eye into top of pump .
0
3 . Disconnect fuel control linkage from injection pump by taking out
screw (43) after unscrewing the nut .
4 . When it is intended to disassemble the injection pump, loosen the
12 nuts (size 30) on the top of the cover now .
5. Turn camshaft so that the respective cam lobe is pointing down-
wards in order to release part of the spring tension .
6. Unscrew 4 nuts (46) on casing flange (size 50), attach injection
pump by lifting eye to tackle, lift pump cautiously and set it
aside .
Note : Use extension (001 .916) for loosening and tightening nuts in
the back of the pump .
7. Close opening in drive gear casing .
Note : For pulling out the roller tappet (36), use two eye screws
(M 10) by means of which the tappet is fastened to the
tackle and pulled out upwards .
40 p. t. 0.
Co
r-:
D36 5612 E
200 .02-2
I Arbei szeit - Stunden
Work I g time Hours
Durke de travail - Heure s
All
Ev ry
Toutes [e s
ü 1 Cada 12 000
Betriebsslunden
Operating hours
Heures de morche
Horas de servicio
Tiempo de trobajo - Horas
SEQUENCE OF OPERATIONS 2 : Mountin g
1 . Check if roller tappet (36) and roller (37) are in good condition and if they move freely. 0
2 . Measure roller clearance G - 0 .4 - 0 .9 mm between fuel cam and suspending roller and correct clearance by
machining the roller tappet if necessary .
Note : The clearance between roller and cam base circle is to be measured within the range H - 14 mm after the
lobe joint on the ramp side of the cam (see illustration) .
3. Clean pump seating surface on drive gear casing .
4. Attach injection pump with eye to tackle and lower it cautiously onto the drive gear casing .
5. Screw on four nuts but do not tighten them yet .
6. Reconnect pump rack with bolt and nut to fuel control linkage and check position of pump rack on scale and
pointer position, if necessary turn pump into correct position .
7 . Reconnect all pipes and check joints for tightness after resuming operation .
8 . Tighten the 4 fixing nuts in diagonally opposite order in several steps with the use of the torque wrench,
the Extension and spanner socket (size 50), applying the specified torque (see work sheet 000 .30) .
SEQUENCE OF OPERATIONS 3 : Refacing delivery pipe seat

Note : The mill cutter (434 .003) is a special tool which is supplied
on request .
It is strongly recommended not to reface the pipe seat with the
pump installed, unless it is in a real emergency, because the 40
millings cannot be completely removed from the injection pump .
1 . Unscrew 12 nuts (size 30) at the top of the pump and remove cover
with the use of the lifting eye .
2 . Clamp pump cover (26) into vice .
3'. Screw on mill cutter and reface seat in cover lightly . This seat
should only be smoothed while removal of stock is to be kept at a
minimum .
4 . Unscrew mill cutter and carefully remove all millings in the pump
cover with the use of an air hose .
5 . Replace pump cover and torque LIP the 12 nuts with the use of the
torque wrench and socket wrench to the specified torque (see work
36 40 279 sheet 000 .30) .
0
D36 5612 E / 200 .02-2
DISMANTLING KSZ - B 200
M+A&+M -INJECTION PUMP Arbeitskarte-Nr .
Work card No .
Carte travail No .
0 Torieto trabajo No . 200 .03
appTicable work sneets.7.=U
200.02

26 I Installing and removing tool . . . . . . . . . . . . . . . . . . 200 .3SB
1 Assembly pliers . . . .
LEGEN D
3 Supporting ring 28 Hexagonal nut
40 5 Retaining ring 40 Valv e
8 Control sleeve
24 13 Pump p) unge r 51 Hexagonal screw
17 Pump barrel 52 Sleev e
23 Pump casing 53 Press plate
24 Valve casing 54 Cu p
25 O-rin g 55 Spherical disc
26 Pump cover 56 Nut
0 27 Stud
1. Unscrew 12 nuts (28) and lift off pump cover (26) .
2. Extract complete valve casing (24) .
3. Remove retaining rings and extract valves (40) .
4. Mount removing tool on pump casing (23) (see illustration) .
5. Push up press plate (53) by tightening nuts (56) until slotted
supporting plate (3) can be removed sideways .
6 . Back off nuts to release spring tension, remove spring plate
with spring and the removing tool .
7. Remove retaining ring (5) from groove in control sleeve (8)'
with the use of pliers .
8 . Withdraw pump plunger (13) cautiously and place it on a
resilient support .
0 C__ p.t. 0 .
co Arbeitszeit -Stunden - Alle Beiriebsstunden
.
D36 5610 E Working time - Hours Ewy Operat ng hours
Durde
e p de
d eir c~voit - Heure s
200 .03-2 Ti rn 0 trabajo - Horas AA
Toules les
Code
12 000 Heures de mar~' he
Horns de servicio
ervici
9 . Unscrew locating screw (34) with
Seal (33) from pump casing, take
cut oper spring plate (9) and
control
u ' sleev e
40
10 . Unscrew fixing screw (10) with seal
(a~ 9 (11), unscrew stop piston (42) and
Pull out pump rack (35) .
Note : Do not remove set ring (30)
from pump rack (full-load stop)
11 . .Unscrew locating screw (15) wit h
seal (16) for pump barrel (17) and
the two baffle screws (18), paying
attention to the seals (19) .
12 . Force out upwards pump barrel using
a wooden driving block and a hammer
or a press, and put it down .
42
Note : Clean all parts of injection
pump with fuel oil, blow dry
with an air hose and check
parts for wear.
When disassembling several

pumps at the same time, be
is
sure not to confuse the parts
with those of different pumps.
LEGEN D is
7 Pressure spring 18 Baffle screw
8 Control sleeve 19 Seal
9 Spring plat e 23 Pump casing
10 Locating screw 30 Set ring
11 Sea l 33 Sea l
15 Locating screw 34 Locating screw
16 Sea l 35 Pump rack
17 Pump barrel 42 Stop piston
0
D36 5610 E/200-03-2
ASSEMBLING - KSZ - 200
0
M *AOL* F4 INJECTION .PUMP Arbelti karfe .Nr.
Work cord No.
Corte travail No .
Tarietatrabolo No . 200.04
applicable work sheets 200.01
200 .05
200.06
TOOLS REQUIRED Tool No.
1 Installing and removing tool . . . . . . . . . . . . . . 200.378
1 Torque spanner 80-300 Nm . . . . . . . . . . . . . . . . . . 003 .003
1 Spanner socket 3iZ8 3002 .5. . . . . . . . . . . . . . . 001 .759
1 Pliers
LEGEN D
15 Locating screw
16 Seal
17 Pump barrel
18 Baffl e screw
19 Seal
0 Aotr. Great care Should be taken when assembling the injection

pump since reliable operation and tightness of all
elements will only be achieved when all parts are in
good condition and spotlessly clean . Special attention
should be given to plunger and barrel assembly as
foreign particles wedged between plunger and barre l
will either result in the plunger to become stuck
or cause damage to the sealing surfaces . When re-
assembling the various parts note that sealing
surfaces must be spotlessly clean*and absolutely dry ;
they must not be lubricated with fuel oil, lubricating
oil or any other lubricant .
For reassembly, consult sectional drawing of injection
pump given on sheet 200 .01 .
SEQUENCE OF OPERATIONS .
1 . Insert pump barrel (17)-into pump casing (23) from above,-
paying attention to the position of the groove for the
locating screw (15) .
0 2 . Insert locating screw and the two baffle screws (18)
17 with seals.
3 . Insert pump rack (35) and screw in and locate stop piston
27
(42) .
25 4. Set pump rack to graduation mark 55 and insert control
23 sleeve (8) with inatch-marks lined up .
I
5. Insert locating screws (10 and 34) with seals .
6. Insert pump plunger cautiously into pump barrel, paying
attention to the locating pin (6) .
10tr. Pump plunger and pump barrel must be spotlessly
clean because even minute particles are likely to
cause disturbances.
7. Insert retaining ring (5) with the use .of pliers and see
that ring ends do not come to lie in one of the two slots
(see illustration) .
8 . Insert pressure spring and lower spring plate .
p.t. 0.
D36 5610 E Arbeitszeit -Slunden All Betrieb3stunden
L.-
200.04-2 Working time -Hours .Every
'0 Operating hours
Dur6edetravoill -Heures
Tlempo de trabalo - Horas
ro u lesles
Cada
12000 Hsu res do marche
No
ras d a serv icio
9. Force press plate of installing tool up-
vards until the slotted supporting plate
(3) can be inserted from the side . 0
10. Relax pressure spring and remove install
ing tool .
Note: Before removing the spring ten-
sioning tool, check to see that
retaining ring, supporting ring
and spring plate are correctly po-
sitioned (danger of accidentl) .
11 . Assemble valve casing (24) with valves,
check valves (40 and 41) for free cove-
ment
12. Insert* valve casing into pump casing
(23) .
Note: Sealing surfaces must be spotless-
ly clean Ad dry .
3 . Mount pump cover (26) with O-ring (25)
and screw on twelve nuts (28) .
14 . Tighten nuts crosswise with torque span-
ner and spanner socket size 30, applying is
a tiohtenino torque of MA - 250 Nm .
LEGEN D
3 Supporting plate 24 Valve casing
5 Retaining ring 25 O-rin g
6 Locating pi n 26 Pump cover
13 Pump plunger 27 Stu d
15 Fixing screw 28 Hexagonal nut
16 Seal 35 Pump rac k
17 Pump barrel 40 Valve
18 Baffle screw 41 Valve
19 Seal 42 Stop piston
23 Pump casing
0
KSZ-B
KSZ-C
WA *A~L* N ADJUSTING INJECTION PUMP Aroeitskorte-N .- .
Work card No .
Carte travail No.
0 Tarieto trcoajo No . 200 .05
applicable work sheets . . . . .000.25
ADJUSTING INJECTION PUMP 103 .01
Extremely close tolerances in the manufacture ofI roller tappet and injection cump permit spare pumps to be
mounted without the need for checking or rework .
After connecting the fuel control linkage to the injection pump, check whether the Du .T.p rack is in its extreme
end position of zero admission when the complete fuel control linkage is in zero Position
* (compare scale and
pointer position with those of the other injection pumps) .
After mounting a new injection pump, indicator diagrams should be taken to check and compare the correct beginning
of delivery (see work sheet 000 .25) . The firing pressures of the individual cylinders should be of about th e
same height, deviations amongst the cylinders should be negligible . Corrections of the firing pressure are made
by turning the cam on the camshaft (cf work sheet 103 .01) . Accurate adjustment is essential with regard to the
engine output, combustion and troublefree operation of the engine .
A correction of the beginning of delivery may become necessary if another fuel (heavy oil) with different
ignition properties is being used . The need for and the extent Of an adjustment oil the cams on the camshaft
can be seen from the indicator diagrams . In this case, all fuel cams must then be adjusted accordingly either
0 in the forward or the backward direction . Re-larded ignition with low firing pressure, compared to the data given
in the Acceptance Records, requires the fuel cams to be adjusted in the forward direction, whereas in the case
of excessive firing pressure the cams must be adjusted in the backward direction-
D36 5610 E Arbeitszeit - Stunden At Betriebsstunden

le Operating hours
200 .05-2 Dur6edetravoil -Heures
Tiempo ce t . obalo - Horas
Tovies les
Coda as necessary Heures
0 de morche
H ras ce Servicio
0
0
TIMING KSZ 70/125 B 200
ENGAGING AND DISENGAGIN G Arbei :skarie-Nr.
Work card No .
INJECTION PUMP Carte frcivai ; No .
0 Torieta froonic, No . 200 .06
TOOLS REQUIRED Tool 11,

1 Rod . . . . . . . . . . . . . . . . . . . . .. . . 20C . 330
1 S'3ckeL wrench . . . . . . . . . . . . . 200 .379
-dtL high-pressure pu :7,p . . . . . . . . VJ" .')U_1 .) ' .~
II
11 40 1 Hexagon screw M20 x 13 0
~~T 41 4243 1 Open-end wren-oh, size SO
R4~1 1
4- 1 Recepta .
LEGEN'D
36 Roller tappet 40 Screw plug
37 Rol I e r 41 Connectin g
38 Thrust piece socket
39 Shut-down bolt 49 High-pressure
hos e
43 Iligh-pressur e
1 .-ofe : 11' a delivery Pipe has been disconnected or an injection pump re .moved in the course of P U .T'P
0 repairs, pipe and iine nust be vented before the engine is restarted .
SEQUENCE F OPERATIONS 1 : Primin g
11 . Sei pump plunger to bottom center by turning the running
(drive rollergea r clear of the fuel cam) .
t_0 . Draw screw connection of delivery pipe at injection pump quite tight .
3 . Screw out screw pluo (40) and replace it by connection socket (41) .
4 . Correct hp hose with hp pump .
5 . Looser. screw correction of delivery pipe at fuel injector (do not unscrew it completely) and Pla .-a re .., epta .-ls
underneath .
6 . Switch on hp pump at a low delivery pressure and run pump until oil escapes free of air bubbles at the loosened
connection .
7 . Tighten screw connection at injection valve and raise pressure to approx . 30 bar (set pressure lirJWg valve
accordingly for this tightness test) .
Note : Injection pump and pipe are ttight if the hp pump is not restarting wit
6hin m
onenu
i te .
S . With the tightness thus checked, release pressure, disconnect puffp and hose and replace connection socket in
angle flange by means of screw plug .
Note : The amount of oil escaping during this operation should be kept as small as possible and no air shoul d
be allowed to enter the pump .
0 ScQUEINCE OF OPERATIONS 2 : Disengagin g
Note : Each inj~cflon pump, if it is defective, can be disengaged individually with the engine at standstill .
1 . Turn camshaft by turning the engine by means of the turning gear until the fuel cam of the pump to be dis-
engaged comes to stop in top center position .
2 . Fit socket wrench together kith rod and fasten by means of screw . During this operation, the cogine must be
at standstill and the fuel control linkage in'zero position .
3 . Lift roller tappet by turning the rod in clockwise direction up to the stop .
SEQUENCE OF OPERATIONS 3 : Lowering the tappet to engage pum p
Note : To re-engage the injection pump, the engine must be at standstill .
1 . Remove casing cover of respective injection pump .
2 . Move fuel cam to the .highest lift position by turning the engine with the turning gear (TDC position) .
Caution! Should the fuel cam not be in the position described above under 2, there is the risk of injury by the
rod when it is suddenly flung round in the course of lowering the tappet .due to the great force of the
pump spring .
3 . Fit socket wrench with rod and fasten by screw .
4 . Lower roller tappet onto cam by moving the rod cautiously in counterclockwise direction down to the stop .
5 . Remove socket wrench and replace casing cover .
0
D36 5612 E Aroeitszeil - Slunden Mer
T ~ul Beiriebsslunden
Working lime - Hours Eve y Operating hours
oi
2 200 .06-2 Durie ce frowiii - Heures ou es les as necessary Heur
0 e s ce marche
TiennDo cie trabolo - Horcs Cada H raS de servicio
0
0
MILLING DAMAGED KSZ -F2OO_
m*A*r4 . DELIVERY PIPE SEATS Arbeitska
Work card No .
Carte travail No. 200 .07
0 Torieta trobajo No .

1 Mill cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 .00 3
LEGEN D
1 Valve casin g
STARTING POSITION
Valve casing remove d
1 . Clamp valve casing into vice with jaw-cover plates applied .
2 . Mount mill cutter and reface valve seat in valve casing slightly . Seat should only be refinished while removing
is as little material as possible .
3 . Remove mill cutter, remove valve casing from vice and clean it carefully - remove all millings .
4 . Replace valve casing in pump casing .
5 . Reconnect fuel delivery pipe after checking tapered seating surface .
Aote, For refacing of delivery pipe seats, see work sheet 221 .04 .
MILL CUTTER IS SUPPLIED

ON SPECIAL ORDE R
is
0 Arbei szeit - Stunden

D36 5610E Alle Betriebssfunden
200.07-2
Work I , g time
Durie de travail
- Hours
- Heures
Every as necessary
Operating hours
rz Tovies les Heures de morche
Tiempo de traboio - Horcs Coda Horas de servicio
0
0
ADJUSTING AND MAINTENANCE KSZ- B 203
0
M *Aftk* M OF FUEL CONTROL LINKAG E Arbeitskarte-Nr.
Work card ~oI ~io .
Corte trava
203 .01
LEGEN D
1 Booster Servomotor 9 Regulating shaft 17 Articulated ]ever

2 Woodward governor 10 Leve r 18 Linkro d
3 Governor leve r 11 Positioner 19 Pump rac k
4 Positioner for speed setting 12 Leve r 20 Injection pump
5 Ro d 13 Ro d 21 Shut-down cylinder
6 Linkro d 14 Pointer
0 7 Clamp leve r 15 Casin g
8 Telescopic imember 16 Spindle (emergency
manual oontrol)
Note : The fuel control linkage was accurately adjusted on commissioning of the engine . The setting should be
checked and, if necessary, readjusted when parts of the system have been replaced . The fuel control linkage
should then be so adjusted that the pump racks of allinjection pumps line up with the 0-mark when the
control lever of the control valve in the control console is in zero position .
SEQUENCE OF OPERATIONS : Adjustin g
1 . Unhook link rod (6) connecting the Woodward governor with the positioner.
2 .. Switch on oil pump .of positioner and set lever of control valve in control console to zero position (see
illustration overleaf) .
3 . Adjust turnbuckle in rod (13) so that the distance to the punch marks on both sides of the turnbuckle agrees
with the figures punched into the rods .
4 . Adjust screw between linkrod and articulated lever (17) of all injection pumps so that the pointer on the in-
jection pump lines up with the zero mark on the pump rack .
p. t. 0.
D36 5610 E Arbeit zeit - Stunden Alle
kk
Betriebsstunden
203 .01-2 Working
' time Hours Every Operating hours
Durk . do troy oil Heures Toutes les as necessary Heures de morche
Tiernpo de trobalo - Horas Cada Horas do servicio
5 . Move hand lever in control console to full load and check to see that set rings on pump racks limiting the
maximum pump setting are seating against the pump casing . I*
6 . Switch off oil pump of positioner and reconnect linkrod (6) connecting the governor with the positioner, and
check and if necessary readjust positioner .
MAINTENANCE
At extensive engine overhauls, check complete fuel control linkage for wear and correct adjustment . The anti-fric-
tion bearings, supporting the shafts, have a grease filling which should be renewed when shafts are being rein-
stalled. The articulated levers on the injection pumps should be regularly checked for free movement . and all
grease nipples should be refilled with lithium-soap multipurpose grease .
CONTROL CONSOLE
-11,Iq
0
r
TESTING INJECTION VALVE KSZ - B 221

M *Atk* M (hand pump) Arbeitskarte-W.
Work card N o
0 Carlo travallp. .
Tarlsta trabojo No .
221 .01
applicable work sheet 009 .02
TOOLS REQUIRED tool No .
1 Feeler rod, dia. 5 1 approx . 600 long
1 Hand pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 009 .410
1 High-pressure hose. . . . . . . . . . . . . . . . . . . . . 009.321
1 Connection fitting . . . . . . . . . . . . . . . . . . . . . 057-363
1 Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221-390
1 Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221-353
2 Hexagonal bolt M 24x 2
1 Receptacle
LEGEND
30 Feeler rod
STARTING POSITION
Engine runnin g
0
SEQUENCE OF OPERATIONS 1 : Checking nozzle needle during operation
1 . Unscrew eye screw (16) (see illustration overleaf) .
2 . Insert feeler rod all the way down onto the spring plato .(10) and hold it down by hand .
Note : A light kick should be clearly felt with each ignition (lift of nozzle needle) .
I LEGENO
05736 3 14 Screw plug
16 Eye screw
31 Receptacl e
.009.321 32 Injection valv e
33 Pressure gauge (0-400 bar)
STARTING POSITIO N
221.390 .Inj"ection valve removed a6d*cleaned on

the outside .
~3 1 SEQUENCE OF OPERATIONS 2 : Testing injecto r

009 .410 performance
1 Fasten in ;--+4-n - .1-- 4- k 1J--
Z. Place receptacle under nozzle so tna t
A40393 injector extends into it. -
3 . Connect hoses to fuel injector and to
hand pump . .
4. Fill container of hand pump with corrosion inhibiting oil .
5 . Operate hand pump vigorously, which will normally cause the valve to become filled with oil,and check on pressure
gauge whether valve is opening at a pressure of 275 bar. Also chock whether fuel is being discharged from all
nozzle orifices and if valve dribbles - a short after-dribble is of no consequence . If the fuel injector had not
been disassembled, the heavy oil It may still contain will cause the needle valve to move somewhat sluggishly
and the valve does not close so quickly as under the higher operational speed of the injection pump and a t
service temperature.
6 . The opening pressure is adjusted by changing the spring proload . To change spring load, unscrew eye screw in the
top of the valve, loosen screw plug and turn press screw accordingly . Then draw screw plug quite tight while
holding the press screw with a spanner (221 .353),' Screw in eye screw and recheck opening pressure .
7 . Take picture of spray pattern on white paper after removi6g the receptacle . - fuel should be spraying from all
nozzle orifices !
Caution! Keep away from fuel Jets as'they will penetrate the skin and cause painful infl amination (blood poisoning) .
peteo f
036 5610 E Arbeitszeit -Stunden Alto Betriabssfundon
1221 .01-2 Working time - Hours
Durdedetravoil -Heures
Every 1500 Operating hours
%D Toules Ise Houres do marcho
Cada 3000 Horas do terviCio
Not@ : The valve may be considered tight when there is no drop falling off within 10 seconds . 0
When testing a now nozzle assembly, the valve needle may be sticking in the preservation oil in which case
the injection valve must first be thoroughly flushed to remove the conservant before the valve is tested .
The hand pump should be filled with corrosion inhibiting oil of a viscosity of 10 mm 2131209C.
SECTION THROUGH INJECTION VALVE AND CYLINDER COVE R
14 15 16 17 18
I 40
LEGEND
1 Nozzle needle 10 Spring plat e
2 Needle guide 11 Pressure spring
3 Nozzle 12 Valve casin g
4 Cylinder cover 13 Press screw
5 Seal ring 14 Cooling water pipe
6 Union nut 15 Screw plu g
7 Straight pin 16 Eye screw
I
8
9
Stop sleeve
Press pin
17 Injection pipe
18 Leak fuel pipe 0
T

(Pneumatic High-Pressure Pump) Arbeitskarte-Nr.
Workcard
cart . trav- M.. 221 .01
Tarjea trobalo No .
applicable work sheet 009 .03

30 Feeler rod 1 Feeler rod, dia . 5/approx . 600 I g
1 Hp pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 009 .302
1 Pressure hose for very high pressures . . . . 009 .321
1 Connection fitting . . . . . . . . . . . . . . . . . . . . . . . 057 .363
1 Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 .396
1 Spanner . . . .~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 .353
2 Hexagonal screw M 24x2
1 Receptacl e
STARTING POSITION
Engine in operatio n
SEQUENCE OF OPERATIONS 1 : Checking operation of nozzle needle with engine running

10 1 . Remove eye screw (16) (see illustration overleaf) .
2 . Insert feeler rod down onto the spring plate (10) and hold it down by hand.
Note : With each ignition a light kick (lift of nozzle needle) should be clearly felt .
LEGEN D
16 Eye screw
31 Receptacle
32 Fuel injector
33 Shut-off valve
34 Pressure gauge
35 Plug
STARTING POSITIO N
Fuel injector removed and cleaned on the outside .
SEQUENCE OF OPERATIONS 2 : Testing injector performanc e

1 . Clamp fuel injector (32), nozzle down, Into holder (221 .390) .
2 . Place receptacle (31) under nozzle so that nozzle reaches into receptacle .
3 . Screw connection fitting (057 .363) into fuel injector and draw it quite tight .
4 . Screw hose (009 .321) to connection fitting .
5 . Connect hose to high-pressure pump and open shut-off valve (33) . Pressure gauge (34) of indicating range
0-400 bar will thus be connected (cf work sheet 009.03) .
6. S'Bal. unused connections by means of plugs (35) .
7. Fill hp pump with corrosion 1 .6hibiting "Oil (cf work sheet 009 .03) .
Note : Do not fill pump with fuel oil . When using corrosion inhibiting oil approx . 10cSt/20 C) for testing fuel
injectors, injectors will be preserved at the saine time (spare valves) .
8 . Switch on hp pump and raise pressure gradually to valve opening pressure . Valve will open and the air expelled
by the Il uid.
9 . Now lower pressure and then raise it gradually to approx . 265 bar (just below opening pressure) - valve should
still be tight .
Note : Valve may be considered tight when there is no drop falling from the nozzle tip within 10 seconds.
The following should be noted with engines operating on heavy oil : If the valve was not disassembled
before the test, the ne0e will move more sluggishly due to the heavy oil and will not close so quickly
as under the higher pumping speed of the injection pump on the engine under operating temperature . .
In the case of new nozzle elements, the nozzle needle may be sticking at the first pressure test due to
the preservant and should therefore be vigorously fl'ushed to remove the preserving oil .
p. t. 0.
B36 5610 E Arbeitszeit -Stunden All* Beiriabsstunden
Working time - Hours Every 1 500 Operating hours
221 .01-3 Durdedetravoil -Houres Toutes lei Heuros do march*
Tiempo do trabalo - Horas Coda 3000 Horos do servicio
10 . Set pump pressure to 275 bar valve opening Pressure (check gauge (34) readings) .
11 . Adi~st valve opening pressure by changing the spring load by turning the set screw accordingly after unscrewing
the eye screw (16) at the top of the valve and the screw plug (14) . Then tighten screw plug while holding the
set screw by means of a 'Spanner (221 .353) . . Replace eye screw and recheck valve opening pressure .
12. Reduce pressure In pump and then again build it up slowly to recheck opening pressure and determine spray 0
pattern on a sheet of white paper after removing the receptacle . Check that fuel is spraying from all nozzle
orifices !
Warning! Keep away from oil jets as they are capable of puncturing the skin and will cause painful inflammation
(blood poisoning) .
The oil mist should, if possible, be sucked off or the test should be carried out in the open air .
13. Release pressure in hp pump, separate hose from pump and unscrew connection fitting in fuel injector .
14. Close shut-off valve (33) on puinp.
SECTION THROUGH FUEL INJECTOR AND CYLINDER COVER

14 15 16 17
LEGEND 4 3 2 1
1 Nozzle needle 10 Spring plate
3 Nozzle nut 12 Valve casing
4 Cylinder cover 13 Set-scre w
6 Union nut 15 Screw plug
8 Stop sleeve 17 Injection pipe
9 Press pin 18 Leak fuel pipe 0
M *Aak* Pd - (Bosch Hand Pump ) Arboitskarte-W .
Work cardfa~~o . .
0 Carts trai 1 40 221 .01
Torieta trobalo No.

1 Feeler rod, dia 5/approx. 600 1g . .
1 Hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 008 .032
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o . .008 .057
1 Holder . . . . . . . . . .. . . . . . . . . . . . . . ?~t~t!?%41?t!~21 .3901221 .389
I Spanner. . . . . . . . . . . . . . . o . . . . . . . o . . . . . . . . . . . . . 221 .353
2 Hexagonal screw M 242
1 Receptacl e
LEGEND The injector tester with Bosch :hani pump
is available on special order.
30 Feeler rod
STARTING POSITION
Ennine in operatio n
36 40 35 0
0 SEQUENCE OF OPERATIONS 1 : Checking operation of nozzle needle during engine operation
1 . Remove eye screw (16) (see illustration overleaf) .
2. Insert feeler rod down to the lower spring plate (10) and hold it down by hand.
Note : A slight kick (lift of nozzle needle) should be clearly felt with each ignition .
16 Eye screw
31 Receptacle
32 Fuel injecto r
33 Pressure gauge
STARTING POSITIO N
I
Fuel injector removed and cleaned at the outside.
SEQUENCE OF OPERATIONS 2: Testing injector performance
1 . Mount injector in holder .
1 2. Place receptacle under nozzle so that nozzle reache s
I
into it.
40 31 3 . Connect pipe with pressure gauge to fuel injector
and hand pump, fasten hand pump with screws on
support
4. Fill tank
* of hand pump with corrosion inhibiting oil
(approx.*10 cSt/200C) . I
5i Operate hand pump as quickly as possible to expell all air from the fuel injector . Check opening pressure . nominal
275 bar, on pressure gauge . Also check whether oil is eiect8d-from all nozzle orifices and for dribble - brief
dribble is of no consequence . If the fuel injector was not disassembled before the test, the needle will move
more sluggishly due to the heavy oil and will not close so quickly as under the higher pumping speed of the
injection pump on the engine under operating temperature .
6. Adjust opening pressure by changing the spring preload by turning the set screw accordingly after removing the
eye screw at the top of the fuel injector and unscrewing the screw plug . Then retighten the screw plug while
hol di ng the set screw by means of a -ipanner (221'. 353) . Repl ace eye screw and recheck val ve openi ng pressure .
7. Obtain spray pattern on a sheet of white paper after removing the receptacle - oil should be emitted from all
nozzle orifices !
WarningI Keep away from oil jets as they are capable of puncturing the skin and will then cause painful
infl ammation (blood poisoning) .
18 p. t.0.
036 5610 E Arbeitszeit ::Sfuknden Alle Betriebssfunden
Warking time Ho ors 011 Every 1500 operating hours
221 .01-4 Durdadetravoil„ ::Heures Toutes les Heures de Marche
Tiempo de troba Horas 2 . 0 .5 Cado 3000 HarGs 40 servicio
SECTION THROUGH FUEL INJECTOR AND CYLINDER COVER
LEGEND
0
1 Nozzle needle 10 Spring plate
3 Nozzle nut 12 Valve casing
4 Cylinder cover 13 Set scre w
I Straight pin 16 Eye scre w
8 Stop sleeve 17 Injection pipe
9 Press pin 18 Leak fuel pipe
D36 5610EI221 .01-4

KSZ 70/125 B 22 1
M +AL+ N FUEL INJECTOR Arbeitskarte-Nr .
Work card No .
Torietc trcba ;o No .
applicable work sheet . . . . . . . 221 .01
36 221-388-2-" Extractor, ciomplete . . . . . . . . . . . . . . . . . . . . . 221 .38 8

1 Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 .388-1
221-388-1 1 Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 .388-2
1 Torque wrench 80-300 Nm . . . . . . . . . . POB .00 3
1 Hexagon nut M 30x 2
37 1 Open-end wrench, size 46 + 19
1 Socket wrench 46 x 2 0
1 Adaptor 20 x 12 .5
15 1 Hamme r
1 Lifting gear with rope
LEGEND
15 Screw plu g
36 34 956 36 Hexagon nut Ill 30 x 2
40 .SEOUENCE OF OPERATIONS 1 : Removin g

37 Hexagon nu t
1 . Shut off cool ing water supply to fuel injector and pipe tracing heating for injection pipe, if provided .
2 . Disconnect fuel injection-, leak fuel- and cooling water pipes .
3 . Unscrew two hexagonal nuts (37) and check whether injector is a loose fit - if not, proceed as described under
4 - 7.
4 . Unscrew eye screw (16) in top of valve (cf work sheet 221 .01) .
5 . Screw spindle into screw plug (15) and place bracket onto both nuts in horizontal positior .
.. Note : The two nuts (37) should be backed off the same distance .
6 . Screw hexagonal nut (36) onto spindle and loosen injector by screwing down the nut .
Note : If injector is a very tight fit, try to loosen it by light tapping on the square head of the spindle
or on valve flange with a hammer .
7 . Unscrew extractor, remove both nuts, screw in eye screw, extract injector with t2 .^kle and pu t it down .
STARTING POSITION : Installin g

Injector has been carefully cleaned, opening pressure checked, tapered seat in cylinder cover and seating -urfa :os
on valve inspected and coated with MoS 2- based lubricant .
0 Ncte : When replacing a fuel injector in a hot engines allowance must be made for thermal .expaisior, of t~.e injc,-t,r-
during operation . Therefore, the fixing bolts should, at first, be tightened lightly and t~crqued tip to
recommended torque only after temperatures have equalized . A fuel injector that has been takLi, fro m
or received on order should be cleaned at the outside and pressure-tested before installation .
SEQUENCE 0: OPERATIONS 2 : Installin g

1 . hang fue, injector by eye screw on tackle and lower it from above into injector hole provided in the cylinder
cover. Connection for injection pipe must be pointing towards engine confrol side .
2. Torque up fixing nuts to 200 Nm (j :~,A 20 mkp) .
3 . Reconnect pipes for fuel, leak fuel and cooling water .
Prime injection pipe and fuel injector to expell air .
Note : Pipe and injector need not cle primed if only one fuel injector has been replaced as the air will be
injected into the cylinder when the engine is started .
0 D36 5612 E Arbei szei, - Stunden Ahe Bttrieossiunden

Every ODerchni; hours
C> 221 .02-2 Work~ time - Hours
I Heures cc marc e
9 Durie"gcc travail
Tiempo de troottio
- Heures
- Horas AA I
Toutes le s
Cada
3000 Horas de servici
cr,
0
0
KSZ 70/125 B ?? I
DISASSEMBLING AND CLEANING KSZ 78/155 B I
NMO *A&&* " FUEL INJECTO R AroeiTSKOrle-Nr .
Work card No .
0 Carte trovcii No.
Taripia trcba:o No . 221 .03
a .D .Dlicabl a wor~ sheets . . . . . . . . 221 . 011

221 . 004
L EG E N D TOOLS REQUIRED Tool No .

2 Nozzle nut 10 Spring plat e 1 Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 .353
3 Needle guide 11 Pressure spring 1 Tommy bar, dia. 1 2
0
4 Nozzle needle 12 Valve casin g 1 Double-head open-end wrench, size J6 x 41
5 Seal ring 13 Set screw 1 Open-end wrench, size 7 0
6 Union nut 14 Screw plug 1 Slugging box wrench, size 7 5
9 Press pin
Tiote : Before disassembling, wash valve -in luel oil

and remove carbon deposits with a wire brush .
The nozzle s .hould, however, only be cleaned
with a wooden spatula to avoid damaging the
nozzle oeifices . Meaning should take place
away from the work bench . The tapered seating
surfaces cf the nozzle nut and the cylindrical
portion below it should be cleaned especially
carefully . 3EQUENCE OF OPERATION'S 1 : Disassemblin g
1 . Clamp injector into clamp of injector tester
or into a vice, but do not grip it by the
cylindrical sea-ling surface below the flange .
0 2 . .Unscrew eye screw and screw plug .

3 . Locsen set screw, using key and tommy bar,
do not screw it out completely .
4 . Unclanp va)ve and put it on work bench .
5. Unscrew set screw, lift valve so that pressure spring, spring plate and press pin will fall out .
6. Clamp in valve with nozzle pointing upwards (observe instructions given overleaf!) .
7. Loosen nozzle nut, using open-end wrench, paying attention to seal ring .
8. Loosen and unscrew union nut, seeing that nozzle needle and needle guide will not fall on the floor .
9. Cautiously take off needle guide and nozzle needle, paying attention to the straight pin .
P. t. 0.
D36 5612 E Arbeilszeit - Stunden All* Betriebsslunden
cy,
221 .03-2 Working time Hours
Durie ce t rovail e' as
Tiernoo de trcboio FHior
res
kk Te'u
Every,
ou es ies
Coda
6 000 Operaling hours
Heures ce marche
Horcs cc servicio
t 6 : No attempt should be made to regrind the lapped surfaces of the needle guide and the valve casing .
Seating surfaces should only be cleaned with newspaper or low pressure air (do not use towels or cotton
waste) . Dirt between and corrosion of rating surfaces cause fueli leakage . Before disassembli,,g the injector,
check whether n :zzle nut was tightened to defined torque (cf work sheet 221 .04) .If nozzle nut had been
tcrqued up properly and injector has been leaking, replace defective parts .

1 Cleaning eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001 .729
I Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 002 .701
1 Set of cleaning wires, dia. 0.8 . . . . . . . . . 002 .727
1 get of cleaning wires, dia. 0. . . . . . . . . . C02 .72-5
1 Grinding pin, complete . . . . . . . . . . . . . . . . . . 221 .37 8
1 Grinding pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 .354-1
1 Tommy bar, dia . 6 . . . . . . . . . . . . . . . . . . . . . . . 221 .354-2
1 Grinding sleeve . . . . . . . . . . . . . . . . . . . . . . . . . 221 .354- 3
SEQUENCE OF OPERATIONS 2 : Cleanin g

1 . Clean nozzle orifices by pushing a clearing wire of
suitable diameter, clamped in chuck, through ihe nozzle
orifices .
2 .Carbor, deposits in the central drill hole of the nozzle
are removed with a spoon bit or a cleaning eye . 0
3 . Check whether nozzle needle moves smoothly and freely in
the needle guide . When held in vertical position, the
nozzle needle should slide down onto its seat by its own
weight .
4 . Sticking and binding nozzle needle ., should be made
movable by lapping with fuel oil .
Note : For cleaning, use grinding pin and then flush out
drill hole thoroughly . If damaged, always replace
both nozzle needle and needle guide .
0
I
KSn0)1 2-5-B
ASSEMBLING KSZ 7qt155 B 22 1
0
M *A&* N FUEL INJEPTOR Arbeit,korte.Nr.
Work card No.
Carts travail No.
Torieta trabolo No . 221 .04
12 applicable work shoot. . . . . . . 221 .01

I T AAQ AM 11
w#4uV .0
(80 - 300 Me)
1 Torque spanner. .
36 34 949 (280-760 Nm)
1 Adotor .... .. . 001 .923
(20 x 12.5)
221-387. 008-003 1 Spanner size 75 ... . ...... o ..o .o.221 .387
I Spanner size 70.o ....o. .. . . . . o..221 .394
008.00 4 I Feeler rod. ...oo. .oooo . .. . . o . . . . 221-392
221-394 ' 1 Spanner... .........ooo . . . . . . o .oo221 .353
I Tommy bar, dia. 1 2
1 Double-ended open-end spanner size 36x4 1
0 I JEENO
2 Nozzle nut 10 Spring plat e
4 Nozzle needle 12 Val ve casing
5 Seal rin g 13 Set screw
9 Press pin
36 35 209
STARTING POSITION
221 .38 4 All parts are spotlessly clean and absolutely dry,
I evei;ially mating surfaces of needle guide and valve
casing . Valve casing clamped in holder of injector tester .

1 . Insert straight pin in valve casing and coat thread
with MoS -based lubricant .
2 . Place neidle guide with needle on top and coat contacting
surface of collar with lubricant .
0 3 . Screw on union nut and torque up to 650 N (w 65 mkp)
4 . Coat seal ring and threads of nozzle nut with MoS 2 -basW
lubricant, screw in nozzle nut - only original seal ring
should be used .
5. Toraus up nozzle nut to 200 Nm (;w20 mkp) .
6 . Check with feeler rod if nozzle needle moves freely .
'Should needle be sticking, remove and check needle and
guide .
7. Unclamp fuel injector and put it on the work bench in
horizontal position . Stack press pin, spring plate and
spring onto set screw and insert assembly into valve
casing .
B .Tighten press screw lightly and screw in screw plug
loosely.
9 . Set valve opening pressure (cf work sheet 221 .01).
10 . Screw eye screw into valve casing .
:11 . Pressure-test cooling waier's'pa'c-s' of valve at a pressure
of 15 bar while checking for tightness .
9 10 1 1 13
36 35 210
p .t .o .
036 5612 E Arbeitszeit - $I unden All@ Beirlebsslunden
r,- 221 .04-3
, Co Working time - Hours Every Operating hours
Dureadetravail -Heures
Tiempo de tr(Lbc;o - Horas
Toutes les 6000 Heures de morche
Coda Moros de servicio
Note : All lapped and sealing surfaces should be absolutely dry and must neither be oiled nor lubricated with any
other lubricant . When storing injecto~s, they should be sparingly oiled on the outside and the opinings
for the pipe connections should be sealed. 0
TOOLS RQUIRED Tool No .

1 Grinding ring . . . . . . . . . . . . . . . . . . . . . . . 221 .379
1 Mill cutter . . . . . . . . . . . . . . . . . . . . . . . . 434 .353
SEQUENCE Of OPERMORS 2: Regrinding tapered seat and remillfng

seat of delivery pip e
1 . Clamp fuel injector upright, nozzle up, into vice, holder or
a suitable jig . .
2 . Apply grinding ring with fine emery and turn it backward and
forward, lifting the grinding ring intermittently in order to -
redistribute the grinding compound .
3 . Lift off grinding ring and clean tapered'seat of nozzle nut
thoroughly .
4. Invert fuel injector, nozzle down .
5. Screw in mill cutter .
6. Reface seat in valve casing lightly .
36 34 955 The seat should only be smoothed, removing as littls material as
possible . 0
7. Unscrew mill'cutter, remove injector from clamp and clean it
thoroughly - all millin93 must be carefully removed.
jotr. Refacing of delivery pipe seats should only be carried out
on the disassembled valve - then flush out valve casing
with fuel oil and blow it dry with an air hose .
,TOOLS REQUIRED Tool No .
1 Mill cutter. . . . . 434 .00 1
1 Mandrel, tapered
LEGEND
1 Fuel delivery pipe
2 Union nut
3 Colla r
SEQUENCE OF OPERATIONS 3 : Widening the delivery pipe diameter and
refacing the delivery pipe an d
1. Widen pipe diameter with the use of the mandrel .

0
2. Slip union nut (2) over collar (3) and screw it down .
3. Screw tool onto union nut and mill seat lightly .
4. Unscrew mill cutter, clean pipe and collar from millings and
blow out with pressure air.
0
KSZ 1 281_
CLEANING- INTERCOOLER
M *AGL+ N DURING OPERATIO N
Arbeilskorle-Nr.
Work card No.
Corte Irovail No. 281 .01
(with turbocharger mounted on engin e Torieta frabajo No .
0
TOOLS REOUIRED
Mixing tank
Cleanser ACC- 9
LEGEND
4
1 Atomize r
2 Charge-air from compressor
3 Charge-air coole r
4 Filling opening
5 Tan k
6 Vent valv e
7 Valve in pressure balancing pipe
1-71 8 Valve in supply pip e
9 Air valv e
10 Air connection (appr . 7 bar )
Val ves 6_ 71 8 1 9
A
Operating position open close d
B
Cleaning position closed ope n
GENERAL
The lengths of the intervals belween cleaning depend in a new engine on the cleanness of the pipes and the inter-
cooler as well as on the contamination of the air drawn in . The charge-air pressure before and after the inter-
cooler is an indication of the contamination of the air side . The difference in pressure is indicated by the dif-
ferential pressure qa~qe .
Recommended intervals : During the first period of operation, fill in three litres of cleaning emulsion every 24
operating hours and observe differences in pressure . Then gradually increase the lengths of intervals until results
are satisfactory with as little cleanser as possible .
Mixing proportion : . 1 part AMEROID ACC-9 and
0 2 parts of freshwater
Note : Prepare emulsion immediately before use and stir it thoroughly . Pour cleanser into the water to obtain a
stable emulsion, not vice versa .
I
Caution! When preparing the emulsion, qoqqles and plastics gloves should be worn and inhaling of the vapour must be
avoided . If ACC-9 comes in contact with the skin, it must be washed off with water immediately . If it has
splashed into the eyes, rinse immediately with plenty of water and consult a doctor .
Undiluted, AMEROID ACC-9 is inflammable and should therefore be kept away from open lights or other igni-
tion sources - Danger of Explosion !
1 . Fill emulsion through opening (4) in tank and close filling opening .
2 . Set lever to position CLEANING (B) to spray in content of tank within five to ten minutes .
3 . Set lever to position OPERATION .
4 . After 10 min . refill tank with five litr~s of freshwater and repeat operations 1 to 3 .
Caution! Undiluted ACC-9 cleanser must not be filled into the tank under any circumstances, only an emulsion should
be used . Any other inflammable cleansers must not be used - Danger of Explosion !
Note : Cleaning during operation should be carried out with the engine running in the upper load range .
All e Belriebsslunde
Arbeilszeit ., Slunden
036 5610 E Working 1i Hours E~ervs as necessary Operafing hours
Heures de rnorche
Durte de lro~ail Heures Toute 1 . ,
281 .01-2 Coda Hares de servicio
I- Tiempo de Irabolo - Hares
0
0
CLEANING INTERCOOLE~ KSZ-B 1 281 _
M *Aft* N WHEN REMOVE D Arbeitskarte-Nr .
Work card No .
Tarieto trobaio No .
applicable work sheet . . . . . . . 000.0 8
is
LEGEN D TOOLS REQUIRED Too', No .
1 Frame 5 Cooler casing 9 Water box 1 Trestle . . . . . . . . . . . . . . . . . . . . . . . . . 281,380

2 Gaske t 6 Cooler element 10 Gaske t 1 Holder . . . . . . . . . . . . . . . . . . . . . . . . . . 281 .319
3 Vent screw 7 Cooling water pipes 11 Tube sheet slide rails (only if cooler i s
4 Flow reversing box 8 Drain screw 12 Gasket mounted horizontally)
Cleaning brush
Vat *
1 Hoist (2 tons )
GENERAL
The cooling element must be removed and placed in a clearing vat when it can no longer be cleaned sati3factorily by
solvent spray during operation .
The cleansers a mongst others are recommended :
Designation Supplie r
0
Ameroid ACC-9 Drew Chemical GmbH, 0-2000 Hamburg 1 1
Atlas D.G . Reiniger C .Haacke & SOne, 0-2000 Hambur g
Gamlen Carbon Solvent Gamlen Chemie GmbH,D-2800 Breme n
Motorclean "KI ftet- Chemie, D-3500 Kassel
I
Nalco 161 - AG Deutsche Nalco-Chemie, D-6000 Frankfur t
Norus Degreaser Norus Sales Co ., Stabekk/Norwege n
12 - S - Degreaser Hans Fick & Co ., 0-2000 Hamburg
Vecom B - 85 Vecom GmbH, D-2000 Hambur g
SEQUENCE OF OPERATIONS 1 : Cooler arranged horizontall y

1. Shut off cooling water supply and drain water from cooler .
2. Separate flanged connections of cooling water pipes (7) .
3. Loosen screws in frame (1), screw out screws in tube sheet (11 )
4. Mount slide rails, hold two suitable planks in readiness for su4orting the cooling element on the rails .
5. Extract cooling element cautiously by means of the lifting gear until it has come free of the casing while rest-
ing on the rails, using care not to damage the fins .
6 . Place cooling element into a cleaning vat filled with a cleanser, using the lifting gear .
. t.0.
de 1 p
Arbeitszeit - Slunden Alle Betriebssfunden
Co D36 5610 E
281 .02-2
Working firne - Hours
Durte de travail - Heures
Tiernpo de trabojo - Horas Ak Every
Toutes les
Coda
as necessary Coercting hours
Heures de marche
Horas de servicio
7 . Clean outside of the finned tubes with a brush and cleaning solution or spray-coat surface with an undiluted
cleanser . For this purpose, the same cleanser may be used as is used in the mounted cleaning system,or any of
the cleansers listed above . 0
Note : If heavily fouled or if the dirt on the finned tubes is encrusted, the cooling element must be soaked in
the cleaning fluid for several hours .
Caution! Some of the cleansers are caustic and will attack the skin, if undiluted, and it is therefore recom-
mended that goggles and plastics gloves be worn during cleaning .
Observe suppliers' recommendations !
8 . When using a water-soluble cleanser, flush cooling element thoroughly with water after cleaning, or use an air
hose.
9 . Remove water box .(9)'and flow reversing box (4) and remove deposits in finned tubes with a cleaning brush . For
removing water scale, cf work sheet 000 .08 .
10. Blow out finned tubes with low-pressure air to remove all loose dirt .
SEQUENCE OF OPERATIONS 2 : Cooler arranged verticall y

1. Shut off cooling water supply and drain water from cooler .
2. Loosen flanged connections of cooling water pipes (7) and remove bend .
3. Remove screws in frame (1) on floating end and loosen gasket .
4. Mount holder and trestle on cooler . 0
5. Fasten lifting gear on holder and trestle .
6. Screw out bolts in frame at fixed end .
7. Remove cooling element downwards with the use of the lifting gear .
8. Proceed as described under 6 to 10 of Sequence of Operations 1 .
To install cooling element, reverse procedure outlined above . and check to see that all gaskets are in good condi-
tion .
Floating end
9TR750
7-75 1
0
t
f
Fixed end 1 9
MAINTENANCE OF EXHAUST MANI- KSZ 70/125 A+B 289
0
M-*A~~ N FOL D Arbeliskorte-Nr.
Work card ~,Io
(BBC exhaust turbocharger VTR 631-1+501-~~ Carte travail i~o. 289 .0 1
Tarjeta trobojo No .
applicable work sheet . . . . 000 .19

3 Strut for VTR 501-2 . . . . . . . . . . 289 .373
VTR 631-1 . . . . . . . . . . 289 .372
1 Blind fl ange with seal for
VIR 501-2. . . . . . . . . . 289 .370
VTR 631-1 . . . . . . . . . . 289 .371
LEGEN D
1 Axial compensator
2 Casing
3 Gri d
1 2 3 5 4 3 2 1 4
5
Pipe sectio n
Axial compensator
289 .370 6 Expansion piec e
289 .371 10 BBC turbocharger VTR 631-1
0 or VTR 501-2
MAINTENANCE
1 . When extensive repairs are made on the cylinders ,
check grids before the turbines for fouling and
and damage.
2. Replace expansion pieces (6), if damaged.
3 . When reassembling, coat bolts and nuts with
mos2 -based lubricant .
4 . When replacing bolts, use bolts of tinder-proof
material . Normal bolts and nuts are unsuitable.
Note: The screw plugs used for scaling th e
openings of the ineasuring points after tho
test run are secured with Loctite and can
thus be screwed out, if necessary (cf
work sheet 000.19) .
0
p .t .o .
B36 561 Arbeitszeil - Stunden Alle Betriebssfunden
289.01-1 Working time - Hours
Durkedetravall -11-feurei
Tlempo de trabolo - Horas kk Every Operating hours
Toutes Its 6WO Houre de marche
Cado HorassZ servicio
289 .373
289 .372
0
SEQUENCE OF OPERATIONS 1 : Replacing compensator
1. Remove cover (2) .

2. Attach 3 struts to compensator and secure with lifting device .
3. Remove screw connections in turbocharger and exhaust manifold .
4. Lower compensator with the use of a hoist and put it down, paying attention to the seals .
Note : It is essential that struts be mounted whenever compensators are being installed or removed or transported . 0
Failure to comply with this will result in damage of the compensator .
5. Mount 3 struts on new compensator (if they are not already fitted) and hang it on a hoist, paying attention
to the installation position .
6 . Cautiously insert compensator between exhaust manifold and turbocharger .
Note : The seals on the compensator flanges may be glued on before installation . Use care not to damage them
when inserting the compensator .
7 . Insert all flange bolts, coated with MoS 2-based lubricant, but do not tighten them yet .
8 . Remove the 3 str~ts and tighten all flange bolts .
SEQUENCE OF OPERATIONS 2 : Installing blind flange (emergency operation )
When engine operation must be continued with a defective exhaust gas turbocharger, the defective turbocharger
must be sealed by means of a blind flange . The exhaust gases from all cylinders are then passed through the
operative turbocharger.

0
2 . Bolt 3 struts to compensator and loosen i6r6ed connections of exhaust manifold .
3 . insert blind flange with seal between the two flanges, fasten bolts while loosening the bolts of the struts
on one flange .
Note : Also see work sheet 281 .03 (charge-air pipe) and section 3 (failing exhaust gas turbocharger) and operating
difficulties with exhaust-gas turbocharger in BBC manual .
0
MAINTENANCE OF EXHAUST MANI- KSZ 701125 B . 28 9
1
M*Ak+N FOL D
(m . A . Nwxhaust tdo*rger NA 48,
Aroeifskorte-Nr.
Work cwd No.
0 57 and
Corte tra~ail No.
Tarieto frobalo No . 289 .01
applicable work sheet . . . . . . 000 .19
10 10
I 11 I
I
I
I
i
I FFV
1 2 5 4 3
TOOLS REOUIRE D Tool No .
9 2 Blind flange wit h seal for ~,'A 48 . . .289 .37 6
289 .380 NA 57 . . . 289 .369
289 .376 NA 70 . . . 289 .380
289 .369 3 Struts for NA 48 . . . 289 .377
NA 57 . . . 289 .365
NA 70 . . . 289 .381
1 Set double-head open-end wrenche s
1 Hoist and rop e
LEGEND
1 Axial compensator
2 Casin g
3 Gri d
4 Pipe sectio n
5 Axial compensators
6 Expansion piece
10 Turbocharge r
NA 48 for 5-cylinder engines
NA 57 for 6-8 cyl . engines
0 NA 70 for 9+10 cyl . enjine s
MA I NT
I ENANCE
1 . At extehsive overhauls on cylinders, check grid before turbines for fouling and damage .
2 . Replace expansion piece (6) if damaged .
3 . When assembling, coat all screws and nuts with KoS -based lubricant .
4 . When replacing bolts, use bolts of tinder-proof maierial . Normal bolts and nuts are unsuitable .
Note : The screw plugs in the measuring points were secured with Loctite after the test run and can
therefore be screwed out again if necessary (see work sheet 000 .19) .
P.t. 0 .
D30 5612 E A-oeitszeit - Slunden Alle Eetrieossluncen
Working time - Hours E~ery Ooerchng hours
289 .01-2 ree ce trcwail - Heure ; soutes les Heures de marche
T.emno
Du de 1rcbajo - Horos Coda 12 000 H ros ce ser~ici3
289 .377
289 .365 0
SEQUENCE OF OPERATION'S 1 : Replacing compensato r

2 . -tach
At 3 struts
Lh to compensator
lifting and secure wi device
t .
3 . Remove screw connections in turbocharger and exhaust manifold .
4 . Lower compensator with the use of a hoist and put it down, paying attention to the seals . 0
-Note : It is essential that struts be mounted whenever compensators . are being installed or removed o.r transported.
Failure to comply with this will result in damage of the compensator .
Mount 3 struts on new compensator (if they are not already fitted) and hang it on a hoist, paying a ttention
.
to the installation position .
6 . Cautiously insert COMpensator between exhaust manifold and turbocharger.
--Note :- The seal s on the compensator fl anges May be gl ued on before -in-stall ation . Use care not to damage them
when inserting the compensator .
t 211 flange boll,-s, coateJ with high, temp, . grease (e .g . Molykolepaste HSC), but do not tighten them yet .
7 . Inser6
8 . Remove the 3 struts and tighten all flange bolts .
SEQUENCE OF OPERATIONS ? : Installing blind flange (emergency operation)

r
When engine operation must be continued with a defective exhaust gas turbocharger, the defective turboc~ .arger
.
must be sealed by T.eans of a blind flange . The exhaust gases from all cylinders are then passed through th e
operative turbocharger. 0
2 . Bolt,3 str~uts to compensator and loosen screwed connections of exhaust manifold .
3 . lnse~t blind flange with seal between the two flanges, fasten bolts while loosening the bolts of the struts
on one flange .
Note : Also see work sheet 281 .03 (charge-air pipe) and section 3 (failing exhaust gas turbocharger) an .4 operating
difficulties iith exhaust-gas turbocharger in BBC manual .
D36 5612 E / 289 .01-2

K5Z 302
MAINTENANCE OF
M*AL+ N CYLINDER LUBRICATO R
Aroeitskorie-W .
Work card No. .
Carle .lrovail N 0 302 .01
0 Tor,el ImbaJo No .
LEGEND TOOLS REQUIRE D

10 Telescopic member 19 Lubricator I Set ring spanner s
11 Pump setting shaft 20 Handcran k 1 Set open-end spanners
0 12 Tommy scre w 21 Sight glass with scale 1-Hamme r
13 Linkro d 22 Vent scre w 1 Punc h
14 Rod (drive) 23 Sight glass 1 Socket-screw spanne r
15 Control shaft 24 Delivery tube
16 Drive shaft 25 Supply pipe
17 Drain pipe 26 Markin g I
18 Bracket with pan 27 Adjustable coupling

28 Roller clutch
SEQUENCE OF &ERATIONS I. Maintenanc e
1 . Check oil level at sight glass (21) and oil delivery to the lubricating points at the sight glasses (23) at
regular intervals .
2 . Check telescopic member (10) and tommy screw (12) for free movement, lubricate parts if necessary .
3 . Give grease cup on roller clutch (28) a slight turn once a week and refill with lithium-soap multipurpose grease
as necessary - do not lubricate excessively .
4 . To drain sludge, screw out oil drain screw at bottom of .pump, then replace screw . Unscrew screw plug in pump
cover and fill Pump with Diesel oil . Now drain Diesel oil completely and refill pump with cylinder oil .
0 p.t.0.
Arbeifszei - Stunden Alie 6000 Beiriebsslunden
D36 5610 E
k
Working Ilime - Hours Every Operaling hours
c0
302 .01-2 Durie de travail
Tiernpo de trabojo
-
-
Heures
Horcs
Toules les
Coda
24000 Heures
0 de morche
H ros de servicio
M
S L~
-'~UENICE 0:: OPERATIONS 2 : Removing and reinstalling pumps
i-Jth the fuel control linkage in STOP position and the tommy screw (12) in mid position, note and, if
necessary, mark out position of the two markings (26) with relation to each other, and also scale position
ol" adjusting coupling (27) . 0
2 Remove clamp screw of right-hand coupling half and back off coupling half until claws are disengaged .
(This will not be necessary when all pumps are removed together with the pump setting shaft) .
Z . Remove taper pin from coupling on the other end of the pump and separate link joint connecting the link rod (13)
with the drive lever on the pump .
4 . Separate all line connections .
Note : When releasing or tightening the screwed connections of the delivery tubes, hold hexagonal head at top of
sight glass . Use great care when removing or installing the sight glasses to avoid damage (danger of break-
age!) .
Screw out screws connecting the bracket witn pan (18) with the pump and lift off pump cautiously, paying aiten-
tion to the coupling .
E . Drain oil from pump and, if indicated, wash pump with light-grade fuel to remove oil sludge . Blow out delivery
.
tubes with low-pressure air and c lean non-return valves in clyinder liners (see illustration) . Check to see that
oil supply pipe to each pump is free .
To _install pumps, reverse sequence of operations outlined above, paying particular attention to the following :
i . Match-mark positiorB(26) must be the same for all pumps . Adjust pump and install it accordingly .
NlotE : With fuel control linkage in STOP position and the tommy screw (12) in mid-position, the pump setting
shaft (11) should be rotated through 90 angle in the direction of full load in the case of engines
0
KSZ 70/125 B
KSZ 78/155 B
KSZ 90/160 B
8 . After refilling the pump, vent delivery tubes at cylinder liner fittings by operating the cylinder lubricators
by means of the hand cranks until oil escapes free of air bubbles .
0 After several years of operation, the delivery volume of the individual pump elements should be checked . To
determine delivery volume, set pump setting shaft to max . delivery, arrange for each PumPto discharge into a
separate receptacle and turn hand crank 100 turns. Compare delivered quantity of individual pump elements, using
a measuring glass . If necessary, adjust delivery quantity by means of the set screw (cfwork sheet 302 .02) and
repeat measuremeni .
10 . The lubricating nipples in the link joints should be lubricated with lithium-soap multipurpose grease after
overhauls .
23 0
28
29 30 31 32 33 34 35
Lubricating fitting in cylinder line r
LEGEND
23 Sight glass 32 Plate spring
28 Ball 33 Rin g
29 Delivery tube 34 Screw-in piece
Sight glass on cylinder lubricator
30 Pipe section 35 Valv e
31 Hexagonal nut
0
Manufacturer of cylinder lubricator (Zentralbler Typ K) : Fa. Apparatebau Roesen & Co ., KG,
D-2800 Bremen 11, LegienstraBe 8
CHECKING DELIVERY VOLUME KSZ 30 2
M *AftL+ M OF CYLINDER LUBRICATO R Arboilskarlo-Nr.
Work card No . 302 .02
Carlo travail No .
0 applicable work sheet . . . . . . . . . 302 .0 1
TOOLS REQUIRED
Stop-watch
Note pa d
LEGEND
20 Control crankshaft
21 Delivery crankshaft
51 Control plunge r
52 Delivery plunger
51 53 Control leve r
20 61 Set screw-
62 Curve yoke
63 Setting pi n
S2
65 Pump-setting shaft
71 Load shaf t
72 Gearwheel for load shaf t
73 Gearwheel for pump-setting shaf t
0
GENERAL
The delivery quantity of each pump element is determined by the position of the control lever (53) limiting
the stroke of the delivery plunger (52) . The operating position of the control lever is dependent upon the
position of the set screw (61) in conjunction with the curve yoke (62) and upon the position of the setting pin
(63) and upon the position of the load shaft (71) (see incircled drawing) . The delivery quantity can thus be
set by the set screw for each,pump separately, and by the load shaft for all pump 'elements in common .
The sight glass with scale mounted in the pump cover serves two purposes, checking the oil . level and the oil
consumption . The distance from the graduation line at the top to the graduation line at the bottom of the scale
is in accordance with an oil volume of 0 .25 liter .
SEQUENCE OF OPERATIONS 1 : Checking delivery volume
1 . Check that all pumps are filled with oil .
2 . Check at sight glass of each pump whether pump elements are delivering (ball lifted up) .
9 3 . Check engine speed (run at rated speed if possible) and do not change-speed during measurement .
Note : During measurements the engine should, if possible, be run at rat , ad maximum load .
4 . Close stop-cock in oil supply line and open venting --screw (26 resp . 22 ; cf work sheet 302 .01) .
5 . Start stop-watch as soon as the oil level has dropped to the top graduation line .
6 . Stop stop-watch when oil level has dropped to the bottom graduation line on the scale .
Note : Consumption measurements will be less accurate if it is based on a smaller oil volume .
7 . After measuring, immediately open siop cock in oil supply line, close venting screw only after all air has
been expelled and oil is escaping free of air bubbles .
EXAMPLE OF CALCULATION engine KSZ . . . . . .
engine output 2450 kW 5330. . * bhp)
engine spee d 122 rpm
oil consumption read off 3
scal e 250 cm
measuring piriod 336 s
3
spec . weight of luboi . 0.9 g1c m
consumption per hou r oil consumption x 3600 s
measuring perio d
250 x 3600 " 2722 cm3/h - 2 .722 1/h p. L 0.
33 6
0 D36 5610 E i Alto Betriebsslunden
Arbeitszeit -Stunden
k Operating hours
302 .02-1 Working time - Hours Every
Durde da travoil - Heurot
Tiempo de trobeic, - Horas
Toules les
Coda
as necessary Houres de marche
Horas do servicio
late- The specific oil consumption can be calculated by multiplying oil consumption by the specific weight
and dividing it by the rated output of the cylinder, notwithstanding the fact that the exact output may
not have been developed during the measuring period .
total consumption per hour x specific weiqht of oil
Specific consumption -
cylinder outpu t
3 3
2722 cm A . 0 .9 q/cm . 1 g/kW h
2450 kW
- (0.73 g/bhp )
Oil consumption of every cylinder is determined by this method . For guide value of cylinder oil consumption
at full load see section 1 .
SEQUENCE OF OPERATIONS 2 : Adjusting delivery volum e

1 . Cylinder lubricators are set to maximum delivery volume when engine is being delivered (break-in) . Oil
consumption should be gradually reduced to normal value within the first 500 operating hours . To reduce
delivery volume, turn tommy screw (1cf worksheet no . 302.0l') back to the marked normal position . Further
reduction is to be made at the set screws (61) of the individual pump elements and it is to be insured that
all set screws are turned back by the same amount.
Changes in the delivery volume that may become necessary under extraordinary circumstances are to be made
at the tommy screw (cf work sheet no . 302.01) for all pumps in common . This holds in particular after re-
placement of pistons, piston rings and cylinder liners . (cf section 3 for running the engine in or for running
in replacement parts) . Changes in the pump setting and the setting of the tommy screw and the reason fo r
the change should be entered in the Engine Log .
2 . If the delivery volume of individual pumps or pump elements must be readjusted, e.g . to equalize differences
in delivery volume, such adjustment is lo be made at the set screws (61) - see illustration on face page .
Note : Maximum quantitiy of oil delivered by each pump element is with the set screw completely screwed in,
i .e . at maximum delivery position at maximum load .
Backing off the set screw reduces the delivery volume .
lf~tfie delivery volume of all pump elements in a pump differ by the same quantity from the delivery volume of
the pump elements of the other pumps, check position of adjustable coupling (16) and correct it, if necessary
Note : The manufacturer's test sheet on the Pump setting,which is supplied with each lubricator, is enclosed
with the engine's Acceptance Records .
D36 5610 E / 302 .02-1

I
MAINTENANCE OF KSZ 70/125_B r30-3

Wid *A&+ CROSSHEAD LUBRICATOR
Aroei!skcrte-Nr.
Worl co-6
0 Tcr!e :c trcbcio No.

303 .01
appHcF'111e worn sheel. . . . . . . . . . 03C .'U6
11
12
13
14
15
16
0
17
LEGEN D TOOLS REQUIRED
1 Collar boli 11 Straine r 1 Set open-end spanners (single-end)

2 Lockwashe r 12 Centering ring 1 Set double-ended open-end spanners
3 Spring-loaded pin 13 Casin g 1 Pressure gaug e
4 Drive ro d 14 Pi r.
5 Screw plug 15 Link plate Note : The lubricator needs no servicing as its %oving part s
C Cove r 16 Threaded bolt are lubricaied by the oil it sipplies . Whien mounting
7 Valve casing 17 Pi n a new pump, check to see that defined clearance (8) .
8 Valv e 18 Leve r between top edge of plunger and vaive casing with the
9 P,. :rp c2rrel 19 Delivery pipe plunger in top center position, is attained . This car
to Pump plurger 20 Blind flang e be checked at the lower end of the plunger,th e
trol edge of which will be flush wiih ihe lower end
to SEQUENCE OF OPERATIONS : Maintenance and Inspectio n of the pump barrel when the running gear is in TDO
position .
1 . Performance of the crosshead lubricators should b e
checked at the same time the crosshead bearings
are checked (cf work sheet-030.06) .
2 . The strainer (11) is removed and the oil supply hole closed by a blind flange (20) wherengine is being com-
missioned .
3 . Check play in link-joints .
4 . After overhauls, check to see that delivery pipes to the bearings are absolutely tight and all screw-conne :tion s
secured .
Note : Remove and clean lubricators at overhauls, when connecting rod is removed or if pump (valve) is defective .
Also check good condition of non-return valves . Check opening pressure 1 .19 bar(-kp/CT,2) with pressure
gauge after removing the screw plug (5) .
0 p .t .o .
D36 5612 E
3)03 .01-2
Arbeitszeit
Working finne
- Stunden
- Hours
Alie
E~ery 24000 Beiriebsstuncen
Ooerating hours
Dureedetrcivail -Heures Touies le s Heures de morche
cr, TiernDo de irobajo - Horos kk 1 Ccdo 3000 Horcs de servicio
I- , e as uri n g NoIr, -I r, a , New Limi t
point dimensior
0
3. 5
1
5 2 .5 +
- 0. 5
28 .7
D H 7*
26
E - 0 .010-0.020
F 26*
G 30 E 8
h - 0.012-0 .053 0 .1 0
30 n6 -
25 E8 -
L - 0 .025-0 .071 0 .1 0
M 25 H -
36403460
* the two parts are lapped to mate
0
ADJUSTING EXHAUST TEMPERATURE M.A .N .-DIESE L 40 9
M *Atk+ M MEASURING PLANT Arbeitskarte .Nr.
Work card No.
0 Corte travoi No . 409 .01
Torieta trob .io
I No .
TOOLS REQUIRED
1 Socket head spanner 10 mm

1 Socket head spanner 6 mm
1 Master thermomete r
LEGEN D
1 Zero correction screw
2 Cable harnes s
3 Balancing resistance (R 1)
4 Selector switc h
Note l: The measuring plant-is a product of Fa .
Hartmann & Braun, D-6000 Frankfurt 90, Post-
fach 90 05 07 .
The instrument is adjusted to an ambient air
0 temperature of 20 0 C, influence of temperature
t 0 .5 % / 100C . Protection type P 43 .
The temperature measuring plant supplied with a new

engine has already been adjusted and the individual
measuring points have been balanced . The zero point
setting .need not be corrected 'Unless the engine room
temperature does not agree with the set temperature .
The indicating instrument must then be readjusted .
1 . Disconnect two leads of a connected measuring point, paying
attention to the poles .
2 . Short-circuit ( + ) and minus terminals leading to the
indicating instrument and set selector switch to the respective
measuring point .
3 . Measure temperature at the disconnected leads to the measuring
point, using a thermometer and set scale pointer to the
measured temperature by turning the zero correction screw
0 accordingly .
Aote . If, for example, the temperature measured at the
connecting point is 35 0 C, set pointer so that it register
with the same temperature on the scale . When it is
intended to check the correctness of the instrument
readings, the engine should be at service temperature .
4 . Reconnect both leads to thermocouple (measuring point) paying
attention to the poles (plus lead is marked in red) .
LoLe .- No instrument readings will be obtained when the leads
are not correctly connected (see connection diagram) .
p. t. 0.
D36 5610 E Arbeitszeit -Stunden All* Betriebsstunden
A 409.01-1 Dur&e do travail - Houros 4 Every
Toutes les 5000 Operating hours
Heures do march*
Tiempo de trabajo - Horas Coda Horas do servicio
5 . Check readings of all measuring points when the plant is
--(D in operation . if no readings are obtained from one 0
measuring point, check whether thermocouple is correctly
connected and, if necessary, replace thermocouple .
Note : When replacing thermocouple, be sure it carries the
same type desgination .
6 . The measuring point label in the indicating instrument

can'be replaced (see illustration) .
: ---0
1.WÜ41w21a ,U",l"
L.- . - - --LI=--:,
I . . .24
0
WATER TRAP WITH FLOAT SWITCH 44 2
KSZ
IN PISTON COOLING SYSTEM
M +Atk* M Type UNA 23, NW 40 - AO 8
Arbeitskari* .Nr .
Work card No .
Carte travail No.
0 Tarjeta trabojo No . 442 .01
applicable work sheet . . . . . . . . . . . . . 035-01
TOOLS REQUIRED
1 Set hexagonal socket screw spanners
1 Socket screw spanner, 7 :m m
C;73
0
.
horizontal desig n vertical design
Content of wear kit
1 Regulating unit, complete with Simplex control,

closing unit AO 8 and seal for sea t
1 Casing gaske t
LEGEND
I Stud 21 Cooling water djscharge
2 Seal 22 Water return pip e
'91.
3 Baffle 23 Check-valv e
4 Seat 24 Three-way valve with check-
5 Casing funne l
6 Seal 25 Water trap w1float valve
7 Type plat e 26 Stop coc k
8 Regulating unit 27 Supply pipe
9 Hoo d 28 Venting piPe
0 10 Pin 29 Stop coc k
11 Bal l 30 Air supply pip e
12 Screw plug 'i:
OPERATION
The water trap has the purpose of separating the
water contained in the air supplied by the air pump,
and draining it into the discharge pipe of the surge
tank. The water contained in the air supply pipe (30 )
36 40 281 is drained through the pipe (27) into the water trap
(25) where it is allowed .to accumulate . As the water
level rises, the float of the regulating unit (8) rises with it until the ball valve uncover .- a discharge opening,
allowing the water to flow through pipe (22) via the three-way valve (24) and the check valve (23) into the cooling
water pipe (21) . The air collecting in the caiing (5) is passed through pipe (28) of air supply pipe (30) to the
piston cooling system . The float switch, dropping with the water level, closes the ball valve .
CHECKING
Proper functioning of the water trap w1float switch can be checked by opening the three-way valve (24), in which
case the disdharge of the water of condensation can be observed . This check should be made at regular intervals ; at
shorter intervals when the engine is still new . It can be made while the engine is in operation .
0
Arbeitsz*it Stunden All e p .t .o .
Beiriabsslunden
035 5610 E
442 .01-1
Working li Hours
Durile do travail Houres
Tiompo do trabojo - Horas
-
kk Evory
Toutes los
Cada
as necessary
Operating hours
Houres do march@
Horas do servicio
Heavy hammering,in the piston cooling system may be caused by a defective float switch of water trap .
0
Ball valve does not open : Water trap, supply pipe and air supply pipe are being filled with water .
Ball valve does not close : Part of the air supplied by the compressor into the air supply pipe flows into the
cooling water discharge pipe (air pad pressure in surge tank too low) .
SEQUENCE OF OPERATIONS 1 : Checking for acculation of sludge (only after shutting off the air pump and switching
I over to air supply from ship's mains .
1. Close three-way valve (24) and stop cocks (26 and 29) .
2. Screw out screw plug (12) and check if sludge has accumulated on bottom of water trap hood (9) .
3. If sludge has deposited on the bottom, remove and clean hood (9) .
4. Before reassembling, check proper functioning of regulating unit (8) .
SEQUENCE OF OPERATION'S 2 : Replacing regulating uni t
Warnina! Before removing the water trap with the engine running or during emergency operation with air for piston
cooling supplied from the ship's air mains, be sure to close stop cocks (26 and 29) (,danger of injury!) .
1. Close stop cocks (26 and 29) and release pressure in water trap .
2. Unscrew nuts from studs (1) and remove hood (9), paying attention to seal (6) .
3. Unscrew two cheese-headed bolts and replace complete regulating unit (8) .
4. When replacing closing unit, remove seat (4) and ball (11) .
Assembly is the reverse of disassembly . After reassembled water trap w/float switch has been put back in operation
retighten flange nuts and check for proper functioning by opening the three-way valve.
114
.D36 5610E/442-01-1
GRUNDWERKZM M.A. N . -DIESEL 1 1490
0 *A&* STANDARD TOOLS
Arbeiiskarle-W.
Work card No.
Carte Irwad He
Ta,jeta trabno No.
. 490.01
gild Benennung Abmabe
Norm Werkzeug-fir .
figure Designation Dimensions Standard Tool No .
A 1 8 1
0
1 Satz .Grun dwerkzeug komplett 000 .002
I Set stand ard tools complete DOO .002
bestehend a us :
consisting of :
QoppelringschlUssel, gerade 24 27 DIN E37 000 .2.2 5

Double ended flat ring 30 32 000 .22 6
spanne r
Dop~pelringschlgssel, gekrapft 13 - 17 DIN 838 000-24 3

Double ended offset, ring 19 22 000 .244
A
spanner 24 27 000 .24 7
30 32 OD0 .24 8
0
A Sechskantschraubendreher 3 - DIN 911 000 .29 2

Hexagon socket head spanner 3L - 000-30 7
4 - 000 .293
Ea== 5 - 000 .294
6 - 000 .295
8 - 000-29 7
10 - 000 .298
12 - 000 .29 9
14 - 000-300
17 - .000-301
19 - 000 .302
A Schraubendreher 5;5 - DIN526504,84,5 000-39 1
Screw driver 9 - BIN52650 .1,2x9 000-39 3
12 - DIN52650_2M OW-395
Drehstift 5 - DIN900-A5 000-507

A Tocmy bar 8 - DIN900-AB 000 .262
10 - DIN900-Alo 000 .26 3
0
12 - DIN900-A12 .000 .26 4
16 - DIN900-A16 000 .26 6
ElmaulsehlOssal 12 - DIN 894 000-557

Single open-end spanner 46 - D00 .56 8
A\:O 50 - 000 .56 9
55 - 000-570
6D - 000-571
65 - DOO-572
DoPpelmaulschlUssel 7 9 DIN 895 000 .601

Double open-end spanner 8 10 000 .602
11 14 ooo .603
13 17 000 .604
19 22 000-605
24 27' 000 .606
3D 32 oooA7
36 41 000 .6D8
036 5600 D+ E
[~90 al -1 slehe RUckseit e - PTO
Bild Benennung AbmaBe Nom Werkzeug-Nr .
Figure Designation Dimension s Standard Tool No .
A A 8
Hebelsen S 550-A15 .001-391 0

Pryba r
fOhlerlehre DIN22750-0,05-1 000 .451

feeler gauge
Knarre 12,5 - 01N 3122 C 001-521

Ratche t
SteckschlUsseleinsatz 11 12,5 DIN 3124 D01-751

Spanner socket 13 12,5 001-752
14
17
12,5
12,5
001-75 3
001-75 4
to
19 12,5 001-755
22 12,5 001-75 6
24 12,5 001-75 7
27 12,5 001-75 8
30 12,5 001-75 9
32 12,5 001-76 0
36 20 001-77 1
41 20 001-772
Kardangelenk 12,5 80 DIN 3123 C 001-87 6

J Universal joint
~ A -E&O- 8111
Ouergriff
lee handl e
12,5 320 DIN 3122 A 001 .89 1 40
Ubergangsteil 20 12,5 DIN 3123 A 001-92 3

External/internal square 12,5 20 001-92 7
drive adapto r
'kf
Verl3ngerung 12,5 125 DIN 3123 8 001 .911

A Extension 12,5 250 D01 .912
0
036 56oo D+E / 490 .01-1
GRUNDWERKZEL* M.A.N. -DIESEL 1 49 0
Arbeilskorfe-Nr .
0 STANDARD TOOLS Work card No.

Carle fro if No. .
Toricto trvcobneo No 490 .02
I
AbmaBe
Bild BenennuM Dimensions Rom Werkzeug4r.
rigure Designation I I R I Standard Tool No .
0
I
Zange for innenspannende io - 25 DIN 5254 A 002 .12 1
Sicherungsringe (Wellen) 19 - 60 002 .12 2
Pliers for contractin g
lockrings (shafts )
Zange for aueenspannende Si- 19 - 60 f DIN 5256 C 002 .16 2

cherungsringe (Bohrungen) 40- 100 002 .16 3
Pliers for expanding
lockrings (holes )
ft Werkzeugkasten mit Inhalt V 555-530

Tool box with tools 25 k g
D36 5600 D+E

490 .02-1
0
0
KSZ-B 49 0
ZUSATZWERKZEUG KSZ-C
M *AtIL* N ADDITIONAL TOOLS Arbeftskarte-W.
Work card No.
Carte travail No.
Tarleta trabolo No .
490.05
Bild Benennung AbmaBe Gewicht kg Werkzeug-Nr .
Figure Designatio n Dimensio n Tool No .
Weight k g
AI B
bsenschraube R12 160 0,26 (2x) 000 .031
Eye bol t M16 160 0,41 (2x) 000 .034
M20x2 250 0,83 (2x) 000 .037
M24x2 250 1,34 (2x) 000 .040
Stecker 10 0,01 000 .086

F] u g 13 0,02 ~000 .087
22 0,07 000 .089
27 0913 000 .090
32 0,21 000 .091
36 0,28 000 .092
Ringschraube Mio 0,11 (2 0 000 .141
Eyebol t m12 0,18 (20 000 .142
0
m16 0,28 (20 000 .143
M20x2 0,45 (2x) 000 .144
M2Ü2 0,74 (20 000 .145
M30x2, 1,66 (20 000 .14 G
Doppelringschlassel, gerade 36 41 0,6 3 "oQ0 .22 7
A N Double ended flat ring
spanne r
DoppalringschlOssel,- offen 14 17 0,11 000 .231
Double ended open ring 17 19 0,14 000 .23 2
spanne r
Drehstift 14 0,40 000 .265
Tommy ba r 18 1,00 000 , 267
20 1,50 000 .268
4K :a= Krouzschlitzschraubendreher
Philips screw driver
GrbBe 1+2
Size 1+2
000 .401
000.402
IA Fahlbleche (1 Satz 0,1-0,3)

Feeler gouge Oset 0 .1-0-3 )
13 1000 0,1 8 000-45 3
0 -T
EinmaulschlOssal 70 2,20 000.573
:D 000.574
Single ended open jaw spanner 75 2,60
80 3,10 000.575
85 3,60 000.576
SchlagringschlOssel 55 000.786
1,50
Ring spanner 60 1,80 000.732
65 2,20 000.733
70 000.734
3120
75 000.735
3,20
80 4,00 000 .736
85 000.737
4,00
90 000.738
5,50
95 000.739
6,50
105 000.741
8,00
115 000.743
D36 5610 M siehe RUckse Ite

c3 %
cl; P .t .o .
Co~
490-05-2
Bil d Benennun g AbmaB e Gewicht k g Werkzeug-Nr .
Figure Designation Dimension s Weight kg Tool No .
A B
Stocker 41 16 0,56 001-351 . 0

Plug 41 20 0,5 8 001 .352
60 22 1,20 001 .353
A 60 25 1 , 20 001 .35 4
Usenschraube A 200 0,02 (2x) 001 .40 4

, Eyebol t M5 250 0,04 (20 001 .406 1
I ~ Fb 125 0,04 (20 001-40 7
::`~
re 140 0,07 Ox) 001-409
MIO 300 0 23 (20 001 .41 2
SteckschlUsseleinsatz 46 iff 11 00 001 .80 2
Spanner socket 50 1" 1112 001-80 3
AD
.D 55 1" 1,42 001 .804
60 1" 1,68 001-80 5
65 1" 2,20 001 .806
70 1" 2,63 001-80 7
75 1" 3,22 001 .80 8
80 ill 3,90 001 .80 9
Verlgngerung 12,5 250 o,4o 001 .91 2

A Elongation 25 400 2,30 001 .916
Zange f6r auBenspannande 19 - 60 f 0,17 002 18 2 1

Sicherungsringe 40 -100 0,29 002 :18 3
41 Pliers for expanding lock -
ring s
Mykotepate 1,00
G-fi (I Dose )
Mykote past e
G-n (1 tin )
40
D36 5610 D+E/490-05-2
ZUSATZWERKZEUG KSZ-B 49 0
ArWitskarte-W .
0 ADDITIONAL TOOLS Work
C 0rcard0~~jo.
o
art oy 1
Taristatrabojo No.
490 .06
We
Bild Benennung Dimensions Norm Werkzeug-Nr .
Figure Designation A18 Standard Tool No.
Drehmomentschlussel 20 - 100 Nm 008 .002
Torque wrench (2 - 10 mkp)
i 80 - 300 Nm 008-003
(8 - 30 mkp )
280 - 760 Nm 008 .00 4
(28 - 76 mkp :
750-2000 Nm 008-005
(75-200 mkp )
Kraftstoff-Handpumpe 008-032
(Bosch-FrOfeinrichtung )
Sonderwerkzeu g
fuel hand pum p
(Bosch testing device )
0 Special devic e
0 D36 5610 D ; E
490 .06-Z
9
0
WERKZEUG FOR WOODWARD-REGLER M.A .N .-DIESE L 490
M *Atk* M TOOLS FOR WOODWARD GOVERNO R
Arbeftskorte-W.
Col.'e'rovol,
Work card No. No
0 . - 490 .10
Tcuiefu Irobalo No.
0 140-113 140.112 140.111
140-123
14o .ii4 140 .12 4
140 .115 140 .119

14o,% 140 .120
140 .117 140 .121
0 140 .11 8 140,12 7
Schlosselwelte Werkzeug.-Nr .
Benennung Designation Size Tool No .
Werkzeugsatz Woodward-Regler Set of tools for Woodward governor - 140 .110

komplett complete
Winkelschraubendreher Hexagon socket screw key 1/16" 140 .111
5/6411 .140 .112
3/V 140-113
1/8 140 .114
5N" 140-115
3/16" 14o .116
02" 140-117
0 1/4 " 140 .11 8
Doppelmaulschlussel Double open-end spanner 1/4"x5/16" 140 .119
5/i6nxii/~2ff 140 .120
3/8"x7/16" 140 .121
7/16"xi/2" 140 .122 I
1/2"x9/16 .140 .123
15/16ffxlff i4o .iA
Hin~ULs Diese Werkzeuge sind nur für Arbeiten a m

Woodward-Regler zu verwenden und nicht bei
metrischen Schrauben l
Note These tools should only be used for work

on the Woodward governor, they must not
be used-on metric screws l
T-
cc D36 5600 off
4 49o.v-i
0
0
MOTORWERKZEUG KSZ 70/125 B 49 0
MaBe und Gewichte I -
0 M*A&*M ENGINE TOOLS
Dimensions and Weights
Arbeitskarte-Nr.
Work card No.
Tarjeta trabolo No.
Bild Benennung Werkzeug4r .

Figure Designation Tool No .
Hochdruck-Mandpumpe 009 .410

UN
C-
'r. High-pressure hand pump
Gewicht 11,5 kg
--820 Weight
36 40 523/6
Hbhe-350 Pneumatische Hochdruckpampe, transportabel 009-302

Pneumatic high-pressure pump, transportabl e
3640755
A Gewicht 30 k g
'~WiI e'
Weigh t
0 -550
1
175
Spannmutter 009-36 4
Tension nut
C3
- I ~0 Gewicht 7,5 k g
I Weigh t
3A 40 523/2
150 Hulse 010-353
1 Sleeve
I Gewicht 4,5 k g
Lr% Weight
1 36 407523/2
Hulse 2 X 013-390
Sleeve 2 pieces
0
I I Gewicht 19 k g
Weight
275
AuMngevorrichtung fur Stopfbuchsenringe 015-374

Holder for stuffing box rings
V- Gewicht 13 k g
Weight
3
36 40 523/ 3
D36 5612 D+ E
slehe RUckseite
10p;
490 .21-2
p .t .o .
I
Bil d Benennun g Werkzeug-Nr .
M Tragkreuz zum Ein- und Ausbau des Zwischen- 015 .37 3 0

bodengeh9uses
Lifting cross for installing and removin g
CD diaphragm casin g
Gewicht 25 k 9
Weigh t
590
36 40 523/3
KlemmstUck zum Ein- und Ausbau der Kolben- 015 .377

stangenstopfbuchs e
4
L Clamp for installing and removing pisto n
F- rod stuffing bo x
- 0 340 Gewicht 20 kg
36 40 523/1 Weigh t
Handfiebelpresse 009 .41 5

Hand lever press
0
410
36 40 523/4
ftchstdruckschlouch 009 .415-1
High-pressure pip e
-~-= - - - ;Sa EinschraubstUck mit Dichtung R 3/8"

Threaded piece with joint M 14 M-39 8
.
Breite 341
I II Width StUtzblcch und PeOvorrichtung for Kurbel- 021 .400
.
wellen- und Drucklage r
+ + Bridge and measuring tool for main an d
thrust bearings
Gewicht 11 k g
Weigh t
713 40
36 40 523/ 3
140
H91se 2 x 021 .404
Sleeve 2 piece s
I
I Gewicht/StUck 4,5 k g
Weight each
"0 F
- -D-- j
36 40 523/ 6
Hdhe 250
Height Aufhtngevorrichtung zum Ein- und Ausbau 030 .42 3
der Treibstange
Lifting tool for installing and removin g
connecting ro d
a Gewicht
Weigh t
35 k g 0
298
MOTORWERKZEU G 490
M a Be un d G ew i c hte KSZ 70/125 B 1
0 ENGINE TOOLS Arbeitskorte-W.
Dimensions wid Weights

Work card No . ..
Corte trovoil N 490 . 22
Tor)efa trobojo No.
Bild Benennung Werkzeug-Nr .

170 Platte 021 .420

Plat e
-I Lgnqe 340
GeWicht 30 kg
Cni Length Weight
I
36 40 523/2
Platte 021 .42 1
Plat e
UN 1 Unge 300
%0
Length Gewicht 20 k g
Weigh t
130
275 HUlse 2 x 030 .433
0 Sleeve 2 pieces
Gewicht 30 kg
Weigh t
Ln
36 40 523/1
160 HUlse 2 x 030 .43 4
Sleeve 2 piece s
I
Gewicht 4,5 k g
Weight
CY,
I 5b 40 ~23/1
351 Laufgitter 100,43 9
Grill
1, Lunge 710
i- Gewicht 18 k g
0 Length We! ght
C)
36 40 523/2
Breite 240
1 Width Halter 030 .440
C;
00 Holde r
T Gewicht 15 k g
Weigh t
470
36 40 5231 l
I Anh2ngebUgel fUr Kreuzkopf 031-36 4
412
Holding tool for crosshea d
Breite 90
Width / Gewi cht 20 k g
Weight
36 40 523/3
D36 5612 D+ E
490 .22-2 slehe Rackselt e
p . t .o .
Bil d Benennung Werkzeug-Nr.
430
Spannvorrichtung fur Kolbenringe 040 .421 0
Ring expander for piston ring s
/! Gewicht 2,5 k g
Weight
36 40 523/4
CO AnhUngelasche fUr KolbenstangenfuS 040 .422

Lifting flange for piston rod foo t
-#I- Gewicht 25 k g
Weigh t
320 -6 4
3 3 6 4 523/4
Kolbeneinfohrung 040-43 8
Taper ring for installing pisto n
,1- 0 844 1 0
Gewicht 20 kg
36 40 523/4 Weigh t
Kolbenaufhlngevorrichtung fUr Kolbenkrone 040.44 6

Piston lifting tool for piston crown
t K4
-= . Gewicht 180 k g
6961 Weigh t
97 2
96
Hulse o4o .447

C- Sleeve
'C96 ~ I
Gewicht 1,1 k g
-A
Weight
104
Hulse 040 .449 0

Sleev e
CO Gewicht 1,3 k g
Weigh t
36 40 523/2
Abstellbock 040-452
Support
I I Gewicht 50 k g
Weight
790
.36 40 523/1
MOTORWERKZEUG
MaBe und Gewichte KSZ 70/125 B 49 0
0
04*Ak* N ENGINE TOOLS
Dimensions and Weights
Arbeitskarte-W.
Work card No .
Tarjeta trabojo No .
Bild Benennung Werkzeug-Nr .

Figure Designatio n Tool No .
Leuchtkarper 050.373
Tubolar lam p
Gewicht 3 kg
Weight
Breite 140 TrIger zum Ausbau der Zylinderbuchse 050-434

Lifting tool for removing cylinder liner
Gewicht 120 kg
Weigh t
36 40 523/5
Abdeckvorrichtung zum VerschlieBen der 050-436
Spul- und Auspuffschlitze be! ausgebautem
Kolben
0 Blanking device for closing scavenge and
exhaust ports when piston remove d
Gewicht 80 kg
Weigh t
VerschluBdeckel 050 .452

9- -
US
Cove r
U -A Gewicht 10 kg
Weigh t
Schlelfring mit Verschalung zum Einschlel- 050-441

fen von Zylinderbuchse und Deckel (Sonder-I I
6
werkzeug )
Grinding-in ring and cover for grinding-in
of cylinder liner and cylinder cover
(~pecial device )
is Gewicht 183 kg
Weigh t
Tr5ger 050-447
Travers e
Gewicht 60 kg
Weigh t
Halse 3 x 050 .447- 1

Sleeve 3 pieces
Gewicht/StUck 15 kg
643
Weight each
36 40 523[~
Steckschlossel 040-450
Socket spanner
Gewicht 6 kg
Weight
D36 5612 D+E

490 .23-2 sieh e RUckseite
P .t .o .
Bil d Benennun g Werkzeug-Nr .
FUhrungsblech 040 .451 0

Guide ti n
Breite 8
W% I Width Gewicht 6,5 k g
Wei gh t
V
cb 36 40 523P
523/1
Tragkranz der hydraulischen Spannvorrich- 055-381
I tung far Zylinderkop f
Suspension ring for hydraulic tensionin g
tool for cylinder head bolt s
Gewicht 550 k g
Weigh t
0
118B Zylinderkopfabloge 055-388
Cylinder head support
Gewicht 62 k g
Weigh t
1011
36 40 523/6 '
865 PrUfvorrichtung Atlantic-Diesel, zur 057-36 2
festen Installation in der Bordwerkstatt
(Sonderwerkzeug) I
Testing device, make Atlantic-Diesel, for I-
permanent installation in workshop o n
board (special device )
t x
Gewicht 60 k g
Weigh t
P
0
550
36 40 523/5
Vorrichtung zum Ausbau des Zwischenrades 100-361
i
am Steuerungsantrie b
Device for intermediate gear of camshaf t
driv e
Gewicht 50 kg
-a-750 - 16 40 523A Weigh t
V I I Ein- und Ausbauvorrichtung for Einspritz- 200-378
pumpenfede r
Installing and removing device for inject -
Brelte 235 ion pump spring
Width Gewicht 23 k g
I - - C) Weigh t
0
36 40 52'3/11 430
MOTORWERKZEUG 49 n.
MaBe und Gewichte KSZ- B 1
Arbeifskart~Nr.
0 ENGINE TOOLS Work card No.
Dimensions and Weights Carle travail No. 490 . 24
Tariela trobajo No .
MoSe Benennung Werkzeug-Nr .

Dimensions Designation Tool No .
170 Anfraswerkzeug fUr Einspritzleltungen 434-001

Milling tool for injection pipe s
Gewicht 2 kg i
Weigh t
CD
CO
110
Anfr2swerkzeug for Einspritzpumpen 434-00 3

(Sonderwerkzeug )
Milling tool for injection pump
(special tool )
M1 I C)
JL~- (D Gewicht 1,5 k g
Weight
110
Anfrgsverkzeug for linspritzventil 434-353

Milling tool for Injecto r
Gewicht 1 kg
I
C N, ni 1 4 Weigh t
D36 5610 04 E
si
(71 490 .24-1 .
0
0
d)
0.
HOCHDR . UCK-HANDPUMPE M.A.N .-DIESEL 1 490

-
0 M#Ak*M HIGH-PRESSURE HAND PUMP Arbeit karfe-Nr.
Work scard
' No .
Carte travail No.
Tariela IrabajoNo 490 .30
&L, 49 162 17 2 .16 S 10 3 25 12 2 9
so
55
54
46
-30
52 1 - - 131
53 13 2
47 64
45, 34
48- =
43 -
14 8 21 26 9 1 14 26 11 7 fit 6 3
0 S1
216 6 13
40~ 1 11 ti -
19 33 22 23 15 26 20 61
Stckz . Werkzeug-Nr .
Benennung Designation
Pieces Tool No .
(1) Handpumpe komplett bestehend aus : Hand pump, complete consists of : 009 .41 0
1 PumpenkUrper Pump casing 009 .410-1

1 Pumpenkolben Plunger 009 .410-2
1 Anschlaggabel Stop fork 009 .410-3
1 Fuhrungsbuchse Guide bush 009 .410-4
1 Hebel Lever 009 .410-5
2 Anschlagwinkel Stop angle oog .4lo-6
1 Ventilsitz Valve seat 009 .410-7
1 Ventilhalse Valve sleeve 009 .410-8
1 Dichtkegel Sealing cone 009 .410-9
1 Stift Stud oog .4lo-l o
1 FuOplatte Plate 009 .410~11
1 Pumpenhebel Pump levir 009 .410-1 2
2 Gleitstein Slide block 009-410-1 3
I Druckfeder Pressure spring 009 .410-14 x
1 . Dichtung Gasket 009 .410-15 x
0 I Zylinderstift 1Om6x3Z Cylindrical pin 1Om6x32 009 .410-16
o
-.r-
C siehe Ruckselt e
C5 D36 5610 D+E
~rl
L~90-30-2 I I p.t.o.
Pieces Tool No .
1 Zylinderstift 10m6x40 Cylindrical pin 10m6x4o 009-410-1 7

1 Schraube R 114ff Screw R 1/4ff 009 .410-1 8
1 Wellendichtring A7x16x7 Shaft seal ring A7xl6x7 009 .410-19 x
4 Sechskantschraube M 6x16 Hexagon screw M 6x16 009 .410-20
4 Senkschraube M 606 Countersunk screw M 606 009 .410-21
2 Zylinderschraube M 6x16 Cylindrical screw M 6x16 009 .410-22
4 PaBkerbstift 542 Adjusting notched pin 502 009 .410-Z3
2 Spannhulse 3x8 Clamping sleeve 3x8 009 .410-24
1 Spannhalse 8x32 Clamping sleeve 8x32 009 .410-25
2 Kugel 5,5 mm I Ball 5,5 mm 1 009 .410-26 x
4 rederring B 6 Spring ring B 6 009 .410-28

1 HEBIE-Griff 22 mm HEBIE-handle 22 mm 009.410-29
1 Abstrelfer Scraper 009 .410-30 x
1 Back-Ring Back-ring 009-410-31 x
1 Manschette Cuff 009 .410-32 x
1 Abla8schraube Drain plug 009-410-33
1 Ansaugfilter Intake filter 009 .410-3 4
1 Ulverteiler Oil distributor 009 .410-41
1 Platte Plate 009 .410-42
1 Anschlu8nippel Connecting nipple 009 .410-4 3
S VerschluBschraube Screw plug 009 .410-4 4
1 Distanzbuchse Spacer bush 009 .410-4 5
5 Anschlu8nippel R 1/4ff Connecting*nipple R 1/4" 009 .410-4 6
4 Schraube R18x7O Screw R1840 009-410-47
1 Schraube M 4x25 Screw M4x25 009 .410-4 8
5 Kerbnagel 3x6 Splined pin 3x6 009 .410-4 9
5 Dichtring Seal ring G09-410-50 X
2 Usit-Ring Usit ring 009 .410-51 x
I O-Ring &-ring 009 .410-52 x
1 Statzring Thrust ring G09 .410-53 x
5 Kupplung R 1/8" Coupling R 1/811 009-410-54
5 Nippel R 1/8" Nipple R 1/8" 009-410-55
5 Verbindungsschnur Connecting cord 009 .410,-56
I Ulbehilter 1000-5,5 Oil containerlOOO-5,5 oog .4lo-61
1 VerschluBkoppe Core plug 009 .410-6 2
1 Dichtring Seal ring 009 .410-63 X
1 Uberdruckventil 100 bar Pressure relief valve 100 bar oog .4lo-6 4
I I I-
Hinweis Die mit x bezeichneten Teile be- lotr. The parts inarked by an x ar e 0
finden sich im Ersatzteilbeutel contained in the spare parts bag .
0
D36 5611 D+E 1 490 .31-2
DISASSEMBLING AND-ASSEMBLING
M .A .N .-DIESEL 49 0
0
M*AL* N HIGH-PRESSURE PISTON PUMP
HKP 10/1 000-5, 5
Arbeitskarte-Nr.
Work card No .
No . 490 .31
Carte travall No.
Tarieto trobalo
TooTTo -oo9.416 applicabli work shoot 490 .30
TOOLS REQUIRED
1 Set open-jaw- . spanner&
1 Screw driver, size 7
1 Set wrench keys, cranked type
1 Hammer 100 g
1 Chisel, small
1 Punch dia 5
1 . Screw out 4 screws on oil distributor, using wrench key, cranked
type .
2. Loosen slotted screw with screw driver.
3 . Pull out oil distributor in straight forward direction .
4. Screw out hexagonal screw, 22, and remove flange .
5. Screw out threaded sleeve, using screw driver, with the pump body
inverted to prevent the ball and the seat of the check-valve from
0 falling out.
~otv. When Installing the ch8ck-valve, apply a little grease to
the spring to make it stick to the valve sleeve so that
it will not fall out when assembling .
6. Loosen screw with the use of cranked wrench and remove holder
with the use of a small chisel .
7. Take out both sliding blocks .
8. Remove upper pin with the use of a punch.
9. Extract lower pin by hand and remove pump lever.
10. Loosen four hexagonal screws on fl ange of oil tank with the use
of open jaw spanner, size 10 and remove tank .
Note : Drain oil tank or set pump up vertically, tank flange at
the top .
11 . Remove relieve valve, using open jaw spanner, size 17.
Note: Do not damage lead seal !
12 . Unscrew suction filter, using open jaw spanner.
13 . Screw out suction valve with open jaw spanner, note sequence of
0 installation of pressure spring and ball .
14 . Pull out pump piston by hand in upward direction and put it down .
15 . Screw out pump barrel, using special pliers or two punches an d
a I ever .
16 . Take out ring and sealing cuff, using screw driver or pointed
pliers .
Note : When installing a now sealing cuff, it must be firmly pressed
in by means of a mandrel while using care not to damage it .
To assemble, reverse sequence of operations of disassembly .
Fill oil tank and vent pump and test it for proper functioning .
0
D36 5610 E R.A.1-oo
Arbeitszeit - Stunden Alle Belrieb!slunden
490.31-2 Working time - Hours Every Operating hours
Toutes lei as necessary
Hevres do Marche
DUrdeclefrcivcdi -Heures
Tiempo de trabolo - Horos Coda Horas de serviclo
cr)
HOCHDRUCKPUMPE GERUPRtSS M.A.N.-DIESE L 49 0
0
M *AL* N HIGH-PRESSURE PUMP GERUPRESS Arbeftkarte-W .
tmvcV
'd I *
Worl card
Cart.
j~,,.
490.33
Torieta frabojo No .
zugehurige Arbeitskarte . . 009 .03
37 38 16 22 24 23 21 19 31 5 11 15 12
36 40 606 A
32403943
/ " ' 1 ~4 l~ 13 17' \ 40 39
' %2 3' A
Stckz Werkzeug-Nr.
B-onennung Designation
Pieces, Tool No .
I
1 Hochdruckpumpe komplett High-pressure pump complete 009 .302
1 Kolben Piston 009 .302-01
2 Lager Bearing 009 .302-02 x
1 Manschette Seal 009 .302-03- x
I DistanzstOck Spacer 009 .302-0 4
1. Bodenkappe (Hydrauliksaite) Bottom cap (hydraulic side) 009 .302-0 5
1 O-Ring O-ring 009 .302-06 x
1 Ventilfeder Valve spring 009 .302-0 7
1 Zahnscheibe Toothed washer 009 .302-0 8
1 Ventilkugel Valve ball 009 .302-0 9
1 Saugstutzen Suction socket 009 .302-1 0
0 1 VentilkugelfChrung Valve ball guide 009 .302-1 1
1 Ventilfeder Valve spring 009 .302-1 2
1 Druckstutzen Delivery socket 009 .302-1 3
1 Ventilkugel Valve ball 009 .302-1 4
1 O-Ring O-ring 009 .302-15 x
1 Bodenkappe (Luftseite) Bottom cap (ai r side) 009 .302-1 6
1 Zylinder Cylinder 009 .302-17 '
1 Luftkolben Air piston 009 .302-1 8
1 FOhrungsteller Guide plate 009 .302-1 9
1 Federplatte Spring plate 009 .302-2 0
2 O-Ring O-ring 009 .302-21
1 O-Ring O-ring 009 .302-22 X
1 O-Ring 0-rfng 009 .302-23
1 O-Ring 0--ring 009 .302-24 X
1 O-Ring d-ring 009 .302-25 X
2 O-Ring O-ring 009 .302-26 X
1 O-Ring O-ring 009 .302-27 x
1 O-Ring 0-ring 009 .302-28 x
0
I
(X> D36 5617 D+E siehe Ruckseite
C'%9D~ 490-33- 2 PA.o .
Stckz~
Bononflun g Designation Warkzeug-Nr.
N scel
Tool No . 0
Schleberbuchse Spool bush 009~302-29
Steuerschleber Spoo l 009 .302-30
Rückholfeder Retrieving spring 009 .302-31
Dämpferkappe Sound damper cap- 009 .302-32
Dämoferrohr außen Damper tube, outer 009 .302-33
Dämpfergeflecht Damper 'screen 009 .302-34
Schraub e Screw 009 .302-35
O-Ring O-ring 009 .302-36 x
Sechskantschraube Hexagon screw 009 .302-37
Unterlagscheibe Washer . 009 .302-38
Zylinderkopfschraube Choose-headed screw 009 .302-39
Federrin g Spring ring 009 .302-40
Sechskantmutter Hexagon nut 009 .302-41
Vontilfeder Valve spring 009 .302-42
Dämpferrohr Damper tube 009 .302-43
O-Rin g O-rin g 009 .302-44
Distanzrohr Spacer tube 009 .302-45
Vontilstösel Valve tappet 009 .302-46
O-Rin g O-rin g 009 .302-47 0
Plastic disc 009 .302-48 x'
Teflonri .ng Teflon seal 009 .302-49 x
Ersatztällbeutel Spare parts beg 009 .302.50
Ersatztellbeutel für Filterdruckregler Spare parts bag for pressure regulat- 009 .302-51
enth31t Membrane und Dichtung (9) und ing valve contains seal (9) and valve
Ventil 0-12 bar (10) - siehe Bild unten 0-12 bar (10) - see illustration belo w
Hin wlil Die mit x bezeichneten Tolle befinden sich Im Ersatztellbeutel 009.302-50
Nit 0 The parts marked by an x are cdntained in the spare parts bag 009 .302-50
036 5617 D+E 1 490 .33-2

.
49 0
HYDRAULISCHE SPANNVORR ICHTUNG KSZ 1
Arbeilskorle-Nr .
Work cord No.
HYDRAULIC TENSION DEVICE CorfelrayoilNo . - 490 .40
Torlela frobojo No.
Stckz . Workzeug-Nr .
Bild Bcnannung Designation
Pieces Tool N o .
figure
(1) Spannvorrichtung Tension device 009-360

009-360 komplett complet e
-1 -2 -3 -11 -5 -9 -10
I GcUuse Casing 009-360- 1
1 Kolbon Plunger 009-360- 2
1 Dichtring Seal ring 009-360- 3
1 Dichtring Seal ring 009-360-A
1 Einschraubstutzen Screw union 009-360- 5
1 Steckkupplungsnippel Connecting nipple 009 .360-1 0
Zul~ssiger Hub = 5 mm Gewicht 3 kg
Permitted lift = 5 mm Weight 3 kg
(1) Spannvorrichtung Tension device 009-37 0

009 370 komplett complet e
0 -1 -2 -11 -6 -7 -9 -10 1
1
Gehjuse
Kolbcn
Casing
Plunger
009 .370- 1
009-371- 2
009-37G- 3
1 Dichtring Sq1 ring
1 Dichtring Seal ring 009-370-6
1 Eitischraubstutzen Screw union 009-370- 7
Mossiger Hub = 6,3 mm Gewicht 7 kg 1 Steckkupplungsnippel Connecting nipple 009-370-1 0
Permitted lift = 6,3 mm Weight 7 kg
(1) SpannvQrrichtung Tension device 009-38 0

009-380 komplett complet e
1 Gelijus e Casin g 009-380- 1
-1 -2 -3 Jt -6 -7 -9 -10 009-38&--2
1 Kolbo n Plunge r
1 Dichtring Seal ring 009-380-- 3
1 Dichtr i ng Seal rin g 009-380- 4
1 Dichtring Seal ring 009-38G- 6
1 Einschraubstutzen Screw union 009-380-7
0 ZuAssiger Hub
Permitted lift
8,8 mm Gewicht 13 kg
8,8 mm Weight 13 kg
I Steckkupplungsnippel Connecting nipple 009-380-10
Spannvorrichtung Tension device 009-390-

009-390 komplett complet e I
1 Gehluse Casing 009-390-1
-1 -2 -3 -11 -6 -7 -9 -10
I Kolben Plunger 009-390- 2
1 Dichtring Seal ring 009-390--3
1 Einschraubstutzen Screw union 009-390-7
Connecting nipple 009-390-1 0
Zul~ssigcr Hub = 11 mm Gewichi 29 kg 1 Steckkupplungsnippel
Permitted lift = 11 mm Weight 29 k q
Cr%
00
D36 561o D+E sieho RUckselt e

490 .40-1 I Pleasp overleaf
1 f
MONTAGE VON DICHTRINGE N
Hnwels Jede Verletzung eines O-Ringes beim Einbau führt BENÖTIGTES WERKZEU G
zu Undichtigkeit !
Doppelmaulschüssel SW 17x19
0
Keine scharfkantigen Werkzeuge benützen ! fet t
Fade n
ARBEITSFOLGE, Einbau des O-Ringes in den Kolben
1 . Nut im Kolben und Dichtring gut einfetten .
2 . O-Ring an einer Seite in Nut einlegen und vor-
sichtig mit Daumen ganz in Nut einstreifen, dabei
beachten, daß Ring nicht verschränkt wird .
Hinweis Der außen am O-Ring sichtbare Grat dient
als Einbauhilfe .
Verschränken des O-Ringes wird vermieden,

wenn vor dem Einbau ein faden oder ein
schmales Band in die Nut gelegt und damit
der Ring rundum etwas angehoben wird um
ihn in gewünschte Lage zu bringen (Grat
ist um ganzen Umfang sichtbar) .
Anschließend Faden wieder herausziehen .
3 . Kolben und Dichtring gut einfetten und'vorsichtig

in Gehäuse einschieben . 0
Einbau des O-Ringes in das Gehäus e
1 . Nut im Gehäuse und Dichtring einfetten .

2 . Dichtring in Nut eindrücken und dabei beachten, daß
'Ring nicht verschränkt wird . -
Hinweis Der Grat innen am O-Ring muß Ober den

ZEICHENERKLÄRUNG LEGEND ganzen Umfang sichtbar sein! ,
1 Kolbe n 1 Piston 3 . Kolben im Gehäuse vorsichtig einschieben .
2 O-Rin g 2 O-ring
3 Kontrollgrat 3 Seam
4 Gehäus e 4 Casing
5 O-Ring 5 O-rin g
6 faden 6 Piece of cord
FITTING O-RING S
Note Any damage inflicted on the O-ring during fitting' TOOLS REOUIRE D
will result In oil leakagel Double end open end wrench, size 1709
0
Do not use sharp-edged tools! Greas e
SEQUENCE Of OPERATIONS, Fitting O-ring in piston Piece of fine cord
1 . Grease groove in piston and the seal ring liberally .
2 . Place O-ring in groove, starting at on point and sliding it into position round the circumference
by carefully guiding it with the thumb, taking care not to twist it .
Note The visible seam on the outside of the ring will serve as an installation aid .
A length of fine cord or narrow strip placed in the groove before fitting the O-ring will
help prevent twisting of the O-ring in so far as the ring can be slightly lifted out of the
groove and can be more easily adjusted (seam is visible round the whole circumference) .
Pull out cord after fitting the :ring .
3 . Grease piston and seal ring liberally and cautiously insert It into the casing .
Fitting O-ring in casin g
1 . Grease groove in the casing and also the seal ring .

2 . Push seal ring into the groove, taking care not to twist the ring .
Note The seam on the inside of the O-ring must be visible round the whole circumference!
0
3 . Cautiously slide piston into the casing .
036 610 D*r 490 .40-1 1? .89
KSZ 49 0
HYDRAULIC TENSIONING TOOL Aroeifskcrle-N~ .
Work cora Na .
Came tra,o,[ No.
i criele frcLoaio N . . 490 .40
Figure Pieces Designation Tool No.
(1) Tensioning tool 009-36 0

1 2 009360 4
complet e
1 Casing 009-360-00 1
1 Piston 009-360-00 2
I Seal ring 009-360-004
I Seal ring 009-360-00 5
36 41 429 5 9 8 1 Screw union 009-360-007
1 Screw union 009-360-01 1
Effective lift 6.5 mm
1 CEJN hydraulic nipple 009-360-00 8
Iffective-piston zrea 68.92 cm2 1 Threaded piece 009-360-00 9
1 Screw union 009-360-01 0
1 2 009370 4
Tensioning tool 009-370
0 complet e
1 Casing 009-370-001
1 Piston 009-370-002
1 Seal ring 009-370-00 4
1 Seal ring 009-370-005
36 41 429 5 9 8 1 Seal ring 009-370-007
Ef fecti ve li ft 5 mm 1 CEJN hydraulic nipple 009-370-008
1 Threaded piece 009-370-009
Effective piston * area 122-52 crr.2 1 Screw union 009-370-011
1 2 009-380 (1) Tensioning tool 009-38 0

complet e
7 11
1 Casing 009-380-00 1
1 Piston 009-38 0 -00 2
1 Seal ring 009-380-00 4
1 Seal ring 009-38MO 5
0 36 41 429
Effective lift
5
7.5 mm
1
I
Seal ring
CEJN hydraulic nipple
009-380-00 7
009-380-00 8
1 Threaded piece 009-380-00 9
219 .91 cm,2 1 Screw union 009-380-01 1
Effective piston area'
(1) Tensionirvg tool 009-390

1 2 009.390 4 complet e
7 1 1 Casing 009-390-001
1 Piston 009-390-00 2
1 Seal ring 009-390-004
I Seal ring 009-390-005
1 Seal ring 009-390-007
13,14 36 41 429 5 9 8 1 CEJN hydraulic nipple 009-390-008
1 Threaded piece 009 . , 390-00 9
Effective lift 11 mm 1 Screw union 009-390-01 1
Effective pistorr area 366 .97 cm2 2 Handle 009-390-01 3
4 Hexagon screw 009-390-01 4
CD
CO
D36 561o E
490 .40-2 P.T.O.
Figur e Piece s Designatio n Tool No .
1 2 009.301 5,6 7 Tensioning tool 009-301 0

complete
Casin g 009-301-001
Piston 009-301-002
O-ring 009-301-003
Supporting rin g 009-301-004
36 41 429 3 : 4 O-ring 009-301-005
Supporting ring 009-301-006
Effective lift 8 .5 mm Threaded piece 009-301-007
2 Sea l 009-301-008
Effective piston area 122-52 cm
UJN hydrauiic nippl e OV9 .301-00 9
W Tensioning tool 009-35 5

complete
Casin g 009-355-001
Piston 009-355-002
O-ring 009-355-004
O-ring 009-355-005 0
Threaded piece 009-355-007
Effective lift 10 mm
Sea l 009-355-008
Effective piston area 376 .8 cm2 CEJN hydraulic nippl e 009-355-000,
Note : Any damage inflicted on the O-ring during TOOLS REOUIRE D

fitting will result in oil leakage !
Double end open end wrench, size 17 x 19
Do not use sharp-edged tools ! Greas e
Piece of fine cord
I 2
SEOUENCE OF OPERATIONS :- Fitting O-ring in pisto n
1 . Grease groove in piston and the seal ring .liberally .

2. Place O-ring in groove, starting at one point and slid-
ing it into position round the circumference by carefull
guiding it with the thumb, taking care not to twist it . I
Note : The visible seam on the outside of the ring will

serve as an installation aid . 0
A length of fine cord or narrow strip placed in
the groove before fitting the O-ring will help
prevent twisting of the O-ring in so far as the
ring can be slightly lifted out of the groove and
can be more easily adjusted (seam is visible round
the whole. circumference) . Pull out cord after
fitting the ring .
3 . Grease piston and seal ring liberally and cautiously

insert it into the casing .
Littina .p-ring in~casin g

1 . Grease groove in the casing and also the seal ring .
2 . Push seal ring into the groove, taking care not to twist
LEGEND the rirtg .
1 Piston 4 Casing Note : The seam on the inside of the O-ring must be
2 O-ring visible round the whole circumference !
5 O-rin g
3 Seam 6 Piece of cord ~ . Cautiously slide piston into the casing .
I*
D36 5610E/490 .40-2

SPANNVORRICHTUNG FOR ZYLINDER- KSZ 70/125 A+B 49 0
DECKELSCHRAUBE N
M *Atk* M TENSION DEVICE FOR CYLINDER Arbeitskarft-W .
Work card No .
0 Carte travail No. 490 .41
COVER SCREW S Tarjetd trabalo No.
zagehurige Arbeitskarte . . . . 490 .4 u
41 22 .62
40
50
51
52
53
55
70 18
69
68
67
66 24
35 25
26
38
3
- 33
0
29
31 30
Stckz . Werkzeug--Nr .
Benennung Designatio n
Piece s Tool No .
(1) Hydraulische Spannvorrichtung komplett Hydraulic tension device complete 055-381

bestehend aus : consists of :
Spannvorrichtung (009-380) Tension device (009-380) 055-381-03
Tragkranz Carrie r 055-381-18
Abstandscheibe Disc 055 .381-22
Stang e Rod 055-381-24
0 Stellring Setting rin g 055-381-25
Spannhülse Clamping sleeve 055-381-26
Huls e Sleev e 055-381-29
Zylinderstift Dowel 055-381-30
Ring Ring 055-381-31
V1utter M 90X4 Nut M 90A 055-381-33
Spindel Spindle 055-381-35
Sechskantschraube M 10 Hexagonal screw M 10 055-381-38
Handra d Handwhee l 055-381-40
Zylinderstift Dowel 055-381-41
Rohrstück Pipe 055-381-50
Rundstahl 6 0- Round steel bar 6 055-381-51
Rohrschelle Pipe clip 055-381-52
Sechskantschraube Hexagonal screw 055-381-53
T-Verschraubung T-connection 055-381-55
Scheibe Disc 055-381-57
Tellerfeder - Cup spring 055-381-58
Iberwurfmutter Cap nut 055-381-61
Dichtkegel Cone 055-381-62
Dichtring Seal ring 055-381-63
2 Steckkupplungsnippe l Lock connection nipple 055-381-64
I
D36 5612 D+E
490 .41-1 siehe RUckseite
I p .t.o .
f
Stckz , Wer kzeuq-Nr .

Piecw Tool No .
10 Rohrspirale Helical pipe 055-381-6 6

10 ReduzierstUck Adaptor 055-361-67
10 Dichtring Seal rin g 055-381-68
10 Uberwurfschraube Cap ' screw 055-381-69
10 Doppelkeilring Double-tapered ring 055-381-70
1 AuMngering Suspension ring 055-381-7 5
3 Schakel Shackle 055-381-7 6
3 Sch~kel Shackle 055-381-7 7
3 Drahtseil 'Wire rope 055-381-78
40
is
D36 5612 D+E/490 .41-1
HYDRAULISCHE SPAN NVORR ICHTU NG M. A . N . -D 1 ESE
-1490
L
M *A&+ N HYDRAULIC TENSION DEVICE Arbeitskarle-Nr .
Work card No .
0 Carte travoil No. 490 .4 2
Torieta frcbojo No .
030 .118
Pieces Tool N
(1) Hydraulische Spannvorrichtung komplett, Hydraulic tension device complete, 030-117

bestehend aus Teil -1 bis -16 consists of parts -1 to -1 6
0 (1) Hydraulische Spannvorrichtung komplett,

bestehend aus Teil -1 bis -15 und -17
Hydraulic tension device complete,
consists of parts -1 to -15 and -1 7
030-11 8
1 CEJN-Hydrauliknippel CEJN hydraulic nipple 030-117- 1

1 Mutter Nut 030-117- 2
1 (2) Dichtung Seal 030-117- 3 I
1 (2) GewindestUck Threaded piece 030-117- 4
1 - Kolben Piston 030-117- 5
I Dichtring Seal ring 030-117- 6
1 Geh%se Casing 030-117- 8
1 Kolben Piston 030-117- 9
1 Dichtring Seal ring 030-117-1 0
1 Dichtring Seal ring 030-117-1 1
1 Beilagscheibe Washer 030-117-1 2
3 Tellerfeder Cup spring 030 .117-1 3
1 Schutzkappe Cover 030-117-1 4
1 Gehtuse Casing 030-117-1 5
1 Hochdruckrohr (030 .119) High pressure pipe (030-119) 030-117-1 6
1 AnschluBstUck Connecting piece 030-118-1 7
9 D36 5610 D+E siehe Ruckseite
490 .42-2 PA .o-
Lr%
0
Stckz . Benennun g Designatio n Werkzeug-Nr .

Piece s Tool No .
(1 ) Hydraulische Spannvorrichtung komplett, Hydraulic tension device complete, 030 .06 4

bestehend aus Teil -1, -3 bis -15 consists of parts -1, -3 to -15
(1) Hydraulische Spannvorrichtung komplett, Hydraulic tension device complete, 030 .12 9
bestehend aus Teil -1 bis -13 und -16 consists of parts -1 to -13 and -16
CEJN-Hydrauliknippel CEJN-hydraulic nippl e 030-129-1

Mutte r Nut 030 .129-2
Dichtung Seal 030 .129-3
Kolben Piston 030-12.9-4
Dichtring Seal ring 030 .129-5
Gehäuse Casing 030 .129-7
Kolben Piston 030 .129-8 0

Tellerfeder Cup spring 030 .129-11
Schutzkappe Cover 030 .129-12
Gehäuse Casing 030 .129-13
Mutter Nut 030 .064-14
Dichtung Seal 030 .06~-15
Anschlußstück Connecting piece 030 .129-16
0
MAIHAK-INDIKATOR TYP 30 M.A. N .-DIESELI 49 0
MAIHAK INDICATOR TYPE 30 ArDeiISKorle-Nr.
Work card No,
0 (C 1 1 .49011-0048 ) Corte tro,ail N 490 .50
Torieto Ircortio No.
36
Hinweis Liste entWt Varianten aller Motortypen . NOTE List contains variety of all engine types . By ordering
bel Ersatzbestellung Werkzeug-Nr . und note tool No . and quantity .
StUckzahl angeben .
Werkzeug-Nr .
Pos . Benennun g Designation .
Tool No .
Indikator Typ 30, komplett Indicator type 30 complet e 419-351
1 Indikator ohne Hahn und ohne MutternschlUssel Indicator without cock and without nut adjust- 419-351-001
(Zylinder und Kolben 1/5 = 9,06 mm ing spanner (cylinder and piston 1/5=9 .06mm
Gebrauchsanweisun g Operating manua l 419-351-003
Diagrammblätter (Packung) Diagram sheets (set) 419-351-004
Indikatorschnur Indicator cor d 419-351-005
Schlüssel für Anschlußmutter Spanner for connecting nut 419-351-006
Zylinderschlüssel Cylinder spanne r 419-351-007
0 Feder/Spring Kolben/Piston 1/5 Kolben/Piston 1/ 2
45 mm 3,5 ba r 419-351-008
30 mm 5 bar 2 ba r 419-351-009
Nr . 1 10 bar 419-351-010
Nr . 2 15 bar 6 ba r 419-351-011
Nr . 14 70 bar 419-351-012
Nr . 16 80 bar 32 bar 419-351-013
Nr . 20 100 bar 40 bar 419-351-014
Nr . 25 125 bar 50 bar 419-351-015
Nr . 30 150 bar 60 bar 419-351-016
Nr . 35 175 bar 70 bar 419-351-017
Nr . 40 200 ba r 80 ba r 419-351-018
Zylinderwischer zu Pos . 29 Cylinder wiper to Pos . 29 419-351-026
Flachzange Pair of flat nose pliers 419-351-028
Komplettes Oberteil mit Zylinder, Kolben Complete top section with cylinderpiston 419-351-029
1/2 = 14,33 mm 0 und Kolbenstange 1/2 = 14 .33 mm V and piston ro d
30 Zylinderö l Cylinder oi l 419-351-030
31 $chnurspannhaken Cord tightening jaw 419-351-031
32 Scheib e Dis c 419-351-032
34 Zylinder 1/2 enthalten in Pos . 29 Cylinder 112 included in Pos . 29 419-351-034
35 Kaste n Bo x 419-351-035
36 SchlUsse l Key 419-351-036
0
(D
CO
D36 5600 D+ E
490-50 -2
0
0
REMOVING AND INSTALLING BBC 54 4
CHAMBER-TYPE SILENCER
M *Atk* M Arbeitskarte-Nr.
Work card No.
0 (BBC exhaust tur6ocharger) Carlo travail No. 500 .01
Torieta trobalo No.
FIGURE see overleaf TOOLS REQUIRED

LEGEND, see text 1 Set open-end spanner s
1 Hexagonal box spanner, size 19
SEQUENCE OF OPERATIONS 1 : Removing 1 Hamme r
1 Chisel, flat
1 . Remove hexagonal screws with nuts (544 .147 and 544 .148) including lock-
1 Screw driver
washers (544 .149) in insert (544 .021) and remove pipe leading to the
1 Lifting gea r
inducer .
2. Unscrew and remove hexagonal screws (544 .019) and discs (544.020) in 2 Rope with shackl e
screw flange of rear wall (544 .001) on compressor side and remove rubber
expansion piece .
3 . Disconnect air delivery pipes at two throttle fittings (544 .175) .
4 . Fasten two ropes with shackles at eyebolts and hang uponlifting gear .
5. Unscrew supports (544 .500) on foundation .
6. Lift silencer cautiously and put it on its braces on wooden supports .
10te . Stop ring (544 .142) is still to be left in place .
SEQUENCE OF OPERATIONS 2 . Installing
1 . Fasten silencer with shackles on lifting eyes and hang on lifting gear .
2 . Move silencer cautiously into installation position and fasten supports on foundation .
3 . Reconnect air delivery pipes to two throttle fittings (544 .175) .
4 . Reconnect rubber expansion piece on screw flange of rear wall (544 .001) with hexagonal screws (544 .019) and
discs (544.020) .
5 . Secure pipe connecting the inducer to insert (544 .021) with hexagonal screws, nuts and lockwashers (544 .147,
. 544 .148 and 544 .149) .
SEQUENCE OF OPERATIONS 3 : Disassembling and Cleanin g
1 . Remove pipe clamps (544 .170), protection plate (544 .192) on insert (544 .021) and magnet field switch (544 .165)
on Europa cylinder (544 .156) .
Note : Connections magnet field switch to terminal box (544 .176) need not be disturbed .
2 . Unscrew and remove hexagonal screws (544 .120) together with lockwashers (544 .121) in sliding tube (544 .100), dis-
connect link joint (544 .159) from supporting bearing (544 .152) and slide off Europa cylinder (544 .156) together
with the connected pipes and screw connections over the silencer insert .
3 . Unscrew four countersunk screws (544 .145) and remove stop ring (544 .142) and withdraw slide tube (544 .100) in
0 the direction of the compressor, with ring (544 .106) left in its position .
4 . Lift silencer by means of lifting gear, turn it about 900 (screw flange of rear wall pointing downwards) and
lower it on wooden support . Remove lifting rope .
5 . Unscrew hexagonal nuts (544 .096) in rear wall (544 .001) and hexagonal nuts (544 .097) in casing face wall (544 .061',
and lift up casing .
6 . Unscrew hexagonal nuts (544 .057) inside the insert (544 .M) after which the insert (544 .021) and the rear
wall (544 .001) are disassembled .
7 . Clean all components of silencer.
The felt lining when covered by dry dirt can be conveniently cleaned with low-pressure air or a brush which should
not be too stiff . Greasy dirt can be removed with diesel fuel or commercial soap powder as is used in the house- .
hold . Cleansers containing acetone, especially Trilene (Trichloroethylene) must not bo used because they dissolve
the glue with which the felt plates are fastened . Heavily warped felt plates must be renewed because they restrict
the flow-sectional area . To as_semble silencer, reverse procedure given on disassembly .
PJ .o ~
Arb*itszeit -Stunden Alle Betriebsstunden
036 5610 E Working time - Hours Every Operating hours
500 .01-1 r6odotravail -Houres Toutes let as necessary Houres de rnarche
CZ Du
Tismpo do trabaio - Horas A Cadd Horas do servicio
T_
0
0
ar
Ur i a-C, - I i
zi i
0
0
NA 57 500
M#Ak+ H L IST OF WORK CARD S Arbeitskarte-Isir,
Work card No.
Carle trova ;l No.
TorielotrabojoNa . 500 .01
0
Work Card Description
500.05 Putting turbocharger out of action

500 .06 Bearing inspectio n
500 .07 Turbine cleaning
500 .08 Compressor cleanin g
500 .10 Removing and installing connection s
Dismounting and mounting complete turbocharger
500 .11 Removing and installing silence r
500.12 Removing and installing oil tan k
500.13 Removing and installing electronic tachometer
500.14 Removing and installing compressor casin g
500 .15 Removing and installing bearing casing with rotor in place
0
500 .16 Removing and installing impelle r
500 .17 Removing and installing end cover on compressor side
500 .18 Removing and installing locating rin g
500 .19 Removing and installing locating bearing
500 .20 Removing and installing thrust ring
500 .21 Removing and installing turbine roto r
500.22 Removing and installing end cover on turbine side
500.23 Removing and installing plain bearin g
500.24 Removing and installing gas admission casin. g
500.25 Removing and installing nozzle ring
500.26 Removing and installing diffuser
036 5645 E
500.01-2
0
0
PUTTING TURBOCHARGER NA 57 500
M *Atk+ N OUT OF OPERATION Arbeitskarte-Nr .
Work card No .
Carte travail No .
Tcrtetc trabojo No. 500 .05
0 applicable work sheet . . . . . . . 500 .1 4
With attached auxiliary blower
TOOLS REQUIRE D Tool No .

Without auxiliary blower
1 Open-end wrench, size 1 9
1 Hexagon socket wrench, size 24
1 Holding wrench. . . . . 0# . . . . . . . . . . . . . . . . . . 596 .018
1 Holding wrenc h
(only with auxiliary blower) . . . . . . . . . . . 596 .215
3 Hexagon screw . . . . 00 .0 . . . . . . 0 . . . . . . . . . . . 596 .021
3 Disc . . . . . . . . . . . . . . . 0 . . . . 00 .00 . . . . . . . 0 . . 596 .022
1 End cover, compressor side . . . . . . . . . . . . . 596 .027
1 End cover, turbine side . . . . o . . . . . . . . . . . 596 .028
1 Seal . . . . o . . . . . . . . . o_ . . . . . . . . . . . . . . . . 596 .029
1 Seal . . . oo . . . . . . . . . . . . . . . . . . . o . . . . . . . . o 596 .030
3 Pull6r screw . . . . . . . . . o . . . . . . . . . o-o . . . 596 .04 2
LEGEND
0 517 .001 Bearing casing 517.094 Locknut
517 .069 Stud 520.061 Claw sleeve
517 .093 Stud 546.001 Compressor casin g
There are two methods of putting the turbocharger out of operation, in the one case by arresting the rotor
and in the other by removing it .
1 . Arrestinq the roto r
This method should only be employed if the damaged rotor cannot be removed . Operations 11 and, in part 14
must be carried out first .
1 .1 Remove cheese-headed bolts (546 .073) and toothed washers (546 .074) and take off intake socket (546 .060), insert
piece (546 .051) and spacer ring (546 .052) (use 3 puller screws for removing insert piece) - cf work sheet
500 .14 .
1 .2 Slip holding wrench (596 .018 or 596.218) onto claw sleeve (520 .061) and fasten it with 3 hexagon screws (596 .021
to compressor casing (546 .001) .
1 .3 Reinstall silencer or intake casing .
Lote- If an auxiliary blower is attached to the turbocharger, special attention must be paid to the electri c
0 and pneumatic connections . The tubular slide valve should be closed during emergency operation .
P,t-
.0 -
Arbeitszeit,ne z Slunde n
1 . 0 .5 Alto Betriebsstunden
20. 05-2 Working ti Hours
Durke de travail - Hevres
Tiernpo de trabojo - Hora& 2 . 008 k Every
Toutes les
Codo as necessary
Operating hours
Heures de marche
Horcis de servicio
1 .4 Seal off lubricating oil supply to turbocharger by installing a blind flange .
1 .5 Supply of coolinq water throuqh the bearinq casinq must be kept up .
0
2. Removinq roto r
It is strongly recommended that the rotor be removed when the turbocharger must be put out of operation .
Operations 11 and 13-23 must be carried out first.
2.1 Seal bearing casing (517.001) on turbine side by means of seal (596 .030), cover (596 .028), studs (517 .069)
and locknuts (517 .094) .
2.2 Seal bearing casing (517.001) on compressor side with seal (596 .029), cover (596 .027) and locknuts (517 .094) .
2.3 Reinstall casings in the normal way after removal of the rotor and after front face sides of bearing casing
have been sealed with the covers .
Note : If turbocharger is equipped with an auxiliary blower, special attention must be paid to electric and
pneumatic connections .
2 .4 Cut off suDDly of lubricating oil to turbocharger by installing a blind flange .

2 .5 Supply of cooling water through bearing casing must be kept up .
Caution! With the turbocharger out of operation, reduce engine output by reducing the fuel pump setting so fa r
that the admissible exhaust temoeratures after the cylinders are not exceeded .
1 0
0
NA 500
CHECKING BEARING S Arbeitskan*-Nr.
Work card No.
Carlo travail No.
Tari*ta trabajo No. 500 .06
0
Plain Boari ng
Reaui red Tools Le qL_
nd
1 Slide gauge 0 Band width
0 2 Gauge bushes d Bearing diamete r
5 Bearing profile radius
T hrust Bearing a Wedge-shaped sector

b Load-carrying sector
STARTING POSITION c Oil groov e
Plain bearing (517-055) on turbine side and locating bearing (517-075) on compressor side are removed .
SQUENCE OF OPERATIONS 1 : Bearing diameter

1. Clean bearing thoroughly .
2 . Cautiously insert no-go gauge, or determine band width (B) .
Note : Replace bearing if no-go gauge can be inserted into bearing bore or if bond width (8) has reached the
value listed in the table .
Notice! The radial bearing clearance cannot be measured with a feeler gauge because the bearing bore is not
concentric .
Dearirg Di3mete r
d mm 35 40 45 50 60 65 70 75 80 35 90 95 10 555 1 1 20 135 150
Band '-sidth max

B Ma . 16 18 20 26 23 _d5
2!.5 1 d
70 27 28 29 30 31 33 42
SEQUENCE OF OPERATIONS 2, Axial surfaces of locating bearing

1 . Clean thrust faces on*both Sides Of the bearing .
2 . Oetermine edge (u-v) of load-carrying sector (b) .
NOTE Replace locating bearing when edge (u-v) has moved up to line (x-y), reducing the 'wedge-shaped (a)
to about one third only .
0 C%i
Co
Arbeitszoil - Slunden
M; D36 564D E Working time -Hours
All@ Befriebsstunden
Optraling hours
Dur 6 ;Odds travoil -Houres
Tiam
500 .06-1 o trobala - Horas
T.o. . i . if necesicvy Heyres do marche
Coda Horas de ser,icia
0
0
NA 500
CLEANING TURBINE
M*Ak*F4 ArbeitslkaMe-Nr.
4
Work cord Noa.
Carte travail 5M.07
Torjeja trcbajo No.
LEGEND
1 Water supply pipe 4 Three-way valve A = OFF-POSITION
2 Stop valve 5 Spray nozzle B = VASHIN G
3 Pressure gauge with pressure 6 Exhaust pipe C = BLOWING OUT
-reducing valve
Note : Number and arrangement of spray nozzles depends on the engine type and may not coincide with those shown
in the drawin g
SEOUENCE OF OPERATIONS
See also plate with cleaning instructions provided on the lagging of the exhaust-manifold .
1 . Reduce engine load until rotor speed has dropped to approx .
0 4700
4000
1/min with NA 34 2300 1/mi'n. with M 70
I/min with NA 40 2000 1/min with KA 83
3400 1/min with KA 48 1000 1/min with KA 100
2800 1/min with NA 57
2. After a lapse of time of about 15 minutes, put washing apparatus-into action .

2 .1 Set three-way valve (4) to WASHING (8) .
2.2 Open water drain slide valve on gas outlet casing .
2.3 Open all spray nozzles by turning the nee dle .
2.4 Set stop valve (2) to flow position. '
3. Washing period approximately 10 - 20 minutes af a water pressure of 1 .5 :. 2 bar - check at pressure gauge (3) .
4 . End of washinq process .
4.1 Cut off water admission at stop valve (2) .
4 .2 Set three-way valve (4) for a short period of time to BLOW OUT (C) .
4.3 Set three-,way valve (4) to OFF position (A) close all spray nozzies (5) and the water drain slide valve .
4 .4 n engine at about 1/4 load for 10 min to allow turbine to dry, then increase load slowly while listenin g
for noise indicating that rotating parts make contact and check for undue vibrations that did not exist before .
0
D36 5640 E Arbeitszeit
Working tiine
- Stunden
- Hours
Alle
Every
Beiriebsstunden
Operating hours
5DO-07-1 DurLtedetravoll -Heur« 0.3 Toules les as required HLures de marche
Tiernpo de trobajo - Horas Cada Horas de servicio
t
0
NA 500
CLEANING COMPRESSOR Arbeitskorle-Nr.
Work cord No.
Carte travail No .
Tarjeto trabojo No. 500.08
0
LEGEN D
1 Hose 4 Filling plug 7 Volute casin g
2 Tan k 5 Suction pipe 8 Air-intake socket
3 Hydrometer cock 6 Hose 9 Spray tube
Depending on the turbocharger type, the individual parts can be arranged in a slightly different order .
SEQUENCE OPERATION S
Also see plate with washing instructions on endcover of compressor .
1 . Run engine at full load .
2 . Unscrew filling plug (4), fill tank (2) with Dure water, replace filling plug .
3 . Press pushbutton of hydrometer coc k (3), for aoor . 20 sec . Compressed air from the volute casing (7) will thus
~e allowed to flow via the cock (3) through the hose (1) into the tank (2), forcing the water through the
hose (6) into the spray tube (9) in the air-intake socket (8) . The water is finely dispersed by the inrushing
air and impinges with high velocity on the impeller vanes, thus washing off the dirt layer .
Caution!
CleLning should only be effected with the enaine at operating temoerature and running at full load and the
engine must not be shut down immediately after cleaning . Only freshwater (no sea water) should be used for
filling the tank .
036 5640 E
Arbeitszeit - Stunden Alle Beiriebssfunden
500.08-2 Working timm - Hours Every (Doerating hours
Duriedetravaii -Heures Toutes lei He"res de marche
Tiernpa de frabojo - Horas Coda as necessary H.raq de servicio
0
0
CONNECTION S NA 500
M *AL* IN DISMOUNTING AND MOUNTING Arbeitskcrte-Nr.
Work card No.
Carte travail No .
COMPLETE TURBOCHARGER Tarjeta trabcjo No. 500 .1 0
0
TOOLS REQUIRED
/2
1 nptni-enA wrenc L , size 3n
1 Rope with 2 shackle s
I
11' IL - 4--' - 1 Hoist
WEIGHT of turbocharger with silencer

NA 48 . . . . . 3040 kg
.U NA 57 . . . .. 4365 k g
35404M
LEGEN D
0 Depending on space conditions in the engine room, a decision has 1 Cooling water outlet 6 Cooling water
to be made as to what is the simplest 'way of dismantling the turbo- 2 Gas outlet inle t
charger. In most cases, it will be sufficient for the purpose of 3 Gas inlet Lubricating oil
carrying out maintenance and inspection work, to remove only .4 Lock -air '
connection 7 supply
sections of the unit . Dismounting the complete turbocharger from 5 Lubricating oil outlet 8 Air outlet
the engine is ndrmally necessary only for a general overhaul . 9 Air inle t
SEQUENCE OF OPERATIONS 1 : Disconnecting ducts and pipe s
1 . Drain cooling water from turbocharger .

2 . Loosen gas outlet (2) on turbine casing, discon.nect pipes, if necessary - paying attention to seal .
3 . Disconnect cooling water outlet (1) at ~op of bearing casing .
4 . Disconnect pipe at air outlet (8) of compressor - paying attention to seal .
5 . Separate or remove pipe (9) from auxiliary blower at tubular slide valve of silencer (if provided) .
6 . Unscrew screws in flange of gas inlet (3) of gas inlet casing - paying attention to seal .
7 . Disconnect and remove cooling water supply pipe (6) at the bottom of bearing casing .
8 . Unscrew lubricating oil discharge pipe (5) at the bottom of bearing casing .
9 . Separate lubricating oil supply pipe (7) at pipe flange .
10 . Remove lock-air pipe (4) on opposite side at bearing casing .
0 11 . Loosen cable of tachometer at terminal box and remove cable gland .
SEQUENCE OF OPERATIONS 2 : Dismounting complete turbocharger

Operations 1 to 11 as abov e
12. Sling rope round compressor casing and bearing casing (turbine side) and hang complete turbocharger on hoist
sheet-metal lagging on exhaust gas casing need not be removed .
13. Remove bolts in casing foot and bracket .
14. Cautiously lift off turbocharger and place it on wooden supports .
Caution! The eyeb~lts in the casings are only intended for liffing the individual assemblies and
must not be used for suspendino the complete turbocharger,
For reconnecting pipes and ducts and mounting the complete turbocharger, see overleaf .
p.t.o.
D36 5645 E Arbeitszelt - Stunden Alle Mriebsslunden
Working tirne - Hours Every Operating hours
500 .10-2 Durike de travail -Heures Toutes le s
Tiernpo de lrobajo - Horas A Coda as necessary Heures de marche
Horas de servicia
TOOLS REQUIRED
1 Hoist
WEIGHT of turbocharger with silencer

NA 48 . . . . . . . 3040 k g
NA 57 . . . . . . . 4365 k g
36404(a
LEGEND
1 Cooling water discharge 6 Cooling water
Operations for assembly depend upon whether only parts of
2 Exhaust gas outlet suppl y
or the complete turbocharger has been removed .
3 Exhaust gas inlet 7 Lubol I supply
SEQUENCE OF OPERATIONS 3 : Mounting complete turbocharger 4 Lock-air connection 8 Air outlet
5 Luboil discharge 9 Air inlet 0
1 . Hang complete turbocharger on hoist, with ro09 slung
round compressor casing and bearing casing (turbine side),
and lower .it cautiously onto the bracket on the Diesel
engine, paying attention to pipe connections .
Caution! The eyebolts in' the casings are only to be used for lifting the individual components and must
not be used for suspending the complete turbocharqer .
2. Insert bolts in casing foot and bracket, but do not yet tighten*them .
SEQUENCE OF OPERATIONS 4 : Connecting pipes and duct s

If only sections of the charger have been removed, recoonect the applicable ducts and pipes .
3 . Connect exhaust gas inlet (3) to gas admission casing .
4 . Fasten exhaust pipe at gas outlet (2) to turbine casing .
5 . Bolt down pipe at air outlet (8) of compressor .
6 . Mount pipe (9) on tubular slide valve of silencer (if provided) .
7 . Connect cooling water discharge pipe (1) at top of bearing casing .
8 . Fasten cooling water supply pipe (6) at the bottom. 0
9. Connect luboil discharge pipe (5) at the bottom of the bearing casing .
10. Fasten luboil supply pipe (7) .
11 . Connect lock-air pipe (4) to bearing casing .
12. Connect cable of tachometer in terminal box and tighten cable gland .
13. Tighten bolts in casing foot and jointing bolts of pipes and ducts .
14 . Switch on luboll and cooling water pumps of engine, if possible, and check all flange connections for
tightness.
Note! Before installation, make sure that all seals in pipe connections are in good condition .
Coat the connectino bolts of the exhaust gas pipes with a lubricant containinq molvbdenumdisulphide
0
REMOVING AND INSTALLING NA 57 544
M *AaL* N SILENCER Arbeilskarie-Nr
Work cord No.
Carte travail No.
Torieta trabojo No. 500 .1 1
0 applicable work sheet. . . . . . . . 500.1 0
LEGEN D
544 .001 Rear wall 544 .145 Countersunk screw TOOLS REQUIRE D
544 .019 Hexagon screw 544 .147 Hexagon bolt
544 .020 Lockwasher 1 Set open-end wrenches
544 .148 Hexagon nut
1 Socket wrench, size 19
544.021 Insert 544.149 Lockwasher
1 Hamme r
544.057 Hexagon nut 544.152 PI ur. mer bl ock
1 Chisel, fl at
544.061 Casing 544 .156 Europa cylinder
1 Key
544 .096 Hexagon nut 544 .159 Suspension piece
1 Hois t
544 .097 Hexagon nut 544 .161 Forked joint
2 Rope with shackle s
544 .100 Tubular slide valve 544 .165 Magnetic switch
0 544 .110 Leve r 544 .170 Pipe clamp WEIGHT of silencer . . . . . . . . . . . 720 kg
544 .120 Hexagon screw 544 .175 Throttle union
544 .121 Lockwasher 544 .176 Terminal box
544 .142 Sto p 544 .197 Guard plate
SEQUENCE OF OPERATIONS 1 : Removing I
1 . Attach two ropes with shackles on suspension eyes and hang silencer on hoist .
2. Remove hexagon bolts and nuts (544 .147 and 544 .148) with lockwashers (544 .149) on insert (544 .021) and
remove pipe connecting the auxiliary blower .
3. Screw out hexagonal screws (544 .019) together with lockwashers (544 .020) in screw flange of rear wall (544.001)
on compressor side.
4 . Disconnect air supply pipes at two throttle unions (544 .175) .
5. Cautiously extract silencer from compressor casing in axial direction, turn it 900 (screw flange for jointing
compressor pointing downwards!) and deposit it on wooden supports .
Note : Silencer must not be supported by its sheet-metal covers or placed on the tubular slide valve.
0
p.t. 0.
. D36 5645 E Arbeitsreit - Stunden Alle Betriebsstunden
9 '500.11-2 Working time - Hours
Dur6ecJetravoil -Heures
Tiernpo de trobajo - Horas kk Every
Toutes let
'Cada
as necessary
Operating hours
Heures de marche
Horas de servido
SEQUENCE OF OPERATIONS 2 : Installing
1 . Fasten ropes with shackles on eyes and hang silencer on the hoist .
2 . Cautiously insert silencer in axial direction into compressor casing .
40
3 . Bolt screw flange of rear wall (544 .001) with hexagonal screws (544 .019) and lockwashers (544.020) to
compressor casing.
4 . Connect air supply pipes to two throttle unions (544 .175) .
5 . Connect pipe of auxiliary blower to tubular slide valve, using hexagon bolts, nuts and lockwashers (544
.147,
544 .148 and 544 .149) .
SEQUENCE OF OPERATIONS 3 : Disassembling and cleaning *
1 . Remove pipe clamps' (544 .170), guard plate (544 .197) on insert (544 .021) and magnetic switch (544.165) on
Europa cylinder (544 .156) .
Note : Connection of magnetic switch to tervinal box (544 .176) need not be disturbed .
MBrk out position of magnetic switch before removing it from the Europa cylinder to ensure it will
later be installed in exactly the same position as when removed which will make for accurate signal
display.
2 . Disconnect forked joint (544 .161) from lover (544.110) - lover will serve as a stop for the time being -
disconnect suspension piece (544 .159) from plum Mier block (544 .152) and slide off Europa cylinder (544
.156),
with the pipes and unions still in place, over the tubular slide valve .
3. Unscrew 4 countersunk screws (544 .145) and remove stop ring (544 .142) .
4 . Screw off hexagonal nuts (544 .096) on rear wall (544 .001) and hexagon nuts (544 .097) on casing face'wall
(544.061) and lift off casing .
5 . Screw off hexagonal nuts (544.057) inside the insert (544 .021) after which insert (544 .021) and rear wall
are separated.
6 . Swiag insert (544 .021), with the tubular slide valve (544 .100) still inside, round 900 , screw out and
remove hexagon screws (544 .120) and lockwashers (544 .121)-from tubular slide valve (544 .100) and take off
lever (544.110) .
7. Extract tubular slide valve in the direction of the compressor .
8 . Clean the individual components of the silencer .
Cleaninq of the felt lining, when deposits are of the dry type, should preferably be effected with an air hose
or a brush which should not be too hard. Where dirt deposits are of a greasy nature, Diesel fuel or
commercial type domestic detergents may be used; never use any solvents containing acetone, and by no
means any trichloroethylene, because these would dissolte the adhesive . If the felt lining is found to
be badly wrinkled, whereby the flow area is restricted,' the lining should be replaced .
For assemblinq the turbocharger, proceed in the reverse order . 0

Note! Locknuts and lockwashers must be in good condition if they are to be reused, otherwise they are to be
replaced . Make sure not to leave any parts or foreign matter behind as they will be swept by the air
current into the compressor where they will cause serious damage to the turbocharger .
M *AaL* N OIL TANK Arbeitskarle-Isir.
Work oard No .
Carte travall No.
Tarj,ta trabojo No . 500.1 2
applicable work sheet . . . . . . . 500 .1 0
Efteltolt A M1 1
LEGEND TOOLS REQUIRED

554 .001 Oil tank 554 .048 Spring ring 1 Open-end wrench, size 19
554 .030 Pipe run 554 .049 Hexagon screw 1 Open-end wrench, size 30
554 .038 Seal 554 .050 Spring ring 1 Hamme r
554 .039 Valve cover .554 .054 Hexagon screw 1 Chisel, pointed
554 .040 Valve ring 554 .055 Lock washer 1 Chisel, blunt
554 .041 Valve plate 554 .056 Hexagon bolt 1 Hoist
554 .043 Pipe run 554 .057 Hexagon nut 1 Rope with two shackles
554 .047 Hexagon screw
WEIGHT of oil tank. . . . . . . . . 60 kg
SEQUENCE OF OPERATIONS 1 : Removing
1*.* Check at sight glass (557.000) whether oil tank has run dry or if it is empty .
- There should be no oil flowing I
2. Hang oil tank with rope and shackle on hoist. I
3. Screw out and remove two hexagon screws (554 .047) together with spring ring (554 .048) in strut at bearing
casing side.
4 . Screw out and remove 2 hexagon screws (554 .C49) together with spring ring (554.050) in two struts in volute
casing .
5. Disconnect pipe (554 .043) at flange on oil tank by unscrewing hexagon bolts (554.056) and hexagon nuts (554.057)
paying attention to seal (554.038) .
6. Separate pipe (554 .030) at flange on oil tank by unscrewing and removing 4 hexagon screws (554 .054) with lock-
washers (554.055) .
7. Lift up oil tank (554 .001) by means of hoist and insert hexagon bolts (554 .054) through pipe flange (554.030),
seals (554 .038), valve ring (554 .D40) and valve cover (554 .039) ; valve plate (554.041) is in position.
Screw 4 hexagon nuts M 12 onto hexagon bolts (554 .054) . This will ensure that these parts are held in their
respective position .
Note: Pipe runs (554 .030 and 554 .043) need not be removed.
0. t. 0.
036 5645 E Arbeits2eit - Stunden - Alle, betriebtslunden
Working firne - Hours Every Ooerating hours
500.12-2 Durte de travail - Heures Toules les as necessary Heures do rnorCho .
Tiernpo de trabojo - Horat Ak I Coda Horas do serviclo
SEQUENCE OF OPERATIONS 2 : Installin g
1 . Hang oil tank with rope and shackles on hoist and lower it onto turbocharger . 0
2 . Fasten oil tank with hexagon screws (554 .049) and spring rings (554 .050) to volute casing and with hexagon
screws (554 .047) and spring rings (554 .048) to bearing casing side .
3 . Connect pipe runs (554 .030) and (554.043) to flange on oil tank .
Note : Check to see that seals are in good condition, otherwise use now seals.
0
M #AAk* N ELECTRONIC TACHOMETE R Arbeitskorte-ISIr.
Work card ~o..,
Carte travc I
Tor)eto trabojo No . 500 .1 3
applicable work sheet . . . . . . 500 .11
562.040 54&= SM.126 TOOLS REQUIRE D
Vi ew A - 1 Socket wrench, size 19
1 Key
LEGEND
2 .086 520.126 Magnet shaft
Press screw
546 .001 Volute casing
546 .049 Screw connection
546 .060 Air-intake socket
546 .085 Protpetion cap
546 .090 Toothed washer
3640414 546 .103 Fixing clamp
562 .004 Holding disc
0 562 .005 Hexagon nut
562 .019 Cheese-headed screw
562.020 Spring ring
562.040 Speed transmitter
562.063 Spacer bol t
STARTING POSITIO N 562 .083 Terminal box
562.086 Cable i nl et
Silencer or air-intake cAing are removed . 562.100 Speed indicato r
SEQUENCE Or' OPERATIONS 1 :_Removing

1. Remove protection cap (546 .085), loosen hexagon nut (562.005) and remove holding disc (562 .004) .
2. Cautiously extract speed transmitter (562 .040) in axial direction from the air intake socket (546.060) .
3. If speed transmitter (562.040) is to be removed completely, first remove cover of terminal box (562 .083)
and disconnect cable inside, loosen press screw at cable inlet (562.086) and then unscrew complete cable
i nl et .
4. Remove hexagon screw (546.089) and toothed washer (546 .090) on volute casing (546.001) and slip cable together
with cable'inlet (562 .086) ff.rough the opened screwed connection (546 .049).
0
Caution! Use care not to bend the two pole shoes at the end of the transmitter !
The intake socket (54E .060) should be left firmly secured to the volute casing as its hub
serves as a guide for the transmitter coil when it is installed or 'removed since the magne t
core in the shaft end is sensitive to jolts . This applies in particular when the speed transmitter
is removed or installed while the en~ine is running .
For installing the transmitter reverse sequence of operations outlined above .
D36 5645 E Aroeitszeil - Stunde n I Alle Betriett'slunaeft-

500.13-2 Working I in* - Hours 1 . 0.17 Every Operat 9 hours
cr: Durie de travoil . - Heures
Tiernpo de traboic, - Horas 2 . 0.25 Toutes Its
Coda
as necessary Heures de morchis
Horas de servicio
0
0
M #Ak# N COMPRESSOR CASING Arbeitskarte-Nr
Work card No.
Corte travail No .
0 Torieto trabojo No. 500 .1 4

appficable worg she-eF'-
. . . . . buu. TU
to
500.1 3
3 Pul I er screw . . . . . . . . . . . . . . 596 .042
1 Angle-type key, size 1 0
1 Hois t
SK042 WEIGHT of compressor casing 800 kg
SlAoso
LEGEN D
0
517 .001 Bearing casing 546 .070 Hexagon nut
546 .031 Diffuser 546 .073 Cheese-headed bolt
546 .045 Hexagon screw 546 .074 Toothed washer
546 .046 LDckwasher 546 .098 Hexagon nut
546.051 Insert 546 .099 Toothed washer
546.052 Spacer ring 546 .108 Eyebol t
546.060 Air-intake socke t 546 .109 Screw plu g
562 .000 Electronic tachomete r
STARTING POSITIO N
Silencer or air-intake casing and charge-air pipe on compressor casing are removed .
1 . Unscrew 2 screw plugs (546 .109), screw 2 eyebolts (546 .108) into volute casing (546 .001) and hang casing with
rope and 2 shackles on hoist .
0 Caution! To keep casing in balance, it may be necessary, depending on the position, to sling rope also round
the delivery socket !
2 . Unscrew hexagon nuts (546 .098), remove toothed washers (545 .099), screw puller screws (596 .042) into flange of
bearing casing (517 .001) and remove volute casing in axial direction . The air-intake socket (546 .060), the
insert ('546 .051), the spacer ring (546 .052), the diffuser (546 .031), and the speed measuring device (562 .000) I
need not be removed .
Note : Pay attention to compressor wheel when removing the casing !
3 . When it is intended to remove the air-intake socket, spacer ring and insert, loosen cheese-headed screws
(546 .073) and toothed washers (546 .074) and extract assembly with the use of puller screws (546 .042) .
The cheese-headed screws can be left in the intake socket and they will not fall out .
Note : Attention must be paid to the electric speed measuring device during removal of the air-intake Socket
4 . Unscrew hexagon nuts (545 .070) and remove spacer ring (546 .052) and insert (546 .051) .
5 . Unscrew and remove hexagon screws (546 .045) and lockwashers; (546 .046) and remove diffuser (546 .031) .
0
p. t . 0 .
Working firne
- Slunden
- Hours
Alle
Every
Setriebsstvnden
Operating hours
500 .14-2
V_
Dur"detravoil -Heures
Tiernpo de frobalo - Horas
Toutes Its
Coda 6000 Heures de marche
Horas de servicio
0
1 . Unscrew 2 screw plugs (546.109) , screw eyebolts (546 .108) into volute casing (W .001) and hang casing
with rope and shackles on hoist .
2. Cautiously insert volute casing (546 .001) - with diffuser (546 .031) installed - in axial direction into
bearing casing
3 . Refit toothed washer
* (546.099) and draw up hexagon nuts (546 .098) .
4 . Unscrew 2 eyebolts (546 .108) from volute casing (546 .001) and seal up tap holes with screw Ougs, (546
.109) .
5 . Cautiously insert air-intake socket (546 .060) with insert (546.051) and spacer ring (546.052) and draw up
cheese-headed screws (546 .073) - speed transmitter is installed .
Aoir. When inserting casing, attention must be paid to the impeller! If indicated, check width of gap
between impeller vanes and insert by means of a soft-metal imprint (cf table 'gaps and clearances'
in section 1) . In this process, press compressor casing with insert (546 .051) against impeller
vane contour while seeing that rear of impeller hub is correctly backed up . The clearance at the
spacer ring (546 .052) is adjusted either by shims or by remachining . For installing the speed
measuring device, see work sheet 500 .13.
0
*A&* M BEARING CASING
WITH ROTOR IN PLACE
Ar6eitskarre-Isir,
Work card N o
Carte travall 40
.
500 .1 5
Torieto trabojo No.
9 applicable work sheets. . . . . 500.10

to
500.1 4

4 Pul I er screw . . . . . . . . . . . . . . . . . . . 596 .041
1 Bearing casing stend . . . . . . . . . . 596 .112
2 Hexagon bolt . . . . . . . . . . . . . . . . . . . 596 .121
2 Hexagon nut. . . . . . . . . . . . . . . . . . . . 596 .122
2 Strut . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .123
5 Hexagon bolt. . . . . . . . . . . . . . . . . . . 596 .124
5 Hexagon nut . . . . . . . . . . . . . . . . . . . . 596 .125
1 EYObDIt . . . . . . . . . . . . . . . . . . . . . . . . 596 .128
1 Key, angl e-typ e
1 HCis t
36 40 406 - WEIGHT of bearing casing with rotor 960 kg
517.0915
LEGEND
517 .001 Bearing casing
517 .060 Packin g
517 .061 Round-section seal ring
517 .096 Bol t
517 .097 Cover plate
517 .100 Eyebol t
520 .000 Rotor, complete
506.001 506 .001 Gas outlet casing
506.099 Stu d
506.104 Locknut
509.001 Diffuser, outer wall
513.008 Shroud ring
STARTING POSITIO N
0
Silencer or air-intake casing and compressor
casing, oil tank are removed .

1 . Screw eyebolt (596 .128) into cover disc
(517.097), hang on hoist, press off disc
with 3 tap bolts M 10, and lift it off .
596125 596J12
2 . Hang bearing casing (517 .001) on hoist .

3 . Remove 12 locknuts (506.104), screw in 4 puller sceews (596 .041) and extract bearing casing overstuds (506 .099)
in axial direction .
4 . Deposit complete bearing casing on stand (596 .112 and 506.121-125) for further disassembling .
Note : Great care must be exercised when removing the casing to avoid damaging the turbine bla6es.
This holds in particular as long as the turbine blades are still within the range of the shroud ring
(513 .008) and the outer wall of the diffuser (509 .001) and when depositing the casing on the stand.
0
p.t.o.
Arknil Izeil -Stunden
Co D36 5645 E Worki .g firne - Hour
1 . 0 .50 Alle Betrieb5stunden
Every Oi)eratmg hours
cz 500.15-2 Durke de travail - Heures s Tovies les as necessary
Heures ce morche
v- Tiempo de trabojo - Horas 2 . 0 .75 1 AA Cad* Horo% de servicio
1 . Hang bearing casing (517 .001) on hoist .

2. Lift bearing casing off the bearing casing stand (596 .112) and cautiously insert it in axial direction 0
over the studs (506.099) into gas outlet casing (506 .001) .
3 . Screw on and tighten 12 locknuts (506 .104), cautiously insert cover disc (517.097), using the 4 bolts
(517 .096) as a guide.
Lotv. Before inserting the bearing casing and the cover disc, check to see that the packing (517.060) as
well as the round-section seal ring (517 .061 - 063) have been refitted, having made sure they are
in good condition .
Caution! When inserting the casing, care must be exercised to avoid damaging turbine blades, outer wall
of diffuser and shroud ring . Turn rotor by hand to see it is running freely.
D36 5645 E / 500 .15-7

REMOVING AND INSTALLING NA 57 52 0
M *Atk* M IMPELLER Arbeitskarte-Nr.
Work card No,
Corte travail No , .
Torieta irabajo No 500 .1 6
0
applicable work sheets 500.1 0
to
500.1 5
LEGEN D
517.001 Bearing casing
520.047 Taper sleeve
520.048 Impelle r
X .W
520 .056 Fitted feather key
520 .061 Claw sleeve
520.067 Nut
520.126 Magnet shaf
t

1 Oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .053
1 Bush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .054
0
1 Cl amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .055
2 Hexagon screw. . . . . . . . . . . . . . . . . . . . . . . . 596 .056
1 Hp tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *' 596 .057
1 Sealing sleeve. . . . . . . . . . . . . . . . . . . . . . . 596 .060
2 Seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .061
STARTING POSITIO N 1 Caliper rul e
,WEIGHT of impeller. . . . . . . . . . . . . . . . . . . 48 kg
Either silencer or intake casing with compressor casing or
only air-intike socket with speed transmitter, spacer ring and insert are removed .
1 . Screw out magnet shaft (520 .126) to prevent it from getting damaged, screw off nut (520.067), remove claw
sleeve (520 .061) and take out fitted feather keys (520 .056) .
Note : If claw sleeve will not come off (i .e . sticking), back off nut by approx . 6 mm and press off impeller
0 as described hereunder.
2 . Replace claw sleeve (520.061) and screw on nut (520 .067) until gap b, shown in the illustration, measures
6 - 10 sm. Claw sleeve is to serve as a stop when pressing off the impeller. Screw sealing sleeve (596 .060)
into center bore of shaft and fasten oil pump (596 .053) with clamp (596.055) and bush (596.054) to bearing
casing (517 .001) or compressor casing with hexagonal screws (596 .056) .
I
3 . Connect delivery tube (596 .057) of pump to sealing sleeve (596.060) .
4. Screw off cylin~rical feeder of oil pump (596 .053), immerse m o'uth piece in clean lubricating oil (viscosity
SAE30-SAE50) and pull piston by eyelet outwards. To expell the air, hold mouth piece upwards while pushing
the ball inwards, then screw oil feeder back on pump .
5 . Then operate pump with opened tommy screw on pump until oil escapes free of air bubbles . After tightening
tommy screw, operate pump until the resistance increases noticeably . If the impeller fails to come off
at once, wait a few minutes to permit oil to spread in the gap between the shaft and the taper sleeve .
Then operate pump again until impeller (520 .048) and taper sleeve (520.047) are jerked loose against the claw
sleeve .
Caution! Keep vour hands out oFthe oap . as lonq as the imooller has not come free! Danaer of iniurv!
6 . Screw off nut and remove claw sleeve, withdraw taper sleeve and impeller in axial direction .
Note : Deposit impeller on wooden supports . The bearing casing is now accessible for inspection of the
locating bearing .
p. t . 0 .
D36 5645 E Arbeit zeit - Sivnden
500 .16-2
5
Alle Setrieb!sfunden
Working time - Hours Eve
Dvri~e de trovalf - Heures 0 .5 Tories les 6000 Operating hours
Heures de rnor~he
Tiernpo de trobojo - Horcs Coda Hores de servicio
INSTALLING IMPELLER
TOOLS REQUIRED XX_ -

0
1 Wedge ring .. .. . .... ..... 596.045 1 Bush .. . . ... .. . .... . 596 .054
%/ 1 Thrust
1~o- V . . .rin . . . . *** 596.
.of
A I Mom r . . . . 00 .0 . . . . . . ;Qr, . n;r,
`~" 1 Hydraulic cylinder .. ... 596.047 2 Hexagon screw.. . ... . 596 .056
1 Seal ring . .... . .. . ... . ..596.04B 1 Hp tube .. . .. .... . .. . 596 .057
1 Seal ring . .... . .. . . .. . .. 596.049 1 Cal i per rul e . n
- I HVdraulic niston
. . . 0 .0 boa
.0 .n ;n -i n ;~i naug e
3634349
1 Steel ball . . .. . .. . . .. . .. 596.051 1 Open-end wren , size 19
1 Vent screw... . . .. . ... . .. 596.052 1 Open-end wrench, size ..70
STARTING POSITION 1 Oil PUMP.. . ... . .. . . .. . .. 596.05 3
wEmni of impeller . . . . . oeltg K g
Turbine rotor, locating bearing and end cover are mounted .
1 . Thoroughly clean seats and taper sleeve (520 .047) of oil, grease and lubricants containing molybdenumdisulphide.
2. Slip impeller (520 .048) with taper sleeve (520 .047) onto rotor shaft, backing up the impeller until it seat s
firmly against the locating ring (520 .035), with the sleeve being pushed up only by hand .
Note : Balance marks on turbine shaft, impeller and sleeve should be in alignment in radial direction (see
illustration) .
3. Place 2 fitted feather keys (520.056) in groove and push wedge ring (596.045) with pressed in thrust ring
(596 .046) in position, paying attention to the position of the claw sleeve .
4. Push hydraulic piston (596.050) into hydraulic cylinder .(596 .047),so that it is .flush with the latter and screw 40
it onto the shaft end until the thrust ring (596 .046) seats against the taper sleeve (520 .047) while turning
the hydraulic cylinder so that the venting screw (596.052) comes to lie at the fop .
5 . Fasten oil pump (596 .053) either on bearing casing or compressor casing and connect delivery tube (596.057)
to hydraulic cylinder (596.047) .
6 . Unscrew cylindrical oil feeder, immerse mouth piece in clean lubricating oil (SAE 30 - SAE 50) and pull piston
outwards by means of the eye ring . To expell air, hold mouthpiece up .and push in ball, then . replace Al feeder on
pump o
7 . Open venting screw (596.052) and tommy screw on pump and operate pump until oil escapes free of air bubbles.
Close screw .
8 . Operate oil pump (596 .053) until impeller is just held on the taper sleeve (520 .047) as it is expanded on the
tapered shaft section .
Note : This condition is attained when the impeller refused to be moved iach way within the claw clearance .
9 . Continue to operate pump (596 .053) until displacement s - 4 .6 - 4 .8 mm has been attained. Measure height of
hydraulic cylinder plus the slightly projecting end of piston by means of a caliper rule and add displacement
(s ) .
Caution! Never exceed the maximum amount of displacement, because otherwise individual parts might undergo plastic
deformation .
10. Release pressure and remove hydraulic tool .
11 . Slide on claw sleeve (520.061) paying attention to fitted feather keys (520.056) and draw up on nut (520 .067) .
0
12 . Screw magnet shaft (520 .126) into shaft ,
13 . Check impeller (520 .048) for aberration from the plane of rotation at maximum radial distance with the use
of a dial gauge (for admissible value see "gaps and clearances', sheet lo53) .
D36 5645 E / 500 .164
j REMOVING AND INSTALLING NA 57 51 7
M*A&* H END COVER ON COMPRESSOR SIDE Arbeitskorte-Nr.
Work cord No.
Carte travail No . 500 .1 7
Torleia frabojo No.
appMcaDie worX sneets. . . . . :)Uu.lr-
to
500.16
517.001 10OLS REQUIRED Tool No .

3 Puller screw . . ..... . . . . . . . . . . . .. . ....... 596 .042
1 Socket wrench, size 1 0
1 Key
517.080 il LEGEN D
517.001 Bearing casing 517 .087 Countersunk
517.061 Round-section seal ring scre w
517.080 Straight pin 517 .089 Labyrinth disc
517.084 End cover - 517 .092 Round-section
0 512085 517 .085 Seal ring seal ring
517087 517.086-Sealing cover 517 .094 Locknu t
517088
u" i STARTING POSITIO N
517086 Either silencer or air-intake casing and compressor
casing are removed or only the air-intake socket,
spacer ring and insert . Impeller taken off .
STARTING POSITION 1 : Removing
1. Unscrew locknuts (517 .094) .

2. Screw 3 puller screws (596 .042) into tap holes and extract end cover (517 .084) together with sealing cover
(517.086) and labyrinth disc (517 .089) as well as seal ring (517 .085) and round-section seal rings (517 .092
and 517.061) .
Note : Use care not to damage the labyrinth disc when withdrawing and depositing the cover .

0
1 . Fasten sealing cover (517.086) together with seal ring (517.085) on end cover (517 .OB4) using countersunk
bolts (517 .087) and hexagon nuts (517 .088) - if disassembled - and press labyrinth disc (517 .089) onto end
cover (517 .084) .
Ade : When pressing on the labyrinth disc, see that straight pin (517 .080) enters the groove .
2 . Fit round-section seal rings (517.092 and 517 .061) into annular grooves in end cover (517.084) and
labyrinth disc (517 .089) .
3 . Cautiously insert end cover (517 .084) with pressed on labyrinth disc (517.089) in axial direction into
bearing casing (517 .001), paying attention to straight pin (517 .080):and draw up locknuts (517 .094) .

Working time
- Stunden
- Hovrs 1 .0.17.1 Alle
Every
getriebsstunden
Operating hours
500.17-2 Dur6e cle travail
Tiempo de trabojo
- Heures
- Horas 2 . b.33 A _- Toutes leg
cadu 6000 Heures de rno!,~he
Horas de servido
I
0
0
REMOVING AND INSTALLING NA 57 52 0
M *Atk+ M LOCATING RING Arbeitskarle-Nr.
Work card No. 500.1 8
Carle travail No .
Tarjeta trabojo No.
0 appTicable work sheets. . . . . . 500 .10
to
500 .1 7
520.M5
596D65
520.038 1 Claw spanner.... ... . . .. . .. * . . 596.065
1 Protection sleeve . . . . . . . . . . . . 596.075
1 Bracket . . . . . . . . . . . . . . . . . . . . . . 596.076
2 Hexagon nut . . . . . . . . . . . . . . . . . . 596 .080
2 Threaded rod. . . . . . . . . . . . . . . . . 596.081
2 Hexagon nut . . . . . . . . . . . . . . . . . . 596 .OB4
520.001 1 Extraction ring . . . . . . . . . . . . . . 596 .090
1 Open-end wrench, ifte 2 4
596.080- LEGEND
596,076- 520 .001 Turbine rotor
596DW- 520 .035 Locating ring
Nxh !" wbuftaft 596DU-, 520 .038 Ring nut
SCLAV"M ~ Gb ~
-59wal
596.075-
Zj
STARTING POSITIO N
Either silencer or air-intake
casing and compressor casing ar e
I!
T removed or only air-intake socket,
spacer ring and insert. Impeller
and cover are removed.
STARTING POSITION 1 - Removin g
1 . Screw off ring nut (520.038), using claw spanner (596 .065) and withdraw locating ring (520.035) .
Aofe : If locating ring is a tight fit, use extracting device.

0
2. Slip protection sleeve (596 .075) over rotor shaft (520 .001) to protect shaft and bearing bore .
3 .- Screw in extracting ring (596 .090) .
4. Screw 2 threaded rods (596.081) into extracting ring .
5. Clamp bracket (596 .076) with 2 hexagon nuts (596 .080) to bearing casing .
6. Remove protection sleeve (596 .075) . I
7. Extract locating ring (520.035) by screwing 2 hexagon nuts (596 .084) onto the threaded rods (596 .031) and
tightening them evenly .
Note: The protection sleeve (596.075) must be removed before the locating ring is extracted .
The 2 nuts (596 .084) should be tightened evenly at the same time.

1 . Slip locating ring (520 .035) over turbine rotor (520.001) .
2 . Draw up ring nut (520.038) until locating ring seats against the step shaft, using claw spanner (596 .065) .
Note : Balance marks on locating ring and turbine rotor must be in alignment .
036 5645 E ArWtszeil - Stunden

1 . 0.17 Alle Beiriebsslunden
500.18-2
Working time Hours
Durte de travail Heur"
Tiempo de trabojo - Hares 2 .0.10 k Every '
Toules les
Coda 6000
Operating hours
Heures de marChe
Herm de servido
0
0
M*Aftk+ M LOCATING BEARIN G Arbeitskarle-Nr .
Work card No.
Carlo travail No, 500
applicabie work sheets . . . . boo .0 ;
500.10
to
500.18

520.001 Turbine rotor 1 Protection sleeve . . . . . . . . . . . . . 596 .075
517 .075 Locating bearing 1 Bracket . . . . . . . . . . . . . . . . . . . . . . . 596 .076
0
517 .080 Straight pin 2 Hexagon nut . . . . . . . . . . . . . . . . . . . 596 .08 0
2 Threaded rod. . . . . . . . . . . . . . . . . . 596 .082
2 Hexagon nut . . . . . . . . . . . . . . . . . . . 596 .085
3640422
STARTING POSITIO N
Either silencer or air-intake casing and compressor casing are removed or only the air-intake socket, spacer ring .
and insert . Impeller, cover and locating ring are taken off .

1 . Screw protection sleeve (596.075) onto rotor shaft (520 .001) to protect the shaft and the bearing bare .
2. Screw 2 threaded rods (596 .082) into locating bearing (517.075) .
3. Fasten bracket (596 .076) with 2 hexagon nuts (596 .080) to bearing casing and screw two hexagon nuts (596.085)
onto threaded rods .
0 4 . Extract locating bearing (517.075) from bearing casing by tightening the two nuts (596 .085) evenly .
Note: The two nuts should be tightened evenly at the same time .
For assessing bearing wear and checking the condition of the bearing,see work sheet 500.OG .
When replacing the locating bearing, the sealing cover (517.086) must be replaced too as the
effectiveness of knife-edge seals depends upon close radial clearances (see work sheet 500.17) . I

1 . Screw protection sleeve (596 .075) onto turbine shaft - unless it has been left in place.
2 . Cautiously insert locating bearing (517 .075) in axial direction into bearing casing .
Note : When inserting the bearing, see that 11 mill drill hole in bearing flange is in alignment with the
straight pin (517 .080) .
3. Screw off protection sleeve (596 .075) .
D36 564E
I.-
500.19-2
Arbeilszeit
Working firne
-
-
Sjunden
Hours 10 .0017. Alle
Every
Betrieb5stunden
Operating hours
Dur6e de travail - Heures
Tiernpo de trabojo - Morm 2, 0.17 Toutes les
Coda 6000- Heures de morche
Horas de servicio
0
0
M *AaL* M THRUST RING Arbeitskarte-Isir.
Work =~Jo~o .
Corte I
Tcrjeta trobaia No. 500 .20
applicable work sheets . . . . . 500.10
to
500.19

1 Protection sleeve . .. ...... . . .. ...... . .. 596 .075
1 Bracket ... ... . ... . .. . ..... . . . . . ..... . .. 596 .076
2 Hexagon nut.. . ... . .. . ... .. . . . . . ..... . .. 596 .080
2 Threaded rod. . ... . . . . ..... . . . . . .... . . .. 596 .081
-2 Hexagon nut ... .. . . .. . ... .. . ... ...... . ..596 .084
1 Assembling ring .. . .. . .. . .. . . .. . ..... . .. 596 .086
LEGEN D
520.001 Turbine rotor
0 520 .028 Thrust ring
STARTING POSITION
Either silencer or air-intake casing and compressor casing are removed or only the air-intake socket, spacer ring
and insert . Impeller removed and complete locating bearing extracted .

1 . Slip protection sleeve (596 .075) onto rotor shaft (520 .001) to protect shaft and thrust ring bore .
2 . Screw assembling ring (596 .086) onto thrust ring (520 .028) .
3 . Screw threaded rods (596.081) into assembling ring (596.086) .
4 . Fasten bracket (596 .076) with two hexagon nuts (596.GBO) on bearing casing and screw 2 hexagon nuts (596 .084)
onto threaded rods .
5 . Extract thrust ring (520.028) from turbine rotor (520 .001) by tightening the 2 nuts (596 .084) evenly .
Note : If the thrust ring cannot be extracted by means of the device, i .e. if it has become a shrink-fit,
proceed with operations described in work sheet 500 .21 and 500.22 (wherein tubine-side bearing is
pushed out by the thrust ring) and cautiously turn thrust ring down on a lathe . No attempt should be
made to force the rotor when removing it . The threads at the compressor end of the shaft must not b e
0 damaged ( screw on protection sleeve) .
+ 0 .01 2
Dimension a
+ 0.007

1 . Screw assembjjng ring (596.086) onto thrust ring (520 .028) .
2. Screw threaded rods (596 .081) into assembly ring .
3 . Screw protection sleeve (596.075) onto rokor shaft and slide assembly ring (596 .086) with thrust ring (520.028)
over shaft. Attach bracket (596 .076) to bearing casing with 2 hexagon nuts (596 .080), unless it has been left
in place (bracket holds rotor in central position) .
4 . Push thrust ring into its end position while turning it in such a way that it will engage the arrest of the
shaft and the balance marks on the thrust ring and the rotor shaft are in alignment .
5 . Remove bracket (596 .076) and assembling ring (596 .086) .
036 5645 E Arbeilsreil

Working tinve
- Stunden
1 0 17 Alle Betriebssiunden
- Hours Every Operating hours
500 .20-2 Toutes Its
Dur6e de travail
Tiernpo de trobojo
-
-
Heures
Harps 2: 0'
. 17 Coda. - 24000 Heures de marche
Horas de servicio
0
0
P01 *AL* M TURBINE ROTOR Ar5eitskorfe-W.
Work card No.
Carte travail !'a .
500 .21
Tarjeta frobojo No.
applicable work ShApts . . . . .500 .1-0

9
to
V1 rope for suspension

of turbine rotor -1
500 .2 0
500 .24
517 55
IF --I ~4_11___T_
596=
STARTING POSITIO N
Silencer or air-intake casing, compressor casing and TOOLS REQUIRED Tool No .

gas admission casing are removed . Impeller taken off
and complete locating bearing removed . 1 Protection sleeve . . . . . . . . . . . . . . . . . . . . . 596 .075
1 Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .076
SEQUENCE OF OPERATIONS 1 : Removin g 2 Hexagon nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .080
1 . Fit 2 protection sleeves (596.095 and 596 .075) and 1 Clamp sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . 596 .092
secure clamping sleove(596 .092) on rotor shaft at 1 Protection sleeve . . . . . . . . . . . . . . . . . . . . . 596 .095
turbine end. 1 Hexagon bolt. . . . . . . . . . . . . . . . . . . . . . . . . . 596 .124
2 . Attach bracket (596 .076) with 2 hexagon nuts (596 .080) 1 Hexagon nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .125
to bearing casing on compressor end (bracket serves as 2 Ropes with shackl e
a guide) . 1 Hoist
3. Push rotor by hand towards plain bearing (517.055) far 1 Open-end wrench, size 19
enough to permit ropes to be applied for supporting it . 1 Open-end wrench, size 2 4
4 . Extract turbine rotor without skewing it to preven t WEIGHT of turbine rotor. . . . . . . . 105 kg
40 damaging the plain bearing (517 .055) .
LEGEND
Note : In withdrawing rotor, make sure that it is kept in
balance; it is good practice to fit a length of 517 .001 Bearing casing
pipe over the clamping sleeve (596 .092) .to prevent 517 .055 Plain bearing
it from tipping . 520 .001 Turbine roto r

1 . Fit 2 protection sleeves (596 .095 and 075) and secure clamping sleeve (596 .092) on rotor shaft at turbine end .
2 . Attach bracket (596 .076) with 2 hexagon nuts (596 .080) to bearing casing on compressor end (bracket serves as
a guide) . -
3 . Cautiously insert turbine rotor, suspended by rope, in axial direction, using care not to damage bearing or
labyrinth seals . Rotor with fitted protection sleeve must be supported by bracket.
4.-Remove rope and push rotor full home .
Note : Never attempt to install rotor without protection sleeves and bracket .
F.or replaCinq labyrinth ring . see overleaf .
036 5645 E ArWtszeit - Stunden Alle Betriebssfunden
H
Working firm - Hourt 1 0 25 Every Operating hours
500 .21-2 Duribe de fravoil - Heures Toutes les Heures de morche
Tiernpo de trabojo - Horas 2.0 .25 Cada 24000 Horas de servicio
REPLACING LABYRINTH RING
- ON TURBINE ROTOR

1 Tommy bar. . . . . . . . . . . . . . . . . . 596 .07 1
1 Assembling ring . . . . . . . . . . . . 596 .08 6
LEGEND
520.001 Turbine rotor
520.018 Labyrinth ring
520.021 Ring nut
STARTING POSITION
Turbine rotor removed.
1 . Fit assembling ring (596 .086) onto ring nut (520.021), paying attention to straight pin.
2. Unscrew ring nut (520.021) with the use of the tommy bar (596 .071) .
3 . Extract labyrinth ring (520.018) from turbine rotor (520 .001) - if it has become a shrink-fit . cautiously turn
it down to dimension a .
4. Slip on now labyrinth ring (520.018) and secure it with ring nut (520.021) .
Dimension a - 110
h6
Arbeitszeit - Stunden
Working time ou
Durte de travoil HHeure rs s
Tiernpo de frabajo Horca
M*A&*14 END COVER ON TURBINE SID E Arbeitskerte-Nr.
Work card No.
Corte trovoil N
500.22
Torieta trabojo No.
ap PD licatile wom sneets . ..... W77
---I
to
500.21
500.2 4
17 094 517 070~~,,

17068
364041 6
LEGEND TOOLS REQUIRED

517 .064 Sealing cover 517.069 Stud 1 Socket wrench, size 13
517 .066 Seal ring 517 .070 Seal 1 Socket wrench, size 24
517 .067 End cover 517 .094 Locknut
517 .068 Locknut
STARTING POSITION
Silencer or air-intake casing, compressor casing and gas admission casing are removed . Impeller taken off and
turbine rotor removed .
1 . Unscrew 5 locknuts (517 .094) on compressor end, using socket wrench .

2 . Withdraw end cover (517 .0671 together with studs (517.069), sealing cover (517.064) seal ring (517 .066) and
seal (517.070) towards turbine end.
0 3 . Disassemble, if necessary.
SEQUENCE OF OPERATIONS 2 : Installlin g
1 . If disassembled, fasten sealing cover (517.064) and seal ring (517 .066) on end cover (517 .067) with locknuts
(517 .068) and screw in studs (517 .069) . I
2. Insert end cover (517.067), complete with seals (517.070), from turbine end into bearing casing, seeing that
the qrDOVe for the locating pin, of the plain bearing is situated at the too .
3. Screw on 5 locknuts (517.094) on compressor end and tighten them evenly crosswise with the use of the socket
wrench .
D36 5645 E Arbeitszelf z Stunde n

500.22-2 Working time Hours 1 * 0 .17 Alle
Every
Befriebssfunden
Operating hours
Durie de travail - HeureS Toutes 24000 Heures de mor~he
Tiernpo de trabojo - Horas 2 . 0 .33 Coda Horas de servicio
1 0 0 0 0
M*Ak* M GAS-ADMISSION CASING Arbeitskarte-Nr

Work card No.
Carte travail No .
Tarjeto trabojo No. 5DO .24
0 applicable work sheets. . . . . . 500.10
3 Pul I or screw . . . . . . . . . . . . . . & . . . . . . . . 596 .041
1 Eyebol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596.134
1 Eyebol t. . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 .135
1 Rope with shackl e
1 Hoist .
WEIGHT of gas admission casing wit h
nozzle ring . . . . . . . . . . . . . . . . . . 395 kg
LEGEN D
501 .001 Gas admission casing
501 .131 Vent pip e
501 .143 Cover
501 .151 Vent pipe
506 .001 Gas outlet casing
506.106 Hexagon screw
506.107 Lockwasher
509 .000 Diffuso r
513.001 Nozzle ring
517.001 Bearing body
STARTING POSITIO N
Exhaust manifold or the complete exhaust turbo-
charger has been removed from the engine .
364040S
1 . Disconnect vent pipes (501 .131 and 501 .151) on gas outlet and gas admission casing .
2 . Screw eyebolt (596 .134) into connecting socket of gas admission casing (501 .001) and hang with rope on hoist .
3 . Unscrew and remove hexagon screws (506.106) and lockwashers; (506 .107) and screw 3 puller screws (596 .041) into
tap holes .
0 4 . Cautiously extract gas admission casing (501 .001) together with nozzle ring (513 .001) and cover (501 .143) by
tightening the 3 puller screws (596 .041) uniformly .
Note : When removing the casing with the turbine rotor installed, use care not to damage the knife edge$ by the
cover (501 .143) . Swinging and tipping of the gas admission casing can be prevented by means of an auxiliary
rope aid an eye bolt (596 .135) screwed into the flange of the gas admission casing .
I
1 . Screw eyebolt (596 .134) into connecting flange of gas admission casing (501 .001) and hang with rope on hoist .
2 . Cautiously insert gas admission casing (501 .001) with installed nozzle ring (513.001) and cover (501 .143) into
gas outlet casing (506.101) .
3 . Screw in and draw up hexagon screws (506 .106) with lockwasher3 (506 .107) .
4 . Reconnect vent pipes (501 .131 and 501 .151) to gas outlet and gas admission casing .
Note : Use care not to damage the knife-edge seals by the cover (501 .143) when installing the casing with the
turbine rotor in place . Swinging and tipping of the gas admission casing can be prevented with the aid of
an auxiliary rope and an eyebolt (596 .135) screwed into the connecting flange .
D36 5645 E I Arbeitszeit - s,unden Alle getriebsstunden

500.24-2 Working time - Hours 1 .0.75 Every Operating hours
Durke de travail - Heures
Tiernoo de trabojo - Horas 2 . 0.50
Toutes lei
Cado
24000 Heurts de march*
Horas de servicio
I
I
M *Atk* M PLAIN BEARING Arbeilskorte-Nr
Work card No.
Carte travail No.
Torieto trabojo No . 50P.23
applicable work sheets. . . . . . 500 .06
500 .1 0
to
500.24
1 Brijcket . . . . . .. . ... . . . . . . . 596 .076

2 Threaded rod... . ... . . . . . . 596.081
2 Hexagon nut ... . ... . . . . . .. 596 .084
LEGEN D
517 .055 Plain bearin g
STARTING POSITION
Silencer or air-intake casing, compressor casing and gas admission casing are removed . Impeller taken off and
turbine rotor removed . End cover on turbine end taken off.

1 . Screw 2 threaded rods (596.081) into plain bearing (517 .055) .
2 . Slip bracket (596 .076) over threaded rods and secure with 2 hexagon nuts (596 .084) .
3 . Extract plain bearing (517.055) from bearing casing by tightening the 2 nuts .(596 .084) uniformly .
Note : If possible, the .2 nuts should be tightened simultaneously .
For assessment of wear and inspection of bearing, see work sheet 500.06 .
When replacing the plain bearing, also replace sealing cover (517.064) as the effectiveness of a
knife-edge-seal depends upon close radial clearance .
If the bearing cannot be extracted by means of the device, i .e . if it has become a shrink-fit, it must be
cautiously turned down after removal of the rotor . Should a lathe of corresponding size not be available, the
bearing must be drilled and split up.
Care must be taken not to damage the bearing surfaces of the turbine rotor !
Note : For inspecting the nozzle ring (513.001) or the'turbine wheel, only the gas admission casing (501 .001)
need be removed (see work sheet 500 .24) .
1 . Install plain bearing (517 .055) on turbine end in bore hole of bearing casing (517 .001) in such a way that
the straight pin for locating the bearing is pointing up . (see illustration) .
2 . Cautiously press plain bearing into casing bore with the threaded rods (596 .081) to guide it and makin§ .sure
it is not cocked . The bearing flange must seat snuggly against the bearing casing .
3 . Unscrew both threaded rods .
Note! The oil catch groove of the plain bearing must be facing the turbine end, i .e . it must be on the out-
side and the straight pin pointing up .
Is
036 5645 E Arbeitszeit - Stunden Alle
500.23-2 Working finie - Hours 1 . 0 17 Tojy
Eve
Betriebssfunden
Operating hours
Durdedefravoil -Heures
Tiernpo de trabojo - Horgs 2 . 0 :17 teß leg 24000 Heures de morche
Cada Horas de servicio
0
i
- I.
. :j
0
REMOVING AND INSTALLING . NA 57 513
M*Ak*M . NOZZLE RING Arbeitskarie-W.
Work cord No.
Carlo travail No.
500.25
Tarjeta trabojo No .
ap-pi nable work sh-ee-t-so-OG.-IO

500.2 4
TOOLS REQUIRED Tool No .'
3 Puller screw. . . . . . . . 596 .04 0
1 Hammer
1 Chisel, pointed
1 Chisel, blunt
LEGEN D
501 .001 Gas admission casin g
50 . Hexagon screw
501 .045 Lockwasher
;nl iwi Fn A
506 .001 Gas outlet casing
0
509 .001 Diffuser - outer wall
509 .010 Clamp dog
1* ~~ 509 .011 Hexagon screw

)509 .014 Lockwasher
J 513 .001 Nozzle ring
513 .008 Shroud ring
513 .010 Clamp dog
513 .014 Lockwasher
513 .024 Lockwasher
STARTING POSITION
Either the gas admission casing or the bearing casing and rotor are removed .
1 . Unscrew and remove 6 hexagon screws (501 .039) and lockwashers (501 .045) in cover (501 .143) and extract cover .
2 . Remove hexagon screws (513 .022) and lockwashers (513 .024) inside the nozzle ring (513 .001) .
3 . Unscrew and remove hexagon screws (513.012), lockwashers (513 .014) and clamp dogs (513 .010) on the outsidd of
the nozzle ring . I
0 4 . Screw 3 puller screws (596 .040) uniformly into nozzle ring (513.001) to extract ring and then remove it .
5 . Loosen and remove hexagon screws (509 .011), lockwashers (509 .014) and clamp dogs (509 .010) at outer wall of
. diffuser (509.001) and take off shroud ring (513 .008) .
1 . Secure shroud ring (513 .008) by means of clamp dogs (509.010), hexagon screws (509.011) and lDckwashers
(509 .014) .
2. Fasten nozzle ring (513 .001) on inside with hexagon screws (513 .022) and lockwashers (513 .024) .
3. Secure nozzle ring (513.001) on the outside by -means of clamp dogs (513.010), hexagon screws (513 .012) and
lockwashers (513.014) .
4 . Fit cover (501 .143) and fasten it with 6'hexagon screvs (501 .039) and 3 lockwashers; (501 .045) .
Note: All hexaqon screws. must be Properlv secured with lockwashers (use new lockwashers, if indicated) .
D36 5645 E Arbeit zeit :: Stunden Alle I Betricbsslunden
r1_
500.25-2 WorkIng time Hours
Dur&e de travoil - Heures
- Tiernpo de trobajo - Horas 2 .1 k Every
Toutes les
Cada
Operating hours
as necessary
Heures do march@
Hora, cle servicio
4
0
i
z
0
z
0
NA 57 509
M*AL*p4 REMOVING AND INSTALLING
DIFFUSER -
Arbeitskorte-Nr
Work card No.
Carte travail !'a.
Torieta trobalo NS.
500.26
0
applicable work sheet . . . . 500.24
i
1 Eyebolt . . . . . . . . . . . . . . . . . . 596 .134
1 Socket wrench, size 1 9
1 Hammer
1 Chisel, pointed
1 Chisel, blunt
1 Rope with shackl e
~- 1 Hoist
WEIGHT of diffuser. . . . . . . . . 140 k g
LEGEND
50S .001 Diffuser, outer wall
509.002 Diffuser, inner wall
'09 .010 Clamp do g
509 .014 Lockwasher
509 .015 Lockwasher
509 .016 Lockwasher
506 .001 Gas 6utlet casing
513 .008 Shroud ring
same 517.067' End cove r
520.001 Turbine roto r
STARTING POSITION
Gas admission casing and complete bearing casing are removed from gas outlet casing, turbine rotor and end cover
on turbine and withdrawn .
0 Note : Removal of the complete diffuser should be required in exceptional cases only, so that normally during
erection work the inner ring of the diffuser can be left on the bearing casing and the outer ring of the
diffuser on the gas outlet casing .
1 . Unscrew and remove 6 hexagon screws (509.012) with 3 lockwashers (509.016) in link plates of inner wall of
diffuser (509.002) and cautiously lift inner wall from bearing casing (517.001) in the direction of the turbine
and.
2 . Screw eyebolt (596.134) through the gas outlet flange of gas outlet casing (506.001) into outer wall of diffuser
(509 .001) and hang on hoist .
3 . If required, - remove shroud ring (513 .008) from outer wall of diffuser (509.001) by loosening the hexagon
screws (509 .011) and the clamp dogs (509 .010) .
4 . Screw out and remove 24 hexagon screws (509.013) and 12 lockwashers (509 .015) from diffuser flange and
cautiously remove outer wall of diffuser through gas outlet opening of gas outlet casing (5ouol) .

1 . Screw eyebolt (596 .134) into tap hole of outer wall of diffuser (509 .001) and hang on hoist .
2 . Cautiously withdraw outer wall of diffuser (509 .001) through gas outlet opening of gas outlet casing (506 .001),
fit lockwashers (509 .015) and screw in and tighten hexagon screws (509 .013) .
P.t.o.
D36 5645 E Arbeit zeit
Working lime
-
-
Stunden
Hours
Alle
Every
Betriebssiunden
Operating hours
500 .26-1 Durtke de trovail - Heures Toutes les - as necessary Heures; de marche
Tiempo de ircbajo - Horos Coda Horas de serviclo
3 Insert .shroud ring (513 .008) into outer wall of diffuser and tighten clasp d9gs .
4.. .' Cautiously-Jit inner wall of diffuser (509,002) on bearing casing (517 .001) in tj~ direction of the
compressor end and feAten it with 6 4x4gon screws (509 .012) and 3 lockwashers (5d9,'016)
' on link plates .
!2U: All lqckwashers should be in good condition, or must be renewed .
I
(a
Date . -Sheet
1
CHECK LIS T
WERK AUGSBURG
To Engineer's report of . . . . . . . . . . . . . . Turbocharger . . . . . . . ..
0 Work-No .
Type . . . . . . . . . . . . . . .
Name of customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Workshop No . . . . . . .
Address, site, ship's name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger inspected - overhauled on . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lost inspection - overhaul on . . . . . . . . . . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service hours since the last inspection - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h
Service hours since commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h
CONDITION OF C OMPONENT S
.
Gas-carrying casing . . . . . . . 0 clean Bearing . . . . . . . . . . 0 reused
rusted 0 replaced
soot covered reason . . . . . . . . . . . . . . . . . . . . . . . . . .
tinder covere d radial clearance measured with no-go
0 cracked gauge bush . . . . . . . . 0 inserte d
Studs 0 satisfactory or band width . . . . . . . . . . m m
0 broke n
Turbine rotor
No=le ring assembl y
traces of wheel 0 no
guide vanes 0 satisfactory -contact, wear 0 yes
0 ben t
location . . . . . . . . . . . . . . . . . . . . . . . .
0 cracke d
wheel blade en . . . . . . 0 withou t
0 tinder covered
0 scarred by foreign
crustation 0 slightly
matte r 0 heavi ly
one-side
traces of wheel contact 0 no
even ly dis-
on cover ring 0 yes
tributed
Bearing casing 0 clean
0 carbon covere d
wheel blades cracked 00 at the foot
at annular
0 0 rusted welding sea m
location . . . . . . . . . . . . . . . . . . . . . . .. . . . . . wheel blades bent 0 no
lock-air pa=ges c lean 0 yes
0 restricted location . . . . . . . . . . . . . . . . . . . . . .
0 clogged frictional oxidation 0 slightly .
seals 8 reuse d -0 heavily
replaced on both sides
Cover . . . . . . . . . . . . . . . . . . 0 reused 8 on turbine
side
0 replaced on compressor
bearing (compressor side) . . 0 reused side
0 replace d condition of . 0 satisfactory
lacing wire . . . . . . . . 0 bad
resason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
radial clearance measured with no-go
Measurements see Sheet 2
gauge bush . . . . . . . . . . . 0 inserted
or bond width . . . . . . . . . . . . . mm
axial clearance . . . . . . . . . . . mm
"5674 E I
0
6
Dote Shee t
CHECK LIS T 2
WERK AUGSBUR G
To Engineer's Report of . . . . . .. . . . . . . . . .
0
Turbine rotor Diffusor
eccentricity . . . . . . . mm guide vanes . . . . . . . . . . . 0sctisfactory
aberration from plane of rotation 0 bent
of impeller . . . . . . .mm 0 cracked
gap turbine wheel - shroud ring . . . . . . . mm 0 loose
gap turbine wheel - cover . . . . . . . mm
Si lence r
gap turbine wheel - cooling ring . . . . . . . mm
gap labyrinth - sealing cover . . . . . . . mm condition . . . . . . . . . . . . . . 0 dust covered
(turbine side) 0 oi I covered
gap locating ring - sealing cover . . . . . . . mm 0 soot covered
(compressor side ) condition of felt plates . . Osatisfactory
gap impeller - cover disc . . . . . . . mm 0 bad
gap impeller - insert piece . . . . . . . mm
Oil pressure setfin g
(radial)
gap impeller - insert piece . . . . . . . mm changed . . . . . . . . . . . . . . .
no
(axial ) 8yes
from . . . . . . . bar (psi) to . . . . . .13gr
Bearing sleeve reused
wear
replaced
even
8 Lock-air valve
0
0 one-sided valve insert . . . . . . . . . . . . 0 reused
shaft-seating 0 free
0 replaced
0 sluggish
8 sh
nor ink-fit Separate lubricating system (if provided )
frictional oxidation
lubricating oi I pump
0 yes
coupling components O'Satisfactory
Condition of collar . . . . . . . . . . . . . . .. . . .
0 worn
Impelle r 0 replaced
reduction gears 0 satisfactory
traces of wheel contact, . . . .0 no
0 worn
wear 0 yes
0 replaced
location . . . . . . . . . . . . . . . . . . . . . . . . . .
ball bearings 0satisfactory
wheel vanes cracked 0 no
0 worn
0 yes
replaced
location . . . . . . . . . . . . . . . . . . . . . . . . . .
delivery wheels 0 satisfactory
condition . . . . . . . . . . . . . . . . n clea n
4C) worn
dirty 0 replaced
0 oily
worm gear sctisfactory
seating quality of hub bore . .() stitisfact .
medium 80 worn replaced
bad
articulated shaft tatisfactor y
Rotor 80 worn replaced
rebalanced 0 no
0 yes Miscellaneous
condition before re . . . . . . . . 0 satisfact .
balancing 0 bad
compressor casing . . . . . . . . . () clean
dirty
0 oily
1~ . . . . . .
signatur e
. . . . . . . . . . . . . . . .
16
036 5674 E 2
0
4
KSZ-B 55 0
AUXILIARY BLOWER AND SLIDE TUBE KSZ- 1
Arbeitskarte-Nr .
IN SILENCER OF TURBOCHARGER Work card No.
0
Tarieto traboic, No.
I TOOLS REOUIRED
1 Set box wrenche s
1 Set open-end wrenches
1 Hoist
1 Rop e
1 Grease gu n
LEG IN D
1 Auxiliary blower
2 Air cylinde r
3 Slide tube
4 Silencer
5 Air intake socket
6 Casing cove r
7 Compressor wheel
8 Fixing bol t
k 9 Shaft seal
e
10 Anti-friction bearing
11 Electric moto r
12 Anti4riction bearing
13 Casing
SEQUENCE OF OPERATIONS 1, Checking Slide Tub e
1 . Remove bolts connecting the two air cylinders (2) with the slide
tube (3) .
2 . Move slide tube by hand to see whether it moves freely .
3 . Replace and carefully secure fixing bolts .
4 . Check whether slide tube is in the end position shown in the
drawing by the dash-dot line when engine is at standstill .
SEOUENCE OF OPERATIONS 2, Maintenance of Electric Moto r

1 . The electric motor (11) needs no servicing except cleaning of the surface of the motor casing, the intervals
depending on the degree of contamination . Dust, sand or objects placed on the surface will reduce surface
cooling with the result that the motor may become overheated.
2 . If the motor is equipped with facilities for adding lubricants, the lubricant should be added while the motor is
0 running, if it can be done without the risk of injury .
3 . If the motor has no facilities for adding lubricants, bearings (10 and 12) must be removed for re-lubrication .
Lubricant : Lithium-soap anti-friction bearing grease type 120 as per DIN 51825 ,
Consistency no, 3, as for example the following trade-mark greases :
Shell Alvania 3
Mobilus Grease 3
BP-Energrease LS 3
Calysol H 443
Alf
Esso Beacon 3
No t e : Removal of bearings for relubrication or renewal should be carried out by a specialised shop, if possible .
. Otherwise, observe manufacturer's instructions which vary with the motor type and the manufacture .
Caution! The free space between the bearing races should only be filled to the half, otherwise there is the risk 6f
overheating which results in excessive wear .
P.T .O.
Co Arbeitszeit - Stvnden Alle Betriebsslunden
12 D36 5610 E
550 .30-3
Working time
Dur6e de travail
Tiempo de Irabojo
-
-
-
Hours
Heures
Harps I Ak. Every
Toutes le s
LCodo
6000
24000
Operating hours
Heures de Marche
Hares de servicio
SEOUENCE OF OPERATIONS 3, Removing Electric Moto r
1 . Remove electric fuses and disconnect cables (mark for re-assembling) .
2 . Attach air intake socket (5) with rope to hoist .
3 . Remove 12 bolts in casing cover (6) and remove complete air intake socket together with the casing cover and put
it down cautiously .
4 . Hang compressor wheel (7) with rope on hoist (pulling from an angular position) orraise wheel by wooden strut$'
unscrew fixing bolts (8) and remove compressor wheel from the shaft .
5 . Remove fixing bolts by means of Vhich electric motor is fastened to the foundation . (Before removal, mark
installed position on foundation) .
6 . Cautiously remove electric motor in axial direction and set it down .
For assemblino reverse ~rocedure outlined above . It isiimportant h,eclk he dimeuirso(V and S~sat thetzi~,
inlet~~tiower whee . These two dimensions, depend ng on the ntomicn diameter DN c ncerned ee ske ch
will be noted from the table below .
SEQUENCE OF OPERATIONS 4, Sealing Air Intake Socket (Emergency Operation )
In the case of a turbocharger failure or a defective auxiliary blower, it may be necessary to seal the air intake
socket to prevent the air from escaping through the inoperative auxiliary blower in emergency operation . For this
purpose, the tools include a scaling cover (14) which is then to be installed on the air intake socket with the
use of 6 bolts .
LEGEND
5 Air intake socket
14
15
16
Sealing cover
T-head bolt
Taper handle
46
17 Holding clamp
18 Seal
1 . Hook sealing cover (14) up on air intake socket (5) with the holding clamp (17) at the top .
2. Push cover with seal up against the air intake socket, taking care not to damage the seal (18) .
3 . Insert T-head bolts (15) into groove of intake socket and tighten taperhandle (16) slightly . ~
4 . Tighten 211 6 taper handles cross-wise and evenly and check to see that cover fits snugly over the entire
circumference.
5. After damage has been repaired, remove sealing cover and store it in such a way that the seal will not be
damaged .
k
0
nominal die . ga p toleranc e overla p toleranc e
DN S S- V V -
250 1 .5 1 .0 4 2
280 1 .5 1 .0 5 2
315 1 .5 1 .0 5 2
355 1 .5 1 .0 6 2
400 2 .0 1 .0 7 3
3642008 450 2 .0 1 .0 8 3
500 2 .5 1 .0 9 3
560 25 1 .0 10 3
630' 3 .0 1 .5 11 4
710 3 .5 1 .5 12 4
800 1 4 .0 1 .5 13 4
900 4 .5 1 .5 14 4
1000 5 .0 1 .5 15 4
035 5610 E / 550 .30-3

KSZ 70-125B

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KSZ 70-125B

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OPERATING MANUAL

MAN B&W DIESEL AKTIENGESELLSCHAFT

This publication is copyright . Reprinting and other duplication and for-

Abschnitt 1 TECHNISCHE DATEN TECHNICAL DATA

Qualittitsonforderung fur Kraftstoff, Quality requirements for fuel ,

Abschnitt 4 WARTUNG MAINTENANCE

D36 5612 - 2 D+E

Inhaltsverzeichnis Abschnitt 1 Table of contents section I I Blatt Shee t

Qualittitsonforderung an Kuhlwasser . . . . . Quality requirements for cooling water . 4 1

M .A . N .-Abgosturbolader M .A .N . exhaust turbocharger

Kurzbeschre i bung, Betriebsdaten . . . . . . . . Brief description, operating data . . . . . . 51

The KSZ engine is a supercharged, low-speed, single-acting, two-stroke engine of crosshead

The Woodward governor (1 40) is linked up to a hydraulic-pneumatic positioner (125) which

Cooling of cylinders, cylinder covers, pistons, fuel injectors and of turbochargers is by

D36 5612 E / 1 . 2-2

D36 5612 D+E 1 .3-3

Engine Specif i cation s

Swept volume of one cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481 dm3

Tota I swept volume

Overhead required (from center line crankshaft) mm

D36 5612 E 1 .5-2 p .t .o .

Axial movement of camshaft, reversible engines . . . . . . . . . . . . . ... . . . . . 165

Sense of rotation of crankshaft when looking on the drive flang e

Number of cylinders Clockwise - ---counterclockwise Firing Interval s

Step-up ratio of mounted instruments n engine n instrument

Service and Test Pressures (bar-kp/cm2 )

service pressure I opening pressure I test pressur e

Lubricating oil Bearing lubrication 2,3-2,6 - -

Weights of Essential Components (approximations in kg )

Piston and piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2180

Complete engine 5 cylinder . . . . . ... . .... . .. . .. . . . .. . ... . .. ... . . . . . . . . . . 310000

0: D36 5612 E 1 .7-3

Drucklager (017) A 550 -0,0 5

Kurbelwellenlager (021) A 550 -0,06 - -

Kreuzkopflager (030) A 400 +0,06 - -

G 'le -itschuh (031 ) A 500 +0,06 -

Kolben (040) A 694,5 10, 1

Zylinderbuchse (050) A 704, 2

Steueruncsantrieb (100) A 280,1 H6 -

Antrieb der EinspritZ- A 195 -010,10

Antrieb fUr Zylinder- A 1,0 1,5 S-

0 Schmierpresse fUr Kreuz- A 3,5

Oz D36 5612 D+E 1 .12-2

Designation of the Cylinder s

The cylinders are designated by numbers only, numbering is consecutively 1, 2, 3 etc .

Designation of the Direction of Rotatio n

Definition of Left-Hand and Right-Hand Engin e

r1i lefthand '. engine righthand engine engine sides

Design with I bearing only

Designation Gas Oil Diesel Oi l

Densit at 150 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g/ml < 0 . 86 < 0 .91 5

Behaviour in the cold Pourpoint . . . . . . . . . . . . . . 0 C a+ - 6 a+ - 6

FlashpLint as per Abel-Pensky . . . . . . . . . . . . . . . . . . 0 C > 55 > 55

0 Specifications . . . . . . . . . . . . . . . . . . . . . . . . ASTM D 396-67 T . . . No 1+2 No 4

+ a = Temperature at which fuel is stored .

Against reimbursement of the net cost, our

Densit at -.1 -59C 9/m1 0.980 0.990

mm2~s = cSt sec

D36 5600 E~l

Beispiel : Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KSZ 901160 B

Hinweis fUr Projektierung

Determinatton of temperatures of heavy fuel oil for separation and heating

Example : Diesel engine .. . . . . . . . . . . . . . ......... KSZ 901160 B

The following lubricating oiles are used in two-stroke engines :